Honda CFR-450 2013 Owner'S Manual Download Page 39

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Maintenance Component Locations

Servicing

Your

Honda

Maintenance Component Locations

clutch lever

front brake fluid reservoir

front brake lever

throttle grip

radiator cap

fuel fill cap

air bleed bolt

spark plug

fast idle knob
(engine idle speed)

air cleaner

crankcase
breather
tubes

drive chain

transmission
oil drain bolt

engine oil filter

front brake
caliper

engine oil
fill cap

rear suspension
spring pre-load
adjuster

front suspension compression damping
adjuster (both left and right)

steering damper
adjuster

front suspension
rebound damping
adjuster
(both left and right)

transmission
oil check bolt

engine oil
drain bolt

rear brake
pedal

rear brake
fluid reservoir

rear brake
caliper

rear suspension
rebound damping
adjuster

• rear suspension high speed

compression damping
adjuster

• rear suspension low speed

compression damping
adjuster

transmission
oil fill cap

PSF air valve
(both left and right)

Summary of Contents for CFR-450 2013

Page 1: ...ASSENGERS This motorcycle is designed as an operator only vehicle and for use by experienced riders only The load limit and seating configuration do not safety permit the carrying of a passenger This...

Page 2: ...2013 Honda CRF450R OWNER S MANUAL COMPETITION HANDBOOK...

Page 3: ...to help you avoid damage to your CRF other property or the environment Unless you are mechanically qualified and have the proper tools you should see your dealer for the service and adjustment proced...

Page 4: ...ges throughout the manual Safety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean Of course it is not practical or possibl...

Page 5: ...1 Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 26 Before After Competiti...

Page 6: ...ase 138 Gearing 139 Tire Selection for Track Conditions 140 Personal Fit Adjustments 141 Control Positioning 141 Handlebar Position Width Shape 141 TIPS 143 Transporting Your Motorcycle 144 Storing Yo...

Page 7: ......

Page 8: ...information and recommendations to help you 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 I...

Page 9: ...e gear Take Time to Get 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...

Page 10: ...y way that would change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride Accessories Modifications WARNING Improper accessories or modi...

Page 11: ...bels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for replacement For Canada NEVER OPEN WHEN HOT Hot coolant w i l l scald you N OUVREZ PAS OUAND CH...

Page 12: ...nstruments Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 Indicator 7 MIL Blink Pattern 7 Current DTC F...

Page 13: ...mponent Locations 6 Instruments Controls Operation Component Locations clutch lever engine stop button front brake lever throttle grip MIL fast idle knob engine idle speed shift lever kickstarter rear...

Page 14: ...000 rpm The MIL has two types of blinks a long blink and short blink The long blinking lasts for 1 2 seconds the short blinking lasts for 0 4 seconds One long blink is the equivalent of ten short bli...

Page 15: ...to poorly connected or corroded connections Check the following connections Remember circuit inspection is not a cure all for other problems in your engine s PGM FI system Circuit Inspection 1 MAP se...

Page 16: ...ion Failure Symptom Fail safe function 1 MAP sensor circuit malfunction Poor performance driveability 2 MAP sensor performance problem Poor performance driveability 7 ECT sensor circuit malfunction Ha...

Page 17: ...10 Instruments Controls...

Page 18: ...eady to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension steering damper and othe...

Page 19: ...g damper and other adjustments see page 111 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...

Page 20: ...mper operation 104 Throttle operation 59 Tires for damage or improper inflation pressure 95 Spokes for looseness 94 Rim locks for looseness 94 PSF air pressure 113 Front and rear suspension for proper...

Page 21: ...14 Before Riding...

Page 22: ...structions This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 16 Starting Stopping the Engine 17 Fast Idle Knob 17 Prepara...

Page 23: ...the Important Safety Precautions begininng 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...

Page 24: ...mission into neutral 2 If the temperature is 95 F 35 C or below pull the fast idle knob 1 fully out 3 With the throttle closed operate the kickstarter starting from the top of the kickstarter stroke k...

Page 25: ...nto neutral 2 Lightly open the throttle 1 two or three times and then close it 3 Push and hold the engine stop button 2 until the engine stops completely Emergency Engine Stop To stop the engine in an...

Page 26: ...nce 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 follow...

Page 27: ...20 Basic Operating Instructions...

Page 28: ...ck with your dealer s parts department Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition...

Page 29: ...ly important because your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenanc...

Page 30: ...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 tools an...

Page 31: ...rms of races 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...

