Honda 2007 CRF250R Owner'S Manual Download Page 1

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Summary of Contents for 2007 CRF250R

Page 1: ......

Page 2: ...make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find inform...

Page 3: ...2007 Honda CRF250R OWNER S MANUAL COMPETITION HANDBOOK Contents qxd 06 6 15 14 27 1...

Page 4: ...re preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KI...

Page 5: ...r 45 Engine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 54 Spark Plug 55 Valve Clearance 56 Piston Piston Rings Piston Pin 64 Chassis Suspension 72 Brakes 77 Wheels 81 Tires Tube...

Page 6: ...u ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF Important Safety Information 2 Important Saf...

Page 7: ...to Know Your CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in compet...

Page 8: ...way that would change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride WARNING Improper accessories or modifications can cause a crash...

Page 9: ...4 Motorcycle Safety 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 001 023 qxd 06 6 15 14 28 4...

Page 10: ...perating Controls 5 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 001 023 qxd 06 6 15 14 28...

Page 11: ...Controls Operation Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip choke knob fuel valve shift lever kickstarter rear brake pedal 001 023 qxd 06 6...

Page 12: ...this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustment for competition see page 95 B...

Page 13: ...ts see page 95 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protecti...

Page 14: ...ion 91 Carburetor throttle operation 47 Tires for damage or improper inflation pressure 82 Spokes for looseness 81 Rim locks for looseness 81 Front and rear suspension for proper operation 72 73 Front...

Page 15: ...10 Before Riding 001 023 qxd 06 6 15 14 28 10...

Page 16: ...is section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 12 Starting Stopping the Engine 13 Preparation 13 Starting Procedure 13 F...

Page 17: ...ease 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 garag...

Page 18: ...e As the carburetor is equipped with an accelerator pump excessive fuel will be charged into the engine and the spark plug will be fouled if the throttle is opened and closed repeatedly Excessive fuel...

Page 19: ...into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle grip 1 two or three times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to...

Page 20: ...ntion 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 piston...

Page 21: ...16 Basic Operating Instructions 001 023 qxd 06 6 15 14 28 16...

Page 22: ...Honda dealer s parts department Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Mainten...

Page 23: ...e Importance of Maintenance Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to get maximum performance during each moto Careful pre ride inspections and go...

Page 24: ...s Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the too...

Page 25: ...and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given tas...

Page 26: ...55 41 57 36 37 48 66 66 39 41 84 84 85 86 86 78 80 77 49 91 87 72 25 73 74 100 92 142 144 81 82 91 R I FORK TUBE SLIDER DAMPER FREQUENCY NOTE Ref Page Each race or about 2 5 hours Every 3 races or ab...

Page 27: ...valent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Gr...

Page 28: ...oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follo...

Page 29: ...e tolerances are quite tight so it s important to keep these dowels absolutely clean page 66 Fuel Filter Periodically drain the fuel from the fuel tank remove and clean the fuel valve filter Replace t...

Page 30: ...ncountered often Use urea based multi purpose grease designed for high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or Shell Stamina EP2 or equivalent W...

Page 31: ...above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action w...

Page 32: ...eaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid u...

Page 33: ...nd damping adjuster transmission oil filler cap transmission oil check bolt rear brake pedal front suspension rebound damping adjuster rear suspension high speed damping adjuster rear suspension low s...

Page 34: ...ward 1 seat mounting bolts 2 seat Installation 1 Install the seat while aligning the front prong 3 with the seat bracket 4 and rear prong 5 with the tab 6 of the subframe 2 Install and tighten the sea...

Page 35: ...carburetor must be disconnected not the fuel line leading to the fuel tank 9 Remove the fuel valve bolt 10 and fuel valve 9 fuel line 10 fuel valve bolt WARNING Gasoline is highly flammable and explo...

Page 36: ...er cover rubber 5 6 Hook the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 8 Install the shroud tab 8 onto the subframe 9 8 shroud tab 9 subframe 9 Install the shrouds 10 and shr...

Page 37: ...he air cleaner cover rubber 3 7 Loosen the screw 4 on the air cleaner connecting tube clamp 5 1 crankcase breather tube 2 fuel tank band 3 air cleaner cover rubber 4 screw 5 air cleaner connecting tub...

Page 38: ...ends of the subframe 1 to the mainframe while connecting the air cleaner connecting tube to the carburetor Be careful not to bend the subframe Install the subframe upper mounting bolt 2 and subframe...

