Honda CRF450X Owner's Manual
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Honda CRF450X Owner's Manual

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See also: Owner's Manual & Competition Handbook
CRF450X
 Honda Motor Co., Ltd. 2006
CRF450X_COVER
1
OWNER'S MANUAL & COMPETITION HANDBOOK
MANUEL DU CONDUCTEUR ET DE COMPETITION
FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG
INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK
MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES
MANUALE D'USO E DEGLI ASSETTI DA COMPETIZIONE
6/1/06, 11:43 AM
HONDA O/M CRF450X (Eu) 3RMEY600 00X3R-MEY-6000
E
F
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  • Page 1 MANUEL DU CONDUCTEUR ET DE COMPETITION FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES MANUALE D’USO E DEGLI ASSETTI DA COMPETIZIONE  Honda Motor Co., Ltd. 2006 CRF450X_COVER 6/1/06, 11:43 AM HONDA O/M CRF450X (Eu) 3RMEY600 00X3R-MEY-6000...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 3 Honda CRF450X OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 When you own a Honda, you’re part of a given to you by your Honda dealer at the line of hot. Additionally, when riding in mud or sand, or worldwide family of satisfied customers–people purchase.
  • Page 5 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, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 6: Table Of Contents

    Break-in Guidelines ..........21 Suspension............84 Spare Parts & Equipment........162 Brakes..............88 Wiring Diagram..........163 Servicing Your Honda ........23 Wheels...............92 Before You Service Your Honda Tyres & Tubes ...........93 Table of Contents...........164 The Importance of Maintenance .......24 Side Stand............95 Maintenance Safety...........25 Drive Chain ............96 Index ...............166...

  • Page 7: 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 Loading..............3 moments to read these pages. This section also Accessories & Modifications .......4 includes information about the location of the Safety Labels ............5 safety labels on your CRF.

  • Page 8: Important Safety Information

    Important Safety Information Do not wear loose clothing which could catch on Keep Your Honda in Safe Condition. It’s Important Safety Precautions the control levers, kickstarter, footpegs, drive important to keep your CRF properly maintained chain, or wheels. and in safe riding condition. Having a breakdown...

  • Page 9: Loading

    Loading Your CRF was designed as a rider-only Loading Guidelines motorcycle. It was not designed to carry a As discussed on this page, we recommended that passenger or cargo. A passenger or cargo could you do not carry any cargo on this motorcycle. interfere with your ability to move around to However, if you decide to carry cargo, ride at maintain your balance and control of the CRF.

  • Page 10: Accessories & Modifications

    Modifying your CRF or using non-Honda accessories can make your CRF unsafe. Because Honda cannot test all other accessories, Such changes could seriously impair your CRF’s you must be personally responsible for proper...

  • Page 11: Safety Labels

    This page shows the locations of safety labels on your CRF. Some labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read these labels carefully and don’t remove them. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. (DK type only)
  • Page 12 Motorcycle Safety...

  • Page 13: Operating Controls

    Operating Controls Read this section carefully before you ride. It Operation Component Locations ......8 presents the location of the basic controls on your CRF. Operating Controls...

  • Page 14: Operation Component Locations

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

  • Page 15: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........10 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride? ....11 you prepared, this section discusses how to Pre-ride Inspection........11...

  • Page 16: Are You Ready To Ride

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

  • Page 17: 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 18 Before Riding...

  • Page 19: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions........14 start and stop your engine as well as break-in Side Stand .............14 guidelines. Tripmeter............14 Starting & Stopping the Engine ......15 Preparation ............15 Fuel Valve .............15 Starting Procedure ........15 Flooded Engine ..........16 How to Stop the Engine........16 Shifting Gears.............17...

  • Page 20: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Side Stand Tripmeter The side stand (1) is used to support your CRF Before riding your CRF for the first time, please The tripmeter (1) is used to record the distance review the Important Safety Precautions while parked (page 19).

  • Page 21: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure 5. Warm up the engine; don’t operate the Starting Procedure throttle. described below. 6. About 15 seconds after the engine starts, push the choke knob back all the way to fully OFF. Your CRF can be started with the transmission in Always follow the proper starting procedure If idling is unstable, open the throttle slightly.

  • Page 22: Flooded Engine

    Starting & Stopping the Engine Hot Engine Starting Flooded Engine How to Stop the Engine 1. Pull the hot start lever (3) all the way in and start the engine following step 4 under “Normal Air Temperature.” Starting the engine after a stall during riding or 2.

  • Page 23: Shifting Gears

    Shifting Gears Remember to close the throttle and pull the clutch lever in completely before shifting. NOTICE Improper shifting may damage the engine, transmission, and drive train. Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high.

