Honda CRF250R Owner's Manual
  1. Manuals
  2. Brands
  3. Honda Manuals
  4. Motorcycle
  5. CRF250R
  6. Owner's manual

Honda CRF250R Owner's Manual

Motocross motorcycle owner’s manual & competition handbook
Hide thumbs Also See for CRF250R:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual

Advertisement

Table of Contents
loading

Related Manuals for Honda CRF250R

Summary of Contents for Honda CRF250R

  • Page 2 CRF and how it works. To protect your Please report any change of address or ownership investment, we urge you to take to your Honda dealer so we will be able to responsibility for keeping your CRF well contact you concerning important production maintained.
  • Page 3 2007 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 5: Table Of Contents

    Pre-ride Inspection..........9 Chassis Contacting Honda..........153 Suspension............72 Your Honda Dealer..........154 BASIC OPERATING INSTRUCTIONS ..11 Brakes..............77 The Honda Rider’s Club .........155 Safe Riding Precautions........12 Wheels...............81 Starting & Stopping the Engine ......13 Tires & Tubes ............82 TABLE OF CONTENTS ......156 Break-in Guidelines ..........15 Drive Chain ............84...

  • Page 6: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Information.......2 information and recommendations to help you Important Safety Precautions......2 ride your CRF safely. Please take a few Accessories & Modifications .......3 moments to read these pages. This section also Safety Labels ............4 includes information about the location of safety labels on your CRF.

  • Page 7: Important Safety Information

    Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.

  • Page 8: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 9: Safety Labels

    Safety Labels Read this label carefully and don’t remove it. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. Motorcycle Safety...

  • Page 10: Operating Controls

    Operating Controls Read this section carefully before you ride. It Operation Component Locations ......6 presents the location of the basic controls on your CRF. Operating Controls...

  • Page 11: Operation Component Locations

    Operation Component Locations hot start lever clutch lever front brake lever throttle grip engine stop button choke knob kickstarter fuel valve shift lever rear brake pedal Operating Controls...

  • Page 12: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....9 you prepared, this section discusses how to Pre-ride Inspection..........9...

  • Page 13: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 14: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the Check the following before each ride: right): •...
  • Page 15 Before Riding...

  • Page 16: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions........12 start and stop your engine as well as break-in Starting & Stopping the Engine ......13 guidelines. Preparation ............13 Starting Procedure ........13 Flooded Engine ..........13 How to Stop the Engine........14 Break-in Guidelines ...........15 Basic Operating Instructions Basic Operating Instructions...

  • Page 17: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 18: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting described below. levels before starting the engine (pages 37,40,41). 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. Your CRF can be kickstarted with the Cold Engine Starting 3.
  • Page 19 Starting & Stopping the Engine How to Stop the Engine (1) throttle grip (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle grip (1) two or three times, and then close it.

  • Page 20: Break-In Guidelines

    Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...
  • Page 21 Basic Operating Instructions...

  • Page 22: Servicing Your Honda

    You’ll also find Exhaust Pipe/Muffler .........87 important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ....91 and tips for keeping your Honda looking good. Maintenance Component Locations....28 Seat Removal .............29 Appearance Care ..........93 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30...

  • Page 23: The Importance Of Maintenance

    Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda...

  • Page 24: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 25: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine...
  • Page 26 NOTE: 1.Clean after every moto for dusty riding conditions. 2.Replace every 2 years. Replacement requires mechanical skill. 3.Replace after the first break-in ride. 4.Inspect after the first break-in ride. 5.Replace the transmission oil, if the clutch discs and plates are replaced. Servicing Your Honda...

  • Page 27: General Competition Maintenance

    Use genuine Honda parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 28 Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White...
  • Page 29 Make certain the throttle operation is to the proper torque specification. For added peace of mind, perfect after servicing and inspecting. remove the nuts, clean the threads, and apply Pro Honda Hondalock or an equivalent prior to torquing the nuts. Servicing Your Honda...
  • Page 30 Application of a thread locking agent to essential fasteners should be replaced. offers added assurance and security. Remove the nuts, clean the threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent and tighten to the specified torque.