Page 39: ...use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure Fuel Tank Capacity 1 9 US gal 7 3R 1 fuel fill c...

Page 40: ...gasoline container 2 Remove the fuel tank page 30 3 Remove the fuel joint 1 from the fuel tank by removing the bolts 2 4 Wash the fuel filter 3 in high flash point cleaning solvent 5 Reassemble the fu...

Page 41: ...ne with insufficient oil can cause serious damage to the engine Oil Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label suggested...

Page 42: ...ce or if the oil level is below or near the lower level mark add the recommended oil until the upper level mark is reached Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5...

Page 43: ...tighten the oil filter cover bolts to the specified torque 9 lbf ft 12 N m 1 2 kgf m 17 Install the left engine guard and bolt then tighten it 18 Fill the crankcase with the recommended oil Capacity 0...

Page 44: ...r 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Servicing Your Honda 39 Suggested 4 stroke engine o...

Page 45: ...oil starts to flow out of the oil check bolt hole Install the oil check bolt with a new sealing washer and transmission oil filler cap Repeat step 1 4 5 After inspecting the oil level or adding oil ti...

Page 46: ...protection Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide add...

Page 47: ...Manual or consult your Honda dealer for replacing the water seal or the oil seal Both seals should be replaced at the same time Coolant Replacement Refer to Safety Precautions on page 19 Coolant shoul...

Page 48: ...ir cleaner assembly 3 and mark 4 of the air cleaner housing by rotating the air cleaner assembly counterclockwise 5 Remove the air cleaner element 5 from the air cleaner holder 6 1 air cleaner retaini...

Page 49: ...two access top tabs 3 air cleaner assembly 4 mark 10 groove 4 10 3 1 2 11 Install the air cleaner assembly 3 into the air cleaner housing keeping the two access top tabs 2 up 12 Carefully position the...

Page 50: ...often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube Draining 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits...

Page 51: ...m 0 4 kgf m 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 you...

Page 52: ...closed in all steering positions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chaf...

Page 53: ...engine must be at normal operating temperature for accurate idle speed adjustment Idle Speed Adjustment 1 Turn the pilot screw 1 in until it is lightly seated and record the number of turns Turn the p...

Page 54: ...kwise 3 Tighten the lock nut 3 cable end adjuster increase freeplay decrease freeplay 5 Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay 3 8 13 16 in 10...

Page 55: ...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 See your Honda dealer or refer to the Honda Service Manual page 15...

Page 56: ...cs and seven clutch plates 11 Turn the lifter bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing pl...

Page 57: ...grease to the clutch lifter rod 3 ends 4 Insert the clutch lifter rod into the mainshaft 5 Apply engine oil to the needle bearing of the clutch lifter 6 Install the clutch lifter 4 onto the clutch li...

Page 58: ...to the brake pedal pivot bolt 11 sliding surface 13 Install the dust seals 9 into the rear brake pedal 10 14 Apply locking agent to the brake pedal pivot bolt threads 15 Install the washer 12 rear br...

Page 59: ...in 2 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster clockwise will incre...

Page 60: ...then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If you re using a new plug ride for at least 10 minutes before taking a plug...

Page 61: ...cover 4 3 cylinder head cover bolts 4 cylinder head cover 4 Remove the spark plug hole packing 1 crankshaft hole cap 2 Remove the spark plug page 55 2 1 4 3 1 Refer to Safety Precautions on page 19 Ex...

Page 62: ...ive gear bolt 2 crankshaft clockwise until aligning the punch mark 3 on the primary drive gear with the index mark 4 on the right crankcase cover In this position the piston may either be on the compr...

Page 63: ...ner stopper tool Tensioner stopper 070MG 0010100 3 Turn the tensioner shaft clockwise with the tensioner stopper 3 until it stops in order to retract the tensioner fully Then insert the tensioner stop...

Page 64: ...the cam chain to prevent it from falling into the crankcase Be careful to not let the set rings of the camshaft holders fall into the crankcase 4 camshaft holder bolts 6 camshaft 5 camshaft holders 6...

Page 65: ...00 mm thickness in intervals of 0 025 mm 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thic...

Page 66: ...stall the newly selected shims 1 on the valve retainers 2 Do not let the shims fall into the crankcase NOTICE 1 shims 2 valve retainers 2 Apply molybdenum disulfide oil a mixture of 1 2 engine oil and...