  • Page 24: Braking

    Braking To slow or stop, apply the front brake lever and rear brake pedal smoothly, while downshifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. To prevent stalling the engine, pull the clutch lever in before coming to a complete stop.

  • Page 25: Parking

    Parking Lower the side stand to support your CRF. If you’re through riding for the day, turn the fuel valve OFF. Always choose a level surface to park. Basic Operating Instructions...

  • Page 26: Post-Ride Inspection

    Post-ride Inspection When you return home after riding, thoroughly clean your CRF and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way. After cleaning, carefully inspect your CRF for leaks or damage. Be sure to lubricate the drive chain (page 98) to prevent rusting.

  • Page 27: 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 25 km (15 miles). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...
  • Page 28 Basic Operating Instructions...

  • Page 29: Servicing Your Honda

    You’ll also find Electrical important safety precautions, information on oils, Service Preparations Battery ..............101 and tips for keeping your Honda looking good. Maintenance Component Locations....35 Headlight & Taillight ........103 Seat Removal............36 The ICM (Ignition Control Module) system is Fuel Tank Removal ..........37...

  • Page 30: The Importance Of Maintenance

    If your CRF overturns or is involved in a crash, be sure your Honda dealer inspects all major parts, even if you are able to make some repairs. Remember, proper maintenance is your responsibility.

  • Page 31: 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 32: 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 33 92,93 STEERING HEAD BEARINGS Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Shop Manual. In the interest of safety, we recommend these items be serviced only by your Honda dealer.
  • Page 34 Maintenance Schedule MAINTENANCE SCHEDULE – COMPETITION USE All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools. Perform the Pre-ride Inspection (page 11) at each scheduled maintenance period.

  • Page 35: 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 36 Follow the servicing instructions in the Maintenance section. Use Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium...
  • Page 37 For added peace of mind, may restrict throttle control in any way. Move the handlebar remove the nuts, clean the threads, and apply Honda Thread from lock to lock to be sure there is no cable interference.
  • Page 38 Remove the nuts, clean damaged mechanical seal. Leaking oil indicates a bad the threads of both the nuts and bolts, apply Honda Thread transmission oil seal. If replacement is necessary, both seals Lock or an equivalent and tighten to the specified torque.

  • Page 39: Before & After Competition Maintenance

    (1) are in the same position on (2) pressure release screw 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 40 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 105). Servicing Your Honda...

  • Page 41: Maintenance Component Locations

    Servicing Your Honda...

  • Page 42: Seat Removal

    2. Install and tighten the seat bolts (1) to the specified torque. 26 N·m (2.7 kgf·m, 19 lbf·ft) (1) seat bolts (2) seat (1) seat bolts (2) seat (3) seat front prong (4) seat bracket (5) seat rear prongs (6) tabs Servicing Your Honda...

  • Page 43: Fuel Tank Removal

    • Wipe up spills immediately. (4) breather tube (10) (5) fuel tank band (6) air cleaner cover rubber (1) shroud A bolts/collars (7) fuel tank bolt/collar (2) shroud B bolts (3) shroud (8) fuel line (10) bolt (9) fuel valve Servicing Your Honda...
  • Page 44 7. Put the breather tube (7) in the steering stem nut. (10) (9) shroud B bolts (10) shroud A bolts/collars 11.Install the seat (page 36). (4) fuel tank bolt/collar (6) fuel tank band (5) air cleaner cover rubber (7) breather tube Servicing Your Honda...

  • Page 45: Subframe Upright Position

    (5) and left side cover (6). (10) (9) subframe upper mounting bolts (10) subframe lower mounting bolts (3) air cleaner housing cover (5) left side cover bolt (4) quick fastener (6) left side cover Servicing Your Honda...
  • Page 46 6. Install the right side cover (10) and right side cover bolt (11). (1) subframe upper mounting bolts (10) (2) subframe (3) subframe lower mounting bolts (11) (10) right side cover (11) right side cover bolt 7. Install the seat (page 36). Servicing Your Honda...

  • Page 47: Fuel System

    If pinging or spark knock persists, steering stem nut. 1. Check for leaks. consult your Honda dealer. 2. Check the fuel line (1) for cracks, WARNING deterioration, damage, or leakage. Replace the...
  • Page 48 Reassemble the fuel joint in the reverse order of removal. 6. Install the fuel tank (page 38) and refill the fuel. Turn the fuel valve to ON or RES; check for leaks. Servicing Your Honda...

  • Page 49: Engine Oil

    • Oil is a major factor affecting the peformance and service life of the engine. Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. Servicing Your Honda...
  • Page 50 27, 28. mark and add the recommended oil until the upper level mark. (Do not overfill) Reinstall the engine oil filler cap/dipstick. Repeat steps 1–5. 6. Install the engine oil filler cap/dipstick securely. 7. Check for oil leaks. Servicing Your Honda...
  • Page 51 You should see the “OUT- SIDE” mark on the filter body, near the rubber steps in Checking & Adding Oil (page 44). seal (12). Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE (4) bolt...