  • Page 31: Before & After Competition Maintenance

    (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...
  • Page 32 If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 93). Servicing Your Honda...

  • Page 33: Maintenance Component Locations

    Servicing Your Honda...

  • Page 34: Seat Removal

    2. Remove the seat (2) by sliding it backward. 2. Install and tighten the seat mounting bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (3) front prong (4) seat bracket (5) rear prong (6) tab Servicing Your Honda...

  • Page 35: Fuel Tank Removal

    3. Remove the shroud A bolts/collars (2). (7) air cleaner cover rubber 4. Remove the shroud B bolts (3) and shrouds (4). (8) fuel tank bolt (9) fuel line (10) fuel valve bolt (2) shroud A bolts/collars (3) shroud B bolts (4) shroud Servicing Your Honda...
  • Page 36 7. Put the breather tube (7) in the steering stem (11) nut. (10) (12) (10) shroud (11) shroud B bolts (12) shrouds A bolts/collars (4) fuel tank bolt/collar (5) air cleaner cover rubber 12. Install the seat (page 29). (6) fuel tank band (7) breather tube Servicing Your Honda...

  • Page 37: Subframe Removal

    3. Remove the seat (page 29). (6) subframe lower mounting bolts (1) crankcase breather tube (7) subframe upper mounting bolt (2) fuel tank band (8) subframe (3) air cleaner cover rubber (4) screw (5) air cleaner connecting tube clamp Servicing Your Honda...
  • Page 38 36 lbf·ft (49 N·m, 5.0 kgf·m) (4) screw (5) air cleaner connecting tube clamp (6) air cleaner cover rubber (7) fuel tank band (8) crankcase breather tube (1) subframe (2) subframe upper mounting bolt (3) subframe lower mounting bolts Servicing Your Honda...

  • Page 39: Fuel System

    If pinging or spark knock persists, WARNING consult your Honda dealer. Gasoline is highly flammable and Never use stale or contaminated gasoline. Avoid explosive. You can be burned or getting dirt, dust or water in the fuel tank.
  • Page 40 Turn the fuel valve to ON; check for fuel approved gasoline container. leaks. 2. Remove the fuel tank (page 30). 3. Remove the fuel joint (1) from the fuel tank by removing the bolts (2). (1) fuel joint (3) fuel filter (2) bolts (4) O-ring Servicing Your Honda...

  • Page 41: Engine Oil

    JASO T 903 NOT RECOMMENDED suggested oil* Pro Honda GN4 4-stroke oil or an equivalent* Other viscosities shown in the following chart may be used when the average temperature in * Suggested 4-stroke engine oils are equal your riding area is within the indicated range.
  • Page 42 6 races or about every 15.0 hours. Repeat steps 1–5. However, if you replace only the oil before 6. Reinsert the engine oil filler cap/dipstick. the recommended interval, see page 21. 7. Check for oil leaks. (cont’d) Servicing Your Honda...
  • Page 43 (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the rubber seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage.

  • Page 44: Transmission Oil

    NOT RECOMMENDED suggested oil* Pro Honda GN4 4-stroke oil or an equivalent* Other viscosities shown in the following chart may be used when the average temperature in * Suggested 4-stroke engine oils are equal your riding area is within the indicated range.
  • Page 45 5. After inspecting the oil level or adding oil, (3) sealing washer tighten the oil check bolt to the specified torque: Oil Check Bolt: 9 lbf·ft (12 N·m, 1.2 kgf·m) 6. Install the transmission oil filler cap securely. Servicing Your Honda...