Page 67: ...001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 18 feeler gauge 14 14 12 13 18 18 8 Remove the tensioner stopper 15 from the cam chain tensioner lifter 15 15 tensioner stopper 9 Install a new seal...

Page 68: ...g to the spark plug hole 2 1 spark plug hole packing 2 spark plug hole 2 Inspect the cylinder head cover packing 3 for damage or deterioration replace it if necessary Install the cylinder head cover p...

Page 69: ...37 3 Drain the radiator coolant after cooling the motorcycle page 42 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 pip...

Page 70: ...inder head gasket 10 and cam chain guide 11 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 9 dowel pins 11 cam chain guide 10 cylinder head gasket 5 6 8 7 9 10 11 15 Remove the...

Page 71: ...e to keep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove...

Page 72: ...Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring a...

Page 73: ...ew piston pin clips 5 Use new piston pin clips Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out...

Page 74: ...cylinder walls NOTICE 3 cam chain 4 cylinder 5 piston rings 7 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the crankca...

Page 75: ...into the crankcase NOTICE NOTICE 4 Install the cylinder bolt 5 and cylinder head bolts 6 and tighten them to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Install the engine hanger plates 7 engine...

Page 76: ...tall the spark plug page 55 9 Install the crankshaft hole cap page 63 10 11 10 Install the cylinder head cover page 63 11 Install the exhaust pipe page 90 12 Install the carburetor page 123 13 Install...

Page 77: ...eriodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension Adjust...

Page 78: ...s described in page 110 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adju...

Page 79: ...ushing 6 when the fork damper is removed To avoid damage hold both the outer tube and slider 7 when removing the fork damper NOTICE 1 outer tube 6 guide bushing 5 fork dust seal 7 slider 3 Drain the f...

Page 80: ...oil capacity 13 9 US oz 410 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 6 US oz 314 cm3 1 scribe mark aftermarket parts No ma...

Page 81: ...mended fork oil to the O ring 2 fork damper 10 O ring 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 Act...

Page 82: ...clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m...

Page 83: ...and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the...

Page 84: ...ten the screws to the specified torque 0 7 lbf ft 1 0 N m 0 1 kgf m Adding Rear Brake Fluid Spilled brake fluid will severely damage the painted surfaces It is also harmful to some rubber parts Be car...

Page 85: ...brake pads Rear Brake Pads Inspect the brake pads 5 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replace...

Page 86: ...ended service in the Maintenance Schedule page 21 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rim 3 rim lock 2 spoke 1 Inspect the wheel rims 1...

Page 87: ...Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air...

Page 88: ...place the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Front Rear Type 80 100 21 51M DUNLOP 100 90 19 57M DUNLOP D742FA D756 bias...

Page 89: ...rockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 0 1 4 in 25 35 mm 1 drive chain slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several point...

Page 90: ...o that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers Adjustment 1 Loosen the rear axle nut 1 2 Loosen both lock nuts 2 and turn the adjusting bolts 3 coun...

Page 91: ...link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the clip will face t...

Page 92: ...pipe exhaust joint pipe and mufflers may reduce engine performance Muffler Removal 1 Remove the seat mounting bolts 1 side cover bolts 2 and side covers 3 1 seat mounting bolt 3 side cover 2 side cov...

Page 93: ...pipe 5 Install each muffler mounting bolt 7 and washer 8 6 Tighten each muffler clamp bolt 9 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 7 Tighten each muffler mounting bolt 7 to the specified...

Page 94: ...oint pipe clamp 3 cut out 2 tab 4 exhaust joint pipe 3 Install a new gasket 5 to the exhaust pipe 6 4 Install the exhaust joint pipe 4 to the exhaust pipe and temporarily install the joint pipe clamp...

Page 95: ...not tighten the bolt yet 5 Tighten the exhaust pipe joint nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 6 Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt page 89 7 Tig...

Page 96: ...ders 3 paint mark Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lu...

Page 97: ...l filter cover bolts Cylinder head bolts Drive sprocket bolt Transmission oil drain bolt Torque lbf ft N m kgf m 7 15 7 11 9 7 7 9 7 23 12 10 21 10 15 12 10 10 12 10 31 16 1 0 2 1 1 0 1 5 1 2 1 0 1 0...

Page 98: ...ng head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your CRF You may use Pro Honda Hondabrite a multi sur...

Page 99: ...bricating items such as the brake and clutch lever pivot points and footpeg pivot pins Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stain...

Page 100: ...f your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The...

Page 101: ...lease screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under th...