  • Page 52: Transmission Oil

    • Oil is a major factor affecting the performance MOTORCYCLE OIL” or and service life of the transmission and clutch. equivalent Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. Servicing Your Honda...

  • Page 53: Checking And Adding Oil

    1–4. 5. After inspection the oil level or adding oil, tighten the oil check bolt to the specified torque: Oil Check Bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft) 6. Install the transmission oil filler cap securely. Servicing Your Honda...

  • Page 54: Coolant

    3. Add coolant to the reserve tank as require to Honda dealer for repair. bring the coolant level to the UPPER level mark.
  • Page 55 Refer to Safety Precautions on page 25. Honda Shop Manual for troubleshooting of leaks). Coolant should be replaced by your Honda 2. Check the water hoses (1) for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.
  • Page 56 If the radiator cap is not installed properly, it will cause excessive coolant loss and may result in overheating and engine damage. (3) radiator reserve tank cap (4) UPPER level line 5. Install the radiator reserve tank cap. (1) radiator cap (2) filler neck Servicing Your Honda...

  • Page 57: 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 58 Air Cleaner 8. Apply a thin coat of Honda White Lithium NOTICE Grease or equivalent to the sealing surface between the air cleaner element and air Improper installation of the air cleaner assembly cleaner element holder. may allow dirt and dust to enter the engine and 9.

  • Page 59: Crankcase Breather

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

  • Page 60: Throttle

    5. Operate the throttle grip to ensure that it functions smoothly and returns completely. (–) 6. Install the fuel tank (page 38). If you can’t get the freeplay within the specified range, see your Honda dealer. (2) dust cover (+) increase (3) upper lock nut (–) decrease...
  • Page 61 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 62: Clutch System

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 58). Servicing Your Honda...
  • Page 63 1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot or clutch cable. 2. Check the clutch cable for deterioration, (9) clutch spring bolts/clutch springs kinks, or damage. (10) clutch pressure plate (cont’d) Servicing Your Honda...
  • Page 64 (12) needle bearing (15) clutch discs/clutch plates a feeler gauge. (13) clutch lifter Measure the thickness of each clutch plate. Service Limit: 0.15 mm (0.006 in) Replace the clutch discs and plates as a set. (2) clutch plate Servicing Your Honda...
  • Page 65 12. Lubricate the dust seals (12), rear brake pedal Clutch Disc/Plate Installation 8. Install the six clutch springs and bolts (9). (13) pivot and pivot bolt (14) with Honda 9. Tighten the bolts in a crisscross pattern in 2 or White Lithium Grease or equivalent.

  • Page 66: Hot Start Lever

    (–) (1) hot start lever (2) freeplay (3) lock nut (+) increase Inspection (4) adjuster (–) decrease Check freeplay (2). Freeplay: 2 – 3 mm (0.08 – 0.12 in) If necessary, adjust to the specified range. Servicing Your Honda...

  • Page 67: Spark Plug

    “leaf-type feeler gauge’’. • Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one. (3) sealing gasket (4) spark plug gap (cont’d) Servicing Your Honda...
  • Page 68 If a plug is too tight, the threads may be damaged. 10. Connect the spark plug cap. Take care to avoid pinching any cables or wires. 11. Install the fuel tank and seat (pages 36, 38). Servicing Your Honda...

  • Page 69: Exhaust Pipe/Muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (4) muffler clamp bolt (1) seat bolt (3) right side cover (5) rear muffler mounting bolt/washer (2) side cover bolt (6) front muffler mounting bolt (7) muffler 4. Remove the muffler gasket. Servicing Your Honda...
  • Page 70 (10) (9) right side cover (11) seat bolt (10) side cover bolt (1) gasket (4) tab (2) muffler clamp (5) cut-out (3) muffler (6) front muffler mounting bolt (7) rear muffler mounting bolt/washer (8) muffler clamp bolt Servicing Your Honda...
  • Page 71 3. Tighten the nuts to the specified torque: 21 N·m (2.1 kgf·m, 15 lbf·ft) (1) exhaust pipe joint nuts (2) exhaust pipe (3) exhaust pipe gasket (1) exhaust pipe gasket (2) exhaust pipe (3) exhaust pipe joint nuts 4. Install the muffler (page 64). Servicing Your Honda...

  • Page 72: Spark Arrester

    4. Install a new gasket and the spark arrester in the muffler and tighten the four bolts (1) to the specified torque: 12 N·m (1.2 kgf·m, 9 lbf·ft) (1) bolts (3) gasket (2) spark arrester (1) bolts Servicing Your Honda...