  • Page 46: Coolant

    Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is low. Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing.
  • Page 47 If oil leaks through the check hole, Always let the engine and radiator cool the oil seal is damaged. See the Honda down before removing the radiator cap. Service Manual or consult your Honda dealer for replacing the water seal or the oil seal.

  • Page 48: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.
  • Page 49 Install and tighten the air cleaner retaining bolt (1) securely. (10) (1) air cleaner retaining bolt (2) two access top tabs (3) air cleaner assembly (4) “∆” mark (10) groove Servicing Your Honda...

  • Page 50: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...

  • Page 51: Throttle

    5. Operate the throttle grip to ensure that it functions smoothly and returns completely. 6. Install the fuel tank (page 31). If you can’t get the freeplay within the specified (–) range, contact your Honda dealer. (2) dust cover (+) increase (3) lock nut (–) decrease...
  • Page 52 If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commercially- available cable lubricant to prevent premature rust and corrosion. Servicing Your Honda...

  • Page 53: Idle Speed Adjustment

    Refer to Safety Precautions on page 19. Idle Speed Adjustment The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled 1. Turn the pilot screw (1) in until it is lightly servicing, including carburetor adjustment.

  • Page 54: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. Servicing Your Honda...
  • Page 55 1. Check for smooth clutch lever operation. If or worn, or the clutch discs may be worn. See necessary, lubricate the clutch lever pivot or your Honda dealer or refer to the Honda Service clutch cable. Manual (page 152). 2. Check the clutch cable for deterioration, kinks, or damage.
  • Page 56 4. Remove the five clutch spring bolts and clutch (9) clutch lifter (11) clutch discs and plates (10) clutch lifter rod springs (7). (2) clutch plate Loosen the bolts in a crisscross pattern in two or three progressive steps. Servicing Your Honda...
  • Page 57 5. Apply engine oil to the needle bearing of the bolts to the specified torque: clutch lifter. 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Install the clutch lifter (4) onto the clutch lifter rod. (7) O-ring (8) clutch cover (3) clutch lifter rod (4) clutch lifter Servicing Your Honda...
  • Page 58 Connect the brake pedal return spring (13) if it was removed. (12) (11) (13) (10) (9) dust seals (12) washer (10) rear brake pedal (13) brake pedal return spring (11) brake pedal pivot bolt 17. Fill the crankcase with transmission oil (page 40). Servicing Your Honda...

  • Page 59: Hot Start Lever

    (1) hot start lever (2) hot start lever freeplay (–) Inspection Check freeplay: (3) lock nut (+) increase (4) adjuster (–) decrease 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda...

  • Page 60: Spark Plug

    10. Connect the direct ignition coil. Take care to with a new one. avoid pinching any cables or wires. (3) sealing gasket 11. Install the fuel tank and seat (pages 29,31). (4) spark plug gap Servicing Your Honda...

  • Page 61: Valve Clearance

    2. Remove the spark plug (page 55). (1) breather tube (2) direct ignition coil 3. Remove the cylinder head cover bolts (3) and cylinder head cover (4). (3) cylinder head cover bolts (4) cylinder head cover 4. Remove the spark plug hole packing. Servicing Your Honda...

  • Page 62: Valve Clearance Inspection

    If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 58) and select the correct shim for each valve. (2) primary drive gear bolt (4) index mark (3) punch mark (5) exhaust rocker arm Servicing Your Honda...
  • Page 63 (3) until it stops, in order to valve clearance. retract the tensioner fully. Then insert the tensioner stopper fully to hold the stopper in the fully retracted position. (1) cam chain tensioner lifter cover bolt (2) sealing washer (3) tensioner stopper Servicing Your Honda...
  • Page 64 Be careful to not let the set rings of the camshaft Do not let the valve lifters or shims fall into the holders fall into the crankcase. crankcase. (8) shims (4) camshaft holder bolts (6) camshaft (7) valve lifters (5) camshaft holders Servicing Your Honda...
  • Page 65 2. Measure the shim thickness with a micrometer and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...
  • Page 66 (1) shims (2) valve retainers 4. Rotate the primary drive gear bolt (4) (crankshaft) clockwise and align the punch mark (5) with the index mark (6). (4) primary drive gear bolt (5) punch mark (6) index mark (cont’d) Servicing Your Honda...
  • Page 67 Tighten the camshaft holder bolts in a criss-cross (18) feeler gauge pattern in two or three steps. (14) (12) (16) (16) sealing washer (17) cam chain tensioner lifter cover bolt (13) (14) (12) camshaft holders (13) intake cam lobes (14) camshaft holder bolts Servicing Your Honda...
  • Page 68 Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) direct ignition coil (8) breather tube 5. Install the fuel tank and the seat (pages 29,31). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 69: Piston/Piston Rings/Piston Pin