Page 102: ...f the ground 2 Remove the number plate bolt 1 and number plate 2 Fork Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heav...

Page 103: ...0 and loosen the front axle pinch bolts 11 on both forks 8 Pull the front axle shaft 12 out of the wheel hub and remove the front wheel 10 front axle nut 12 front axle shaft 11 front axle pinch bolts...

Page 104: ...bolt from the axle holder of the slider by pushing the fork damper 21 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as shown if you do not have the special tool 19 slider...

Page 105: ...the fork damper 25 Remove the special tool or mechanic s stopper tool between the axle holder and lock nut 31 while applying pressure to the fork damper Be careful not to damage the lock nut and fork...

Page 106: ...the fork cap bushings If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 1 fork damper 4 for...

Page 107: ...compressed air to the oil hole Wipe the oil completely off the fork damper 16 If you can not use compressed air remove the pressure release screw 10 on the fork cap Hold the fork damper up side down...

Page 108: ...8 F 1 outer tube slider 2 Tighten the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3...

Page 109: ...ock nut 7 O ring 5 stopper tool 8 center bolt 6 push rod 9 adjusting rod 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of...

Page 110: ...ssion Slightly softer as it nears full compression Minimum oil capacity 10 6 US oz 314 cm3 No mark factory products 3 scribe marks 1 scribe mark aftermarket parts or Optional Stiffer 0 47 kgf mm Fork...

Page 111: ...ench The lock nut wrench increase the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 15 align 16 upper fork clamp 19 Tighten the...

Page 112: ...er on the slider and tighten the caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 18 fork protector bolts 19 fork protectors 20 brake hose clamp bolts 21 brake caliper 22 cali...

Page 113: ...brake applied pump the fork up and down several times to seat the axle and check front brake operation 29 While keeping the forks parallel alternately tighten the right axle pinch bolts 32 to the spec...

Page 114: ...t one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 87 A...

Page 115: ...d damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed damping adjuster has 3 1 2 turn or more To adjust to the standard position 1 Turn the adjuster clo...

Page 116: ...oad adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers...

Page 117: ...tep 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF With the spring pre load set to obtain the proper race sag the rear suspension s...

Page 118: ...t springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress t...

Page 119: ...pecially downhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound d...

Page 120: ...pension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained If initial trav...

Page 121: ...el too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer lo...

Page 122: ...the cylinder when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4...

Page 123: ...hragm 7 accelerator nozzle 4 inlet check valve 8 leak jet Slow Circuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture enters the venturi through the bypass 3 a...

Page 124: ...ir ratio from half 1 2 to full throttle 4 4 The size should be reduced at higher altitudes Honda carburetor jet sizes are numbered in increments of 2 or 3 When changing the main jet size increase or d...

Page 125: ...e hot start cable holder 4 4 hot start cable holder 10 Disconnect the rear suspension 5 upper mounting nut and bolt 6 5 rear suspension 6 upper mounting nut bolt 11 Remove the throttle drum cover bolt...

Page 126: ...throttle valve 3 Remove the link arm torx screw 6 When installing the link arm torx screw apply a locking agent to the link arm torx screw threads 4 Remove the throttle valve 7 throttle valve roller...

Page 127: ...er screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 8 Remove the pump rod 22 Clean the pump rod and rod passage 23 Install the pump rod into the link lever 24 Push the rod forci...

Page 128: ...ng the carburetor adjust the throttle grip free play and hot start lever free play After installing the carburetor check the throttle sensor connector 3 for correct routing as necessary After installi...

Page 129: ...ou ve determined what changes are necessary Adjustment Pilot screw opening Slow jet Jet needle Needle clip position Main jet Float level Identification number Standard settings 2 1 4 turns out 42 NKBT...

Page 130: ...ong straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one size when it is very humid or raining or it is hotter than 113 F 45 C After using th...

Page 131: ...he number of turns Turn the pilot screw out the same number of turns 2 Warm up the engine 3 Adjust the engine idle speed page 48 4 Make two or three laps of a course with the standard setting or corre...

Page 132: ...on the carburetor with the slot 13 on the insulator 12 lug 13 slot 21 Tighten the connecting and insulator band screws 22 Install the fuel tank page 31 23 Start the engine If the engine idle speed is...

Page 133: ...rless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain indica...

Page 134: ...can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to re check race sag and adjust if necessary In...

Page 135: ...to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or sandy conditions use a higher gear less t...