  • Page 73: Cylinder Head Cover Removal

    4. Remove the cylinder head cover A bolt (3), cylinder head cover B bolts (4) and cylinder head cover (5). (3) cylinder head cover A bolt (4) cylinder head cover B bolts (cont’d) (5) cylinder head cover Servicing Your Honda...
  • Page 74 (2) primary drive gear bolt (4) index mark (3) “punch” mark (1) feeler gauge (2) valve lifters (3) intake cam lobes Valve Clearance: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in) Servicing Your Honda...
  • Page 75 If measured right exhaust valve clearance is 0.28 mm (0.011 in), decompressor clearance is: 0.28 mm (0.011 in) + 0.35 mm (0.014 in) = 0.63 mm (0.025 in) If only decompressor arm clearance needs adjustment, see Decompressor Arm Clearance Adjustment (page 74). (cont’d) Servicing Your Honda...
  • Page 76 (4) cam sprocket bolts (7) camshaft holder bolts (5) cam sprocket (8) camshaft holder assembly (6) cam chain (10) (9) intake valve lifters (10) shims Servicing Your Honda...
  • Page 77 2.450 mm. Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3.000 mm. (1) valve lifter (2) shim 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda...
  • Page 78 Tighten the camshaft holder assembly bolts in a crisscross pattern in 2 or 3 steps. (2) valve lifters (1) shims (3) camshaft holder assembly Exhaust side (3) camshaft holder assembly (4) intake cam lobes (5) camshaft holder assembly bolts Servicing Your Honda...
  • Page 79 Do not let the bolts and sprocket fall into the (9) cam sprocket crankcase. (10) index line (6) primary drive gear bolt (11) “ ” mark (7) “punch” mark (12) cam chain (8) index mark (13) (13) cam sprocket bolts (cont’d) Servicing Your Honda...
  • Page 80 (16) cam chain tensioner lifter cover bolt (1) feeler gauge (5) adjusting screw 10.After installing the cam shaft assembly, (4) lock nut (6) right side rocker arm perform the valve clearance and decompressor arm clearance inspection. Recheck the decompressor arm clearance. Servicing Your Honda...
  • Page 81 Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) spark plug cap (8) breather tube 6. Install the fuel tank and the seat (pages 36, 38). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 82: Piston/Piston Rings/Piston Pin

    (3) primary wire connector (4) bolts/clamp (1) left radiator grill (5) ignition coil (2) left radiator lower mounting bolt/washer 12. Loosen the radiator hose clamp (6) and disconnect the radiator hose (7). (6) radiator hose clamp (7) radiator hose Servicing Your Honda...
  • Page 83 (8) engine hanger nut (9) engine hanger bolt (10) fuel hose guide (11) engine hanger plate bolts (12) clutch cable stay (13) left engine hanger plate (14) right engine hanger plate (18) (17) cylinder head nuts/washers (18) cylinder head Servicing Your Honda...
  • Page 84 (2) cylinder bolt 3. Remove the dowel pins (4) and cylinder gasket (5). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (4) dowel pins (5) cylinder gasket Servicing Your Honda...
  • Page 85 We recommend you consult the Shop Manual or 1. Clean the piston ring groove throughly. oil ring your authorized Honda dealer for correct Service 2. Apply engine oil to the piston rings and install Limit measurements. them. NOTICE Do not damage the piston ring by spreading the ends too far.
  • Page 86 Do not align the piston pin clip end gap with the piston cut-out. (1) dowel pins (2) cylinder gasket 5. Clean the any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) cut-out Servicing Your Honda...
  • Page 87 Push the cam chain guide until it bottoms in the crankcase guide hole. (1) dowel pins (2) cylinder head gasket (3) cam chain (5) piston rings (4) cylinder (10) (8) cam chain guide (9) cam chain guide tabs (10) cylinder cut-outs (cont’d) Servicing Your Honda...
  • Page 88 (12) fuel hose guide 26 N·m (2.7 kgf·m, 19 lbf·ft) (13) engine hanger nut Tighten the engine hanger nut to the specified torque: 54 N·m (5.5 kgf·m, 40 lbf·ft) (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
  • Page 89 12.Install the crankshaft hole cap (page 75). 13.Install the cylinder head cover (page 75). 14.Install the spark plug and plug cap (page 61). (17) (19) (18) (16) (16) ignition coil (18) clamp/bolts (17) ground wire (19) primary wire connector Servicing Your Honda...