    4. Remove the seat and fuel tank (pages 29,30). 5. Remove the subframe (page 32). 6. Remove the carburetor (page 119). 7. Remove the exhaust pipe (page 90). (3) engine hanger nuts/bolts (4) engine hanger plates (1) water hose clamp (2) water hose Servicing Your Honda...
  • Page 70 Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. (10) (5) cylinder head bolts (6) cylinder bolt (11) (9) dowel pins (11) cam chain guide (10) cylinder head gasket (7) cylinder head nuts/washers (8) cylinder head Servicing Your Honda...
  • Page 71 2. Remove the dowel pins (3) and cylinder (1) piston ring gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 72 1. Clean the piston ring thoroughly. oil ring We recommend you consult the Service Manual 2. Apply engine oil to piston rings and install or your Honda dealer for correct Service Limit them. measurements. NOTICE Do not damage the piston ring by spreading the ends too far.
  • Page 73 Do not align the piston pin clip end gap with the piston cut-out (6). (1) dowel pins (2) cylinder gasket 5. Clean any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) piston cut-out Servicing Your Honda...
  • Page 74 Do not damage the piston rings and cylinder walls. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (4) cylinder (5) piston rings (cont’d) Servicing Your Honda...
  • Page 75 Do not let the washers and nuts fall into the (7) engine hanger plates crankcase. (8) engine hanger nuts/bolts of the frame side (9) engine hanger nut/bolt of the engine side (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
  • Page 76 – abnormal engine noise (page 29). – secondary air leaks – coolant leaks (10) (11) (10) radiator hose (11) radiator hose clamp 7. Install the shims, valve lifters and camshaft (page 61). 8. Install the spark plug (page 55). Servicing Your Honda...

  • Page 77: Suspension

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's (1) fork protector (2) dust seal front suspension.

  • Page 78: Rear Suspension Inspection

    (page 113). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Remove the subframe (page 32). The instructions found in this owner’s manual are 3.

  • Page 79: Fork Oil Change

    (5) and guide bushing viscosity (weight) 5 W (6) when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage, hold both the outer tube and slider (7) equivalent when removing the fork damper.
  • Page 80 12.5 US oz capacity (369 cm Maximum oil 13.9 US oz Slightly stiffer as capacity (410 cm it nears full compression. Minimum oil 10.6 US oz Slightly softer as capacity (314 cm it nears full compression. (cont’d) Servicing Your Honda...
  • Page 81 7. Temporarily install the fork damper to the outer tube. After installing the fork leg (page 106) tighten the fork damper to the specified torque: Actual: 25 lbf·ft (34 N·m, 3.5 kgf·m) Torque wrench scale reading: 23 lbf·ft (31 N·m, 3.2 kgf·m) Servicing Your Honda...