Page 136: ...cceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound...

Page 137: ...en sitting or standing comfortably on your CRF Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and stand...

Page 138: ...ul 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 137 118...

Page 139: ...tach the lower ends of two straps to the tie down hooks on your CRF Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the ti...

Page 140: ...n good condition and reinstall the drain bolt sealing washer and radiator cap 1 drain bolt sealing washer 2 water pump 6 Lubricate the drive chain 7 Inflate the tires to their recommended pressures 8...

Page 141: ...ay see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvent...

Page 142: ...t cylinder compression AIR CLEANER NOT DIRTY 3 Install a larger carburetor main jet P 126 CORRECT CONDITION WORSE Lack of fuel in tank P 34 Clogged fuel line P 34 Clogged fuel fill cap breather tube P...

Page 143: ...138 Tips 134 160 qxd 06 6 15 14 49 138...

Page 144: ...ins dimensions capacities and other technical data Vehicle Identification 140 Specifications 141 Torque Specifications 142 Oxygenated Fuels 145 Competition Logbook 146 Optional Parts List 148 Spare Pa...

Page 145: ...be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side...

Page 146: ...001 in 0 12 0 03 mm 0 011 0 001 in 0 28 0 03 mm Engine oil capacity After draining After draining and oil filter change After disassembly After disassembly Transmission oil capacity After draining Ty...

Page 147: ...aft hole cap Clutch cover bolts Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket bolt Transmission oil drain bolt Torque Remarks lbf ft N m kgf m 7 15 7 11 9 7 7 9 7 23 12 10 21...

Page 148: ...m nuts swingarm side shock link side 39 39 53 53 5 4 5 4 15 Fork fork damper fork cap 25 22 34 30 3 5 3 1 NOTE 1 3 NOTE 1 3 NOTE 1 3 13 Shock absorber 32 44 4 5 NOTE 1 9 Chain adjuster lock nuts 20 27...

Page 149: ...NOTE 4 NOTE 1 NOTE 1 NOTE 5 NOTE 4 Item Torque Remarks lbf ft N m kgf m 39 40 41 Fork air pressure release screw Rear brake reservoir cap bolts Front brake reservoir cap screws FRAME 0 7 1 0 0 1 0 7 1...

Page 150: ...iary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol...

Page 151: ...time on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same th...

Page 152: ...t Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Technical Information 147 Competition Logbook 134...

Page 153: ...CARBURETOR Remarks Main jet Standard 175 Slow jet Standard 42 165 185 in increments of 2 or 3 38 48 in increments of 2 or 3 Jet Needle Standard needle NKBT Straight diameter 2 775 mm Jet needle numbe...

Page 154: ...torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler ga...

Page 155: ...150 Technical Information Wiring Diagram THROTTLE POSITION SENSOR SPARK PLUG 134 160 qxd 06 6 15 14 49 150...

Page 156: ...ut contacting Honda and how to get an official Honda service manual Authorized Manuals 152 Contacting Honda 153 Your Honda Dealer 154 The Honda Rider s Club 155 Consumer Information 151 Consumer Infor...

Page 157: ...t For purchases outside U S A please write to the address shown below for a quotation Customer Name Attention Street Address No P O Box Number Apt City State Zip Code Daytime Telephone Number P A Y M...

Page 158: ...nt to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcyc...

Page 159: ...ondaline accessories The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the p...

Page 160: ...ial Honda Common Service Manual contests insider information and more Reimbursement up to 75 for successful completion of a Motorcycle Safety Foundation training course Separate complimentary training...

Page 161: ...mission Oil 39 Coolant 41 Air Cleaner 43 Crankcase Breather 45 Engine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 54 Spark Plug 55 Valve Clearance 56 Piston Piston Rings Piston P...

Page 162: ...48 minor adjustments 126 care appearance 93 chain drive 84 chassis adjustments 129 choke knob 13 cleaner air 43 cleaning appearance care 93 clutch system adjustment 49 competition logbook 146 consumer...

Page 163: ...onal parts list 148 sprockets 130 oxygenated fuels 145 pads brake 80 parts optional 148 personal fit adjustments 132 pinging engine 34 plug spark 55 pre load rear suspension 109 pre ride inspection 9...

Page 164: ...ion 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...

Page 165: ...Pa 1 0kgf cm2 standard R0409B 8 NGK optional R0409B 9 NGK D I D 520DMA2 114 Tires Tire Pressure cold Spark ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Hond...

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