  • Page 90: Suspension

    (Adjusting two or more your CRF. If any suspension components appear clicks at a time may cause you to pass over worn or damaged, see your Honda dealer for the best adjustment.) Test ride after each further inspection. Your dealer is qualified to adjustment.
  • Page 91 (page 126). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Lift the subframe to the upright position (page The instructions found in this owner’s manual are 39).
  • Page 92 (weight) 5 W when the fork damper is removed. To avoid suggested oil Honda ULTRA CUSHION OIL damage hold both the outer tube and slider when SPECIAL or equivalent removing the fork damper.
  • Page 93 Minimum oil Slightly softer as 14.3 Imp oz) compression. (10.3 US oz, capacity it nears full Minimum oil 309 cm Slightly softer as 10.8 Imp oz) compression. capacity (10.5 US oz, it nears full 10.9 Imp oz) compression. Servicing Your Honda...

  • Page 94: Brakes

    (page 91), there is probably air in the brake system. (1) lock nut (3) piston Refer to the Honda Shop Manual or see your (2) adjuster Honda dealer to have the air bled from the (–) system.

  • Page 95: Fluid Level Inspection

    (0.8 in), there is probably air in the brake If the brake lever freeplay exceeds 20 mm system and it must be bled. Refer to the Honda (0.8 in), there is probably air in the brake Shop Manual or see your Honda dealer for brake system and it must be bled.
  • Page 96 Do not bend to the diaphragm during installation. 4. Tighten the screws to the specified torque: 4. Install and tighten the bolts to the specified 1 N·m (0.1 kgf·m, 0.7 lbf·ft) torque: 1 N·m (0.1 kgf·m, 0.7 lbf·ft) Servicing Your Honda...
  • Page 97 1 mm (0.04 in) (4) brake pads (6) brake disc (5) rear brake caliper replace wear indicator grooves 1 mm (0.04 in) replace (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...

  • Page 98: Wheels

    It’s also important that the rim locks are 3. Check wheel rim runout. If runout is secure to prevent tyre slippage. noticeable, see the Honda Shop Manual for inspection instructions. It is not necessary to remove the wheels to perform the recommended service in the Regular Axles &...

  • Page 99: Tyres & Tubes

    Overinflated tyres make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 100 • Use a replacement tyre equivalent to the original. • Replace the tube any time you replace a tyre. The old tube will probably be stretched and, if installed in a new tyre, could fail. Servicing Your Honda...

  • Page 101: Side Stand

    2. Check the side stand assembly for freedom of movement. (1) side stand spring If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with grease. Servicing Your Honda...

  • Page 102: Drive Chain

    27 N·m (2.8 kgf·m, 20 lbf·ft) binding. Kinking and binding can frequently be eliminated by thorough cleaning and lubrication. If the drive chain requires adjustment, procedure is as follows: Servicing Your Honda...
  • Page 103 It should only be removed or replacement chain or sprocket(s) will wear rapidly. replaced by your Honda dealer. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any The O-rings can be damaged by steam cleaning, high pressure washers, and certain solvents.
  • Page 104 Replace the chian guide slider if it is worn to the bottom of the wear limit groove (3). (1) upper drive chain roller (3) lower drive chain roller (2) “ ” mark (2) chain guide slider (3) wear limit groove Servicing Your Honda...

  • Page 105: Additional Maintenance Procedures

    (1) handlebar (2) handlebar upper holder bolts not see any movement in the steering head, the fork bushings may be worn. Refer to the Honda Shop Manual for replacement or adjustment procedures, or see your Honda dealer. Servicing Your Honda...
  • Page 106 Engine oil drain bolt (5) transmission oil check bolt (8) oil filter cover bolts Transmission oil drain bolt (9) cylinder head bolts (6) clutch cover bolts (10) drive sprocket bolt (11) engine oil drain bolt (12) transmission oil drain bolt Servicing Your Honda...

  • Page 107: Battery

    If your battery seems weak and/or is leaking then the positive (+) terminal (4) and remove electrolyte (cause slow starting or other electrical the battery (5). problems), see your Honda dealer. Battery Storage (1) battery band If you plan to store your CRF, we recommend...
  • Page 108 However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions. Avoid using an automotive-type battery charger. An automotive charger can overheat a motorcycle battery and cause permanent damage. (1) “trickle” charger Servicing Your Honda...

  • Page 109: Headlight & Taillight

    Remove the dust cover (5). Install and tighten the front visor bolts. (11) (12) (7) headlight bulb (9) groove (8) tab (3) clamp (5) dust cover (3) clamp (11) grommets (4) headlight connector (4) headlight connector (12) tabs Servicing Your Honda...
  • Page 110 (1) adjusting screw Taillight The taillight uses LED illumination. If the taillight does not function properly, see your Honda dealer for service. Servicing Your Honda...

  • Page 111: Appearance Care

    Detergent Frequent cleaning and polishing will keep your wheel hubs Honda looking newer longer. Frequent cleaning muffler outlet also identifies you as an owner who values his area under seat 1. Rinse your CRF thoroughly with cool water to motorcycle.
  • Page 112 Dry with chamois or a soft towel. If necessary, remove heat stains by using a commercially available fine texture compound. Then rinse by the same manner as removing mud or dust. Servicing Your Honda...