  • Page 82: Brakes

    (page (1) lock nut 80), there is probably air in the brake system. (2) adjuster Refer to the Honda Service Manual or see your (–) Honda dealer to have the air bled from the 1. Loosen the lock nut (1).
  • Page 83 Worn brake pads should be replaced. If the pads (20 mm), there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda dealer for If the brake lever freeplay exceeds 13/16 in brake bleeding.
  • Page 84 Do not mix different types of fluid, they may not be compatible. not be compatible. • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent. DOT 4 brake fluid or an equivalent.
  • Page 85 0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) front brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 86: Wheels

    3. Check wheel rim runout. If runout is control. It’s also important that the rim locks are noticeable, see the Honda Service Manual for secure to prevent tire slippage. inspection instructions.

  • Page 87: Tires & Tubes

    Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 88 • Use a replacement tire equivalent to the original. • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 89: Drive Chain

    Lubricate the drive chain (page 85) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed. (2) chain guide slider (3) wear limit Servicing Your Honda...
  • Page 90 2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda HP Chain Lube or an equivalent, or SAE rollers and replace them if below the service Align the index marks (4) of the axle plates 80 or 90 gear oil is recommended.
  • Page 91 17 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 92: Exhaust Pipe/Muffler

    1. Remove the seat mounting bolts (1), side cover bolts (2) and side covers (3). (4) muffler clamp bolt (5) muffler (6) muffler mounting bolt (7) washer (1) seat mounting bolt (3) side cover (2) side cover bolt Servicing Your Honda...
  • Page 93 (7) muffler mounting bolt (8) washer 3. Install a new gaskets (5) to the exhaust joint (9) muffler clamp bolt pipe (6). 4. Install each muffler to the exhaust joint pipe. (5) gasket (6) exhaust joint pipe Servicing Your Honda...
  • Page 94 (3) joint pipe clamp bolt (4) exhaust joint pipe mounting bolt (5) exhaust joint pipe (4) exhaust joint pipe (5) gasket (6) exhaust pipe Servicing Your Honda...
  • Page 95 6. Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt (page 89). 7. Tighten the muffler clamp bolts and muffler mounting bolts (page 88). 8. Installation can be done in the reverse order of removal. Servicing Your Honda Servicing Your Honda...

  • Page 96: Additional Maintenance Procedures

    (3) paint mark not see any movement in the steering head, the fork bushings may be worn. Refer to the Control Cables Honda Service Manual for replacement or adjustment procedures, or see your Honda dealer. Periodically, disconnect the throttle, clutch and hot start cables at their upper ends.
  • Page 97 (10) drive sprocket bolt (11) transmission oil drain bolt (1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cover bolts (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts Servicing Your Honda Servicing Your Honda...

  • Page 98: Appearance Care

    Wet any heavy deposits with water first. Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge.
  • Page 99 #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda Servicing Your Honda...

  • Page 100: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......96 for maximum competition performance. Rear Suspension Adjustments ......109 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ...........113 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....114 break-in time.