Page 32: ...2 5 hours Every 3 races or about 7 5 hours Every 6 races or about 15 0 hours Every 9 races or about 22 5 hours Every 12 races or about 30 0 hours Ref Page FUEL LINE NOTE 6 I R 39 FUEL PUMP FILTER NOT...

Page 33: ...Genuine Parts or their equivalent 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...

Page 34: ...n low rpm performance 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 cle...

Page 35: ...our palms and be sure to bend the wire ends well into the handgrip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the throttle...

Page 36: ...s no continuous coolant leakage from the bleed hole while operating the engine A small amount of coolant weeping from the bleed hole is normal See an official Honda Service Manual or consult your deal...

Page 37: ...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 Afte...

Page 38: ...drive chain clean and lubricate it pages 98 99 Be sure the chain is wiped clean and is dry before lubricating the chain Routine Cleaning If your CRF is only slightly dirty it is best to clean it by h...

Page 39: ...ake caliper engine oil fill cap rear suspension spring pre load adjuster front suspension compression damping adjuster both left and right steering damper adjuster front suspension rebound damping adj...

Page 40: ...Installation 1 Install the seat while aligning the seat front prong 1 with the front seat bracket 2 and seat rear prong 3 with the seat stopper plate 4 2 Install and tighten the seat mounting bolts to...

Page 41: ...shrouds as shown in the figure and then remove them 7 Install a hose clamp 7 to the breather tube 8 and shut the hose clamp securely 8 Pull the breather tube 8 out of steering stem nut 9 Unhook the fu...

Page 42: ...the clamp 2 if it is removed 2 Install the fuel tank 3 on the frame 3 Install the collar and fuel tank bolt 4 4 Hook the air cleaner rubber 5 and the fuel tank band 6 WARNING Gasoline is highly flamma...

Page 43: ...o that the shroud tabs 14 and the tabs on the air cleaner housing covers 15 are aligned 10 Install the shroud B bolts 16 collars and shroud A bolts 17 Tighten the shroud B bolts to the specified torqu...

Page 44: ...subframe 9 Installation 1 Loosely attach the upper and lower end of the subframe to the main frame and loosely install all subframe bolts 2 Align the subframe with the rear wheel and tighten the subf...

Page 45: ...ar fender with the hole in the subframe and then install the rear fender mounting bolts 5 5 Hook the fuel tank band 6 6 Install the air cleaner mounting bolts 7 7 Install the left and right mufflers p...

Page 46: ...el tank 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the...

Page 47: ...fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary 5 Remove the bolt 4 clamp and setting rubber 5 6 Pull and release the joint rubber 6 of the injector side from the...

Page 48: ...he connector 2 by aligning its locking pawls 3 with the connector grooves 4 Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected If the joint rubber is dama...

Page 49: ...between the flange 6 and retainer tab 7 5 Install the rubber 8 clamp 9 and bolt 10 by aligning the clamp tab 11 with the groove 12 of the stay 6 Install the fuel quick connect fitting cover 13 and se...

Page 50: ...el tank when removing the stopper cable 5 Remove the fuel pump unit 8 and O rings 9 Be careful not to damage the fuel pump unit 6 Disconnect the fuel pump wire terminals 10 from the fuel pump base 11...

Page 51: ...15 from the fuel pump base 16 and remove the O ring 17 Wipe the spilled out fuel immediately 10 Remove the fuel pump stopper 18 and damper rubber 19 11 Remove the fuel pump assembly 20 with fuel pump...

Page 52: ...fuel pump stopper 12 5 Apply small amount of engine oil to a new O ring 13 Install a new O ring to the fuel pump base 14 6 Install the fuel pump unit holder assembly 15 into the fuel pump base while a...

Page 53: ...al spring washers 29 collars 30 washers 31 stopper cable 32 stopper cable guide 33 and fuel pump mounting bolts 34 13 Install the fuel tank Make sure that the convex surfaces of the conical spring was...

Page 54: ...es can be used to change power delivery as follows ECM selector switch ON Power to ECM only PUMP selector switch ON Power to fuel pump only Both selector switches ON Power to ECM and fuel pump 8 Run t...

Page 55: ...ngine oils displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication Other viscosities shown in the following chart may be used when...

Page 56: ...ngine oil fill cap dipstick 1 8 Check for oil leaks 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil fill cap...

Page 57: ...OTICE If the oil filter is not installed properly it will cause serious engine damage 13 Apply engine oil to a new O ring and install it to the oil filter cover 14 Install the oil filter cover being c...

Page 58: ...r higher 4 stroke engine oils displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication and clutch performance Other viscosities sho...

Page 59: ...essary 7 Reinstall the transmission oil fill cap 1 8 Check for oil leaks 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove th...