  • Page 113: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......108 for maximum competition performance. Rear Suspension Adjustments ......122 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ............126 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....127 break-in time.

  • Page 114: 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 115 See the Shop Manual or your adjusters are firmly located in a detent, and not extension. If the fork is too hard on big bumps, Honda dealer for this service. between positions. turn the damping adjuster counterclockwise 1- turn and lower the oil level in increments of 5 1.
  • Page 116 Front Suspension Adjustments 4. Loosen the top bridge pinch bolts (3). 7. Remove the tripmeter cable (7) and front axle Do not support the brake caliper by the brake 5. Loosen the fork damper (4), using the lock nut (8) and loosen the axle pinch bolts (9) on hose.
  • Page 117 Front Suspension Adjustments 11.Clean the fork assembly, especially the sliding 16.Temporarily install the fork damper to the NOTICE surface of the slider (18) and dust seal (19). outer tube. 12.Record the rebound and compression damping The outer tube can drop on the slider and 17.Set the axle holder (26) of the slider in a vise adjuster positions and turn the adjuster damage the fork dust seal and guide bushing...
  • Page 118 Front Suspension Adjustments 19.Push out the fork centre bolt (27) from the 24.Remove the fork damper assembly (31) from (28) axle holder (26) of the slider by pushing the the fork assembly (32). (29) fork damper. While the fork centre bolt is Remove the fork from the vise.
  • Page 119 Recommended Oil: Do not disassemble the fork cap assembly. Honda ULTRA CUSHION OIL SPECIAL 2. Make sure the compression damping adjuster Replace the fork cap as an assembly if it is 5W or equivalent is set to the softest position.
  • Page 120 Front Suspension Adjustments 9. Extend the fork damper piston rod to 14.Screw in the lock nut (8) to the fork damper 11.Place the fork damper (1) in a vise with a piston rod (5) fully. maximum length. Adjust the oil level of the piece of wood or soft jaws to avoid damage.
  • Page 121 Front Suspension Adjustments 17.Blow out the oil from the fork damper spring 15.Cover the fork piston rod end with soft jaws 16.Drain the extra oil from the fork damper (1). chamber using compressed air to the oil hole. to prevent fork damage. Blow the extra oil off to the fork damper (1) Wipe the oil completely off the fork damper.
  • Page 122 Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Amount of fork oil left in the fork Fork Assembly (without damper and spring) unit: cc thread length (A) as shown. minute Standard: 11 – 13 mm (0.43 – 0.51 in) 1.
  • Page 123 Front Suspension Adjustments 4. Set the axle holder of the slider in a vise with 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the fork centre bolt O-ring a piece of wood or soft jaws to avoid to fork centre bolt (8) clearance.
  • Page 124 Optional Stiffer (0.49 kgf/mm) Fork Spring outer tube (1). Standard (0.47 kgf/mm) Fork Spring No mark Recommended Oil: (factory products) 3 scribe marks Honda ULTRA CUSHION OIL SPECIAL 5W or equivalent. 1 scribe mark (aftermarket parts) Standard oil 335 cm Standard oil...
  • Page 125 Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper (4) to the specified (16) assembly (4) is in good condition. Apply fork torque using the lock nut wrench (14). oil to the O-ring. Actual: 34 N·m (3.5 kgf·m, 25 lbf·ft) 15.Pull up the outer tube (1) slowly and install...
  • Page 126 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Check the left side collar (24) and tripmeter (18) and axle holder thoroughly. gear box (25) for wear or damage. (30) Apply locking agent to the fork protector bolt Install the left side collar to the left wheel threads.
  • Page 127 Front Suspension Adjustments 27.Install the handlebar (34), mounting rubbers 30. While keeping the forks parallel, alternately 32. Install the disc cover (39) and tighten the (35), washers and handlebar lower holder nuts tighten the right axle pinch bolts (37) to the bolts (40) to the specified torque: (36) and tighten the handlebar lower holder specified torque:...

  • Page 128: Rear Suspension Adjustments

    Min. : 249 mm (9.8 in) 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, 5.30 kgf/mm): 251 mm (9.9 in) limited to adjustments of the rear shock absorber Min.
  • Page 129 Rear Suspension Adjustments High Speed Compression Damping: Rebound Damping Rear Suspension Damping The high speed damping can be adjusted by The rebound damping adjuster (3) is located at turning the hexagonal portion of the compression the lower end of the shock absorber. adjuster.