  • Page 101: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).
  • Page 102 See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and •...
  • Page 103 Front Suspension Adjustments 3. Remove the washers/handlebar holder nuts (3), 6. Remove the disc cover (8) by removing the Do not support the brake caliper by the brake mounting rubbers (4) and handlebar (5). disc cover bolts (9). hose. Do not operate the brake lever after the front wheel is removed.
  • Page 104 Front Suspension Adjustments 12.Clean the fork assembly, especially the sliding 17.Temporarily install the fork damper to the NOTICE surface of the slider (19) and dust seal (20). outer tube. 13.Record the rebound damping adjuster position 18.Set the axle holder (28) in a vise with a piece of The outer tube can drop on the slider and and turn the adjuster counterclockwise until it wood or soft jaws to avoid damage.
  • Page 105 Front Suspension Adjustments 22.Apply pressure to the fork damper and insert a Damper Oil Change special tool or mechanic’s stopper tool (30) (see below) between the axle holder (28) and lock nut (31) 1. Set the fork damper (1) in a vise with a piece 23.Hold the lock nut and remove the center bolt of wood or soft jaws to avoid damage.
  • Page 106 (1) as shown. Recommended Oil: Be careful not to damage the fork cap bushing Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5W or equivalent (4). Recommended Amount: Do not disassemble the fork cap assembly.
  • Page 107 Front Suspension Adjustments 10.Tighten the fork cap assembly (2) while 12.Screw in the lock nut (7) to the fork damper 14.Drain the extra oil from the oil hole (9). piston rod (5) fully. holding the fork damper (1) using the lock nut wrench (3) to the specified torque: By doing this procedure, about 0.6 US oz (17 22 Ibf·ft (30 N·m, 3.1 kgf·m)
  • Page 108 Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 1. Drain the fork oil from the outer tube/slider (1) by placing it upside down. Wipe the oil completely off the fork damper.
  • Page 109 Front Suspension Adjustments 4. Set the axle holder in a vise with a piece of 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the center bolt O-ring (7). wood or soft jaws to avoid to damage. center bolt (8) clearance.
  • Page 110 (1). No mark 1 scribe mark and (factory products) Recommended Oil: 3 scribe marks 75 degrees apart Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) Standard oil 12.7 US oz Standard oil 12.6 US oz...
  • Page 111 Front Suspension Adjustments 15.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the assembly (4) is in good condition. Apply the specified torque using the lock nut wrench recommended fork oil to the O-ring. (14).
  • Page 112 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle Fit the brake caliper (21) over the disc, taking (18) and axle holder thoroughly. clamps contact each other. care not to damage the brake pads. Apply locking agent to the bolt threads.
  • Page 113 Front Suspension Adjustments 25.Install the handlebar (25), mounting rubbers 27.Install and tighten the number plate bolt (31). (32) (26), washers and handlebar holder nuts (27) and tighten the handlebar holder nuts to the specified torque: 32 Ibf·ft (44 N·m, 4.5 kgf·m) (31) (26) (25)

  • Page 114: Rear Suspension Adjustments

    Min. gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 5.1 kgf/mm): 9.9 in (252 mm) limited to adjustments of the shock assembly Min.
  • Page 115 Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping The high speed damping adjuster has 3 1/2 turn Compression damping may be adjusted in two or more.
  • Page 116 Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT Standard Race Sag: 3.9 in (100 mm) important for competition use.
  • Page 117 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 118: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 119: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 96 – 113. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 120 Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 121 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: –...

  • Page 122: Cold/Hot Start Circuit

    (2) and is mixed with air from circuit resulting in a lean condition. your CRF. See your Honda dealer. the air passage (3) (located above the throttle valve (4)) to provide a rich mixture for starting.

  • Page 123: Accelerator Pump/Slow Circuit

    Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.
  • Page 124 Honda carburetor jet sizes are numbered in The minimum to maximum range of pilot screw increments of 2 or 3. When changing the main jet adjustment is 1 3/4 to 2 1/2 turns out from the size, increase or decrease it gradually until the lightly seated position.
  • Page 125 Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 30). 9. Remove the hot start cable holder (4). 11.Remove the throttle drum cover bolt (7) and 5. Remove the subframe (page 32). throttle drum cover (8). 6. Loosen the insulator band screw (2). (4) hot start cable holder (7) throttle drum cover bolt 10.Disconnect the rear suspension (5), upper...
  • Page 126 Carburetor Adjustments & Tuning Tips 3. Remove the link arm torx screw (6). When installing the floating valve (9) onto the Carburetor Disassembly/Assembly When installing the link arm torx screw, apply throttle valve (7) make sure the floating a locking agent to the link arm torx screw valve’s flat side faces out and the hole (10) threads.
  • Page 127 Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (18), throttle stop 9. Measure the float level (25) with the float (11) and accelerator pump cover (12). screw holder (19), float bowl screws (20), level gauge (26) while the float tab is just tube guides (21) and float bowl (17).
  • Page 128 Carburetor Adjustments & Tuning Tips To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. • Route the throttle cables (1), hot start cable (2) and throttle sensor wire correctly. • After installing the carburetor, adjust the throttle grip free play and hot start lever free play.
  • Page 129 Carburetor Adjustments & Tuning Tips Standard Tuning Recommendations For the following recommendations to be accurate, you must use the standard settings as a baseline. Also, don’t change any of the settings until you’ve determined what changes are necessary. Adjustment Standard settings Pilot screw opening 2 1/4 turns out Slow jet...
  • Page 130 Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the atmospheric conditions or race day situations that situations that may require additional...
  • Page 131 Carburetor Adjustments & Tuning Tips 6. Adjust the pilot screw as required. Carburetor Minor Adjustments WARNING The standard carburetor settings are ideal for the Gasoline is highly flammable and following conditions: sea level altitude, and 20°C explosive. You can be burned or (68 °F) air temperature.
  • Page 132 Carburetor Adjustments & Tuning Tips 12.Change the main jet (4) and slow jet (5) as 17.Remove the jet needle/holder assembly (8). 19.Reinstall the jet needle/holder assembly, required. carburetor top and carburetor top bolts. 20.Rotate the carburetor and align the lug (12) on the carburetor with the slot (13) on the insulator.
  • Page 133 Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may Refer to Spark Plug on page 55.