Page 60: ...of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Refer to Important Safety Precautions on page...

Page 61: ...erating the engine A small amount of coolant weeping from the bleed hole is normal See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil seal Both seals...

Page 62: ...elp you determine the correct service interval for your riding conditions Your CRF s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model...

Page 63: ...air cleaner element and holder Install the holder tabs in the holes of the air cleaner element 8 Apply 0 1 0 2 oz 3 5 g of Pro Honda White Lithium Grease or equivalent to the air cleaner housing cont...

Page 64: ...rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plugs 1 from the crankcase breather tubes...

Page 65: ...n and back out one turn Tighten the lock nut 3 to the specified torque 3 0 lbf ft 4 0 N m 0 4 kgf m Install the dust cover and make the adjustment with the lower adjuster Lower Adjustment The lower ad...

Page 66: ...to fully closed in all steering positions If there is a problem see your dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the throttle body If the cable is kinked o...

Page 67: ...d adjustment When pushed in the fast idle knob acts as the idle adjust screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed...

Page 68: ...ction until it seats lightly and then turn it out five turns 5 Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay at the tip of lever Freeplay 3 8 13 16 i...

Page 69: ...tall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your CRF should move smoothly and accelerate gradually If you can t get proper adjustment or the clutch...

Page 70: ...needle bearing 11 and washer 12 by removing the clip 13 Turn the needle bearing with your finger The needle bearing should turn smoothly and quietly Replace the needle bearing and washer if the needle...

Page 71: ...e spring seat 1 and judder spring 2 onto the clutch center as shown Coat the clutch discs 3 and clutch plates 4 with engine oil 2 Install the clutch disc A larger I D disc 5 onto the clutch outer Stac...

Page 72: ...1 0 kgf m 11 Lubricate the dust seals 16 and rear brake pedal pivot bolt 17 with urea based multipurpose grease or equivalent 12 Apply locking agent to the brake pedal pivot bolt threads 13 Install t...

Page 73: ...f the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 031 0 035 in 0 8 0 9 mm 7 To obtain accurate spark plug readings accelerate up to speed on a stra...

Page 74: ...earance will change as engine temperature rises Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and hang the fuel tank to the left of the frame pa...

Page 75: ...compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arms 5 If they are free an indication that the valves are closed an...

Page 76: ...ove the condenser 1 and disconnect the condenser connector 3 Remove the cam chain tensioner lifter cover bolt 2 and sealing washer 3 4 Insert the tensioner stopper 4 into the cam chain tensioner lifte...

Page 77: ...rings are remained on the camshaft holder remove the set rings carefully 6 Slide the left camshaft bearing 10 and remove the camshaft 11 by removing the cam chain 12 NOTICE Do not let the cam chain f...

Page 78: ...lculate 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 thickness Make sure of the correct shim thickness...

Page 79: ...er The plunger should be retracted and protruded smoothly If the operation is not smooth refer to an official Honda Service Manual page 162 for decompressor disassembly or see your dealer 5 Make sure...

Page 80: ...e camshaft holder bolts in a criss cross pattern in two or three steps 12 Remove the tensioner stopper 22 from the cam chain tensioner lifter 13 Make sure that the piston is at TDC on the compression...

Page 81: ...1 Install the spark plug page 66 2 Coat a new O ring 1 with engine oil and install it onto the crankshaft hole cap 2 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft...

Page 82: ...3 Check that the rubber seals 4 are in good condition replace them if necessary Install the rubber seals onto the cylinder head cover with the UP marks 5 facing up 4 Install and tighten the cylinder...

Page 83: ...t holder camshaft valve lifters and shims page 69 10 Disconnect the ignition coil connectors 1 Remove the ignition coil 2 by removing the bolts 3 11 Disconnect the ECT sensor connector 4 12 Loosen the...

Page 84: ...dy and support it with a suitable strap 19 Remove the cylinder head hanger bolts 18 Remove the cylinder head hanger plate bolts 19 left cylinder head hanger plate 20 and right cylinder head hanger pla...

Page 85: ...pins and cam chain fall into the crankcase 23 Remove the cam chain guide 27 from the cylinder 28 1 Remove the water hose joint bolts 1 water hose joint 2 and O ring 3 2 Remove the cylinder 4 while ho...

Page 86: ...3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced every 6 races or about every 15 0 hours of running Replace the pisto...

Page 87: ...ide rails 2 to the piston 3 4 Install the top ring 4 to the piston with R mark 5 side facing up NOTICE Do not damage the piston ring by spreading the ends too far Do not damage the piston during pisto...