  • Page 130: Spring Pre-Load & Race Sag Adjustment

    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 (without rider) important for competition use.
  • Page 131 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 132: 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 133: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 108 - 123. 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 134 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 135 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 136: Carburetor Adjustment & Tuning Tips

    Carburetor Adjustment & Tuning Tips The carburetor used on your CRF will seldom Hot Start Circuit Carburetor Components experience trouble with the standard settings A lean mixture must be delivered to the cylinder under average load, and average climatic and when a hot engine is being started.
  • Page 137 Carburetor Adjustment & 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 138 Carburetor Adjustment & Tuning Tips 6. Raise the rear wheel off the ground by placing 9. Loosen the insulator band screw (5) and Carburetor Removal an optional workstand or equivalent under the remove the carburetor (6) from the insulator engine. (7).
  • Page 139 Carburetor Adjustment & Tuning Tips 11.Remove the throttle drum cover bolt (10) and 3. Remove the link arm torx screw (7). Carburetor Disassembly/Assembly throttle drum cover (11). When installing the link arm torx screw, apply a locking agent to the link arm torx screw threads.
  • Page 140 Carburetor Adjustment & Tuning Tips When installing the floating valve (10) onto 5. Remove the accelerator pump cover screws 7. Remove the holder screw (19), throttle stop the throttle valve (8) make sure the floating (12) and accelerator pump cover (13). screw holder (20), float bowl screws (21), valve’s flat side faces out and the hole (11) tube guides (22) and float bowl (18).
  • Page 141 Carburetor Adjustment & Tuning Tips 9. Measure the float level (26) with the float To assemble, reverse the disassembly procedures. level gauge (27) during float tab just To install the carburetor, reverse the removal contacting the float valve and the carburetor procedures.
  • Page 142 Carburetor Adjustment & Tuning Tips Idle Speed Adjustment 1. If the engine is cold, start it and warm it up 3 minutes. Then shut it off. 2. Connect a tachometer to the engine. 3. Shift into neutral. Start the engine. 4.

  • Page 143: 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. Standard Position Adjusting your CRF’s wheelbase can offer subtle The position of the outer tubes in the clamps is changes in overall handling.

  • Page 144: Gearing

    Honda Shop Manual, • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate sprocket changing should be done by your Honda higher gear (less teeth) to keep engine rpm appraisal of the change. “Seat-of-the-pants”...

  • Page 145: Tyre Selection For Track Conditions

    Tyre Selection for Track Conditions Choosing the correct tyre tread pattern and If you choose a tyre with a sticky compound for rubber compound can affect your placing in added traction, remember that it may transfer competition. The tyres on your CRF offer a additional loads to the transmission because it “happy medium”...

  • Page 146: Personal Fit Adjustments

    Handlebar Position, Width & Shape Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained. • Position the handlebar so that both gripping •...

  • Page 147: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ......142 Storing Your Honda..........143 You & the Environment ........145 Troubleshooting..........146 Tips...

  • Page 148: 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- •...

  • Page 149: Storing Your Honda

    7. Remove the reserve tank cap (7). such as during the winter, thoroughly inspect (2). Disconnect the siphone tube (8) from the your Honda and correct any problem before Remove the centre engine guard mounting reserve tank (9). storing it. That way, needed repairs won’t be bolts, collars (3) and centre engine guard (4).
  • Page 150 Storing Your Honda 9. Install the centre engine guard (4) while 11. Remove the battery and charge it fully. Store Removal from Storage aligning its tabs (10) with the grooves (11) of in an area protected from freezing the radiator reserve tank.

  • Page 151: 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 152: Troubleshooting

    The items that require use of the 1. Disconnect fuel FUEL FLOW • Lack of fuel in tank CHECK POSSIBLE CAUSES Honda Shop Manual are followed by an asterisk. (P.41) line at carburetor RESTRICTED 1. Check if air INCORRECT •...

  • Page 153: Taking Care Of The Unexpected

    Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........148 solve problems. If Your Battery Is Low (or Dead).....149 Taking Care of the Unexpected...

  • Page 154: If A Fuse Blows

    CRF. side cover. Leave the blown fuse in that circuit and have your CRF checked by your Honda dealer. Recommended Main Fuse: 15A 1. To prevent an accidental short circuit, stop the engine.

  • Page 155: If Your Battery Is Low (Or Dead)

    CRF’s electrical system. Bump starting is also not recommended. If you can’t charge the battery or it appears unable to hold a charge, see your Honda dealer. Taking Care of the Unexpected...
  • Page 156 Taking Care of Unexpected...

  • Page 157: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........152 other technical data. Specifications ...........153 Torque Specifications ........155 Petrol Containing Alcohol........158 Competition Logbook ........159 Optional Parts List..........161 Spare Parts & Equipment.........162 Wiring Diagram..........163 Technical Information...

  • Page 158: Vehicle Identification

    Vehicle Identification The engine number (2) is stamped on the left Serial Numbers crankcase. The VIN and engine serial numbers are required ENGINE No. when you register your CRF. They may also be LEFT SIDE required when ordering replacement parts. The VIN number (1) is stamped on the right side of the steering head.