  • Page 134: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle not adjustable. Align the groove in the outer tube changes in overall handling.

  • Page 135: Gearing

    Honda Service Manual, higher gear (less teeth) to keep engine rpm appraisal of the gearing change. “Seat-of-the- sprocket changing should be done by your Honda down, and avoid unwanted wheelspin. The pants” feelings can’t be trusted. Eliminating dealer.

  • Page 136: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 137: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to the threads of these bolts prior to adjustment to Handlebar Position, Width & Shape help ensure the correct torque is retained.

  • Page 138: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ......134 Storing Your Honda..........135 You & the Environment ........136 Troubleshooting..........137 Tips...

  • Page 139: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 140: Storing Your Honda

    Removal from Storage such as during the winter, thoroughly inspect bolt/sealing washer (1) at the water pump (2) to your Honda and correct any problem before drain coolant. storing it. That way, needed repairs won’t be After the coolant has been completely 1.

  • Page 141: You & The Environment

    You & the Environment Owning and riding a motorcycle can be NOTICE enjoyable, but you must do your part to protect nature. When you show respect for the land, Improper disposal of drained fluids is harmful to wildlife, and other people, you also help preserve the environment.

  • Page 142: Troubleshooting

    The items that require use of the • Lack of fuel in tank CHECK POSSIBLE CAUSES 1. Disconnect fuel FUEL FLOW Honda Service Manual are followed by an (P.34) line at carburetor RESTRICTED • Over-oiled air cleaner. 1. Check if air INCORRECT •...
  • Page 143 Tips...

  • Page 144: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........140 other technical data. Specifications ...........141 Torque Specifications........142 Oxygenated Fuels..........145 Competition Logbook ........146 Optional Parts List ...........148 Spare Parts & Equipment.........149 Wiring Diagram..........150 Technical Information...

  • Page 145: Vehicle Identification

    Vehicle Identification The VIN (vehicle identification number) (1) is Serial Numbers stamped on the right side of the steering head. RIGHT SIDE The VIN and engine serial numbers are required when you register your CRF. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of this manual.

  • Page 146: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 85.5 in 2,172 mm Overall width Single 10˚ inclined from Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement vertical...

  • Page 147: Torque Specifications

    Torque Specifications Torque Nuts, Bolts, Fasteners Remarks Item lbf•ft N•m kgf•m ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts RIGHT SIDE Water pump cover bolts Crankshaft hole cap NOTE 1 Transmission oil check bolt...
  • Page 148 Torque Specifications Frame Torque Item Remarks lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1 Chain adjuster lock nuts...
  • Page 149 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (38) (42) FRAME (34) Caliper mounting bolts NOTE 4 (28) Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 Brake pedal pivot bolt NOTE 5 Spoke (front) 3.68 (37) (rear) Rim locks...