Page 88: ...ide of the engine 4 Apply molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the piston pin 6 outer surfac...

Page 89: ...into the crankcase 4 Clean any gasket material off cylinder 3 5 Apply engine oil to the cylinder wall piston outer surface and piston rings 4 Route the cam chain 5 through the cylinder Install the cy...

Page 90: ...OTICE Do not damage mating surfaces when installing the cylinder head 5 Apply engine oil to all cylinder head bolt threads and seating surface Install the washers and cylinder head bolts 7 and tighten...

Page 91: ...9 Set the rear shock absorber 16 and install the rear shock absorber upper bolt 17 and nut 18 as shown Tighten the rear shock absorber upper nut to the specified torque 32 lbf ft 44 N m 4 5 kgf m 10 I...

Page 92: ...tall the crankshaft hole cap page 74 18 Install the cylinder head cover page 75 19 Install the spark plug page 66 20 Install the exhaust pipe page 103 21 Install the subframe page 37 and left and righ...

Page 93: ...Periodically 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 Adju...

Page 94: ...more clicks 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 adjust it by turning all the compression and reb...

Page 95: ...id damage hold both the outer tube and slider when removing the fork damper 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil holes 6 of the fork damper 4 Drain the fork oil b...

Page 96: ...th a lock nut wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper Amount of fork oil left in...

Page 97: ...Loosen the lock nut 1 2 To position the front brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the front brake lever closer to the handgrip turn the adjuster count...

Page 98: ...ake sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Rear Brake Fluid Level Check With the motorcycle in an upright position check the fluid level It should be...

Page 99: ...0 1 kgf m Adding Rear Brake Fluid NOTICE Spilled brake fluid will severely damage painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure t...

Page 100: ...1 from the rear side of the caliper to determine the brake pad wear If either brake pad is worn anywhere to a thickness of 0 04 in 1 0 mm both brake pads must be replaced Check that the front brake l...

Page 101: ...s also important that the rim locks are secure to prevent tire slippage 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Spokes 2...

Page 102: ...air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding conditi...

Page 103: ...eed rating and load range as 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 Tire Replacement WARNING Instal...

Page 104: ...points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking NOTICE Excessive chain slack ma...

Page 105: ...x marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm 3 Tighten the rear axle nut to the specified torque 94 lbf ft 128 N m 13 1 kgf m 4 Recheck chain slack and...

Page 106: ...and any kinked joints straightened measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measur...

Page 107: ...at page 33 2 Remove the side covers 1 and air cleaner housing covers 2 by removing the bolts 3 3 Loosen the right muffler clamp bolt 4 4 Remove the right muffler mounting bolt 5 washer 6 and right muf...

Page 108: ...of the left muffler 5 Install the washer B 7 left muffler mounting B bolt 8 washer A 9 and left muffler mounting A bolt 10 6 Tighten the left muffler clamp bolt 11 to the specified torque 15 lbf ft 2...

Page 109: ...Tighten the right muffler clamp bolt 18 to the specified torque 15 lbf ft 20 N m 2 0 kgf m 14 Tighten the right muffler mounting bolt 16 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 15 Install...

Page 110: ...et 3 Install the left muffler page 101 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 5 Tighten the left muffler clamp bolt l...

Page 111: ...making any adjustments Check the spherical bearings and dust seal for dust dirt and foreign materials Make all damping adjustments in one click increments Adjusting two or more clicks at a time may c...

Page 112: ...e 104 2 Remove the steering damper mounting bolts 1 collar 2 and steering damper 3 1 Check the damper rod 1 operation The damper rod is fully extended and compressed by hand Release the damper rod the...

Page 113: ...rk 2 facing up and forward Turn the damper rod and its stopper ring 3 facing toward the front side 3 Install the collar 4 and steering damper mounting bolts 5 Be sure to install the collar with its wi...

Page 114: ...adjustment procedures or see your dealer 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its original position where the end of the right handlebar holders 2...

Page 115: ...1 5 2 8 Exhaust pipe joint nuts 15 21 2 1 9 Drive sprocket bolt 23 31 3 2 10 Engine oil drain bolt 12 16 1 6 11 Transmission oil drain bolt 12 16 1 6 12 Coolant drain bolt 7 10 1 0 13 Water hose joint...

Page 116: ...e cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Pro Honda Hondabrite and rinse...

Page 117: ...remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild...

Page 118: ...uires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by adjusting the PSF air pressure and oil capacity Front Suspension Adjustments 112 Fro...

Page 119: ...he standard position when the adjuster is turned counterclockwise 14 clicks Make sure that both fork legs are adjusted to the same position Rebound Damping Adjustment The fork rebound damping adjuster...

Page 120: ...re secure If necessary install new caps If you need to adjust the PSF air pressure when the front forks are warm after driving refer to page 30 Oil capacity Adjust the oil capacity refer to Fork Assem...

Page 121: ...tarting position 1 Remove the number plate page 104 2 Place your CRF on an optional workstand or equivalent support with the front wheel off the ground 3 Remove the handlebar lower holder nuts washers...

Page 122: ...5 and fork protectors 16 9 Clean the air valve and surrounding area and then apply the specified PSF air pressure page 113 Measure the distance 17 between the outer tube and the axle holder 10 Clean t...

Page 123: ...outer tube then remove the fork damper 24 from the outer tube using a lock nut wrench 23 Gently slide the outer tube down onto the lower end axle holder 26 Lock nut wrench 23 070MA MEN010 NOTICE The...

Page 124: ...amper piston rod If the lock nut is removed the piston rod will fall in the fork damper and you may not reassemble the fork damper 21 Remove the push rod 33 from the fork damper 22 Remove the fork dam...

Page 125: ...sembly Replace the fork cap as an assembly if it is damaged 4 Empty the fork oil from the oil holes 6 of the fork damper oil air chamber 7 by pumping the damper rod several times 5 Clean the fork cap...

Page 126: ...it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level 10 Temporarily install the fork cap assembly 1 to the fork damper 2 using an adjustab...

Page 127: ...cm3 of fork fluid will be drained from the damper oil spring chamber through the oil hole and cause 11 6 US oz 343 cm3 of fork fluid to be left in the chamber Pour the drained oil into a suitable cont...

Page 128: ...3 5 mm If the clearance is out of specification check the fork center bolt lock nut and fork center bolt installation Amount of fork oil left in the fork without damper unit US oz cm3 minute F C 5 10...

Page 129: ...ified torque 41 lbf ft 55 N m 5 6 kgf m 10 Pour the recommended fork oil 8 into the fork assembly 1 Recommended Oil KHL15 11 KYB Fork Oil Capacity Be sure the oil capacity is the same in both fork leg...

Page 130: ...e lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 15 Tighten the fork cap 13 to the specified torqu...

Page 131: ...Tighten the fork bride lower pinch bolts 10 to the specified torque 15 lbf ft 20 N m 2 0 kgf m 21 Tighten the fork bridge upper pinch bolts 18 to the specified torque 16 lbf ft 22 N m 2 2 kgf m NOTICE...

Page 132: ...t side collar 27 and right side collar 28 into the wheel hub 27 Install the front wheel between the fork legs while inserting the disc between the pads being careful not to damage the pads 28 Insert t...

Page 133: ...lbf ft 20 N m 2 0 kgf m NOTICE To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 33 Install the disc cover 34 and tighten...

Page 134: ...tandard length Adjust as necessary by loosening the shock spring lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 0 06 in 1 5 mm 5 After a...

Page 135: ...eed Damping The low speed damping can be adjusted by turning the center screw of the compression adjuster The low speed compression adjuster has 18 positions or more Turning the adjuster one full turn...

Page 136: ...loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly u...

Page 137: ...d terrain It may even top out when you dismount your CRF Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottomin...

Page 138: ...In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be under sprung because of the added weight of the clinging mud...

Page 139: ...is too quick Front end darts while cornering or riding in a straight line Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments Mid...

Page 140: ...ial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff...

Page 141: ...eels stiff further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large bumps 1 Test softer high speed compression adjustment 2 If it still feels stiff...

Page 142: ...celain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Light gray or white color streaks the porce...

Page 143: ...just the adjuster to the standard setting proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard p...

Page 144: ...s Turn the steering damper adjuster in one click increments at a time Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment Symptom Acti...

Page 145: ...0 110 mm range The position of the fork tube in the clamp is not adjustable Align the top of the outer tube not the top of the fork cap with the top of the top bridge Standard Position The top of the...

Page 146: ...m good to great and back 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...

Page 147: ...use remember they will be less acceptable 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 cho...

Page 148: ...CRF Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward handlebar...

Page 149: ...142 Adjustments for Competition Personal Fit Adjustments...

Page 150: ...e on how to transport and store your CRF as well as three troubleshooting flow charts Transporting Your Motorcycle 144 Storing Your Honda 145 Preparation for Storage 145 Removal from Storage 145 You t...

Page 151: ...e front wheel against the front of the truck bed or trailer rail Attach 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 r...

Page 152: ...an optional workstand or equivalent