  • Page 159: Specifications

    Specifications Item Metric English Item Metric English Item Metric English Dimension Frame Engine Overall length Type Twin tube Type Liquid cooled, 4-stroke 2,180 mm 85.8 in Telescopic fork, Single 6 inclined from Overall width 821 mm 32.3 in Cylinder arrangement travel 279 mm (11.0 in) F.
  • Page 160 Specifications Item Metric English Drive train Clutch type Wet, multi-plate type Transmission 5-speed, constant mesh Primary reduction 2.739 Gear ratio I 2.230 Gear ratio II 1.625 Gear ratio III 1.235 Gear ratio IV 1.000 Gear ratio V 0.826 Final reduction 3.923 Left foot-operated return Gear shift pattern...

  • Page 161: Torque Specifications

    Torque Specifications Nuts, Bolts, Fasteners Torque Remarks Check and tighten nuts, bolts, and fasteners before every outing. Item N•m kgf•m lbf•ft ENGINE Engine Cylinder head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap Oil filter cover bolts Cylinder bolt Cylinder head bolts...
  • Page 162 Torque Specifications Frame Torque Remarks Item N•m kgf•m lbf•ft FRAME Steering stem nut 11.0 Top bridge upper pinch bolts (11) (19) (14) Bottom bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Axle pinch bolts Rear axle nut NOTE 2 13.1...
  • Page 163 Torque Specifications Frame Torque Remarks Item N•m kgf•m lbf•ft FRAME Front brake master (46) (32) cylinder holder bolts (43) Brake hose bolts Caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 2 Rear brake disc nuts NOTE 2 (39) Brake pedal pivot bolt Spokes (front)

  • Page 164: Petrol Containing Alcohol

    Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is not yet complete. Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol.

  • Page 165: 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 166 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 167: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your TOOLS Remarks FRAME Remarks Honda dealer. Shock spring Pin spanner A To adjust spring pre-load. 5.50 kgf/mm (308.0 lbf/in) Standard (two spanners required) FRAME Remarks No mark Driven sprocket <...

  • Page 168: Spare Parts & Equipment

    Honda 4-stroke oil (without molybdenum Spare Parts additives) (Transmission Oil) Honda thread Lock General Tools spark plugs Honda ULTRA CUSHION OIL SPECIAL 5W shims DOT 4 Brake Fluid air cleaner (clean & oiled, sealed in a plastic bag) sockets (3/8 in drive) Chain Lube chain &...

  • Page 169: Wiring Diagram

    Wiring Diagram Technical Information...

  • Page 170: Table Of Contents

    Table of Contents The following presents the contents of each Servicing Your Honda ........23 Chassis section of your owner’s manual. Before You Service Your Honda Suspension............84 The Importance of Maintenance .......24 Brakes..............88 Motorcycle Safety..........1 Maintenance Safety...........25 Wheels...............92 Important Safety Precautions......2 Important Safety Precautions .......25...
  • Page 171 Table of Contents Technical Information........151 Vehicle Identification ........152 Specifications ..........153 Torque Specifications ........155 Petrol Containing Alcohol.......158 Competition Logbook ........159 Optional Parts List...........161 Spare Parts & Equipment........162 Wiring Diagram..........163 Table of Contents...........164 Index ...............166 Table of Contents...

  • Page 172: Index

    Index accessories ............4 capacity, fuel ............41 engine, adjustments, carburetor, flooded ............16 carburetor............136 adjustment...........136 idle speed ............136 chassis ............137 circuit functions ..........130 number ............152 control freeplay......54,56,60,88 components ..........130 pinging ............41 for competition ...........107 disassembly/assembly.........133 starting ............15 gearing ............138 idle speed ............136 stop button ............16 personal fit ..........140 care, appearance..........105...
  • Page 173 Index gap, spark plug...........61 oil, safety, gearing .............138 fork..............86 a few words about....Safety Messages guidelines, suspension adjustment....127 transmission ..........46 important information........2 operating, important precautions ........2 controls ............7 labels ...............5 operation component locations.......8 maintenance ..........25 handlebar inspection ..........99 optional, riding precautions .........14 parts list ............161 schedule, maintenance ........27,28 sprockets .............161...
  • Page 174 Index transmission oil..........46 tuning tips ............130 throttle, freeplay ............54 inspection............55 tyres, air pressure............93 flat ..............93 selection ............94 tools..............162 torque specifications.........155-157 transporting ............142 tripmeter.............14 troubleshooting ..........146 tubes, replacing ..........93 valve, fuel............15 vehicle identification no. (VIN).......152 washing your motorcycle.........105 weight limit............3 wheels ..............92 wiring diagram..........163 Index...

Table of Contents