  • Page 150: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States use oxygenated Fuel system damage or performance problems fuels to help reduce emissions.

  • Page 151: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.
  • Page 152 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 153: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 296.8 lbf/in (5.30 kgf/mm) Standard 51 Teeth, Aluminum. Standard CARBURETOR Remarks <114>...

  • Page 154: Spare Parts & Equipment

    Pro Honda GN4 4-stroke Oil brake hoses (front & rear) (Engine and Transmission Oil) SAE80 or 90 gear oil Spare Parts Pro Honda HP Fork Oil 5W General Tools Pro Honda DOT4 Brake Fluid spark plugs Pro Honda HP Chain Lube air cleaner (clean &...

  • Page 155: Wiring Diagram

    Wiring Diagram SPARK THROTTLE POSITION PLUG SENSOR Technical Information...

  • Page 156: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........152 contacting Honda and how to get an official Contacting Honda..........153 Honda service manual. Your Honda Dealer...........154 The Honda Rider’s Club ........155 Consumer Information...

  • Page 157: Authorized Manuals

    For purchases outside U.S.A., please write to the address shown below for a quotation. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service...

  • Page 158: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 159: Your Honda Dealer

    Your Honda Dealer Once you purchase your new Honda, get familiar Your dealer can inform you about competition with the organization of your Honda dealer so events in your area. You’ll also find that your you can utilize the full range of services dealer is a source of information the Honda available.

  • Page 160: The Honda Rider's Club

    • 24-hour, toll-free roadside assistance for your new Honda (includes roadside assistance for your transport vehicle [up to one ton] as long as your Honda is aboard or in tow) For street- legal motorcycles and scooters only. • An exclusive HRCA website complete with...

  • Page 161: Table Of Contents

    Optional Parts List ..........148 Suspension............72 Spare Parts & Equipment........149 SERVICING YOUR HONDA......17 Front Suspension Inspection......72 Wiring Diagram..........150 Before You Service Your Honda Rear Suspension Inspection......73 The Importance of Maintenance .......18 Fork Oil Change ...........74 CONSUMER INFORMATION ....151 Maintenance Safety...........19 Brakes..............77 Authorized Manuals ........152...

  • Page 162: Index

    & practice maintenance ...26 front ..............96 filter ..............35 brakes, rear..............110 recommendation...........34 fluid level .............78 dealer, your Honda ..........154 refueling ............34 lever, front adjustment .........77 diagram, wiring ..........150 system............34 pad wear ............80 drive chain............84 oxygenated ..........145 pedal height ..........77 tank capacity ..........34...
  • Page 163 Index gap, spark plug ..........55 maintenance, rear suspension maintenance......73 gasohol ............145 additional procedures ........91 Rider’s Club Honda.........155 gasoline..............34 after competition ..........26 riding, gearing.............130 before & after competition......26 basic operation ..........11 guidelines, suspension adjustment ....114 between motos & practice......26 before..............7 component locations ........28 important safety information......2...
  • Page 164 Index suspension, front ............72,96 rear............73,109 suspension adjustment, front ..............96 rear..............109 for track conditions ........113 guidelines ...........114 transmission oil ..........39 tuning tips ............117 throttle, freeplay............46 inspection .............47 tires, air pressure ...........82 flat ..............82 selection............83 tools ...............149 torque specifications ........142-144 transporting............134 troubleshooting..........137 tubes, replacing ..........82 valve, fuel............13 vehicle identification no.

  • Page 165: Quick Reference

    Engine No. important notes. Owner’s: Name How To Avoid Costly Repairs Address City/State The engine of your Honda can be the most Phone expensive component to repair. Proper Dealer’s: maintenance, especially the use of the Name recommended fluids and filters, prevents Address premature wear and damage.

This manual is also suitable for:

2007 crf250r

Table of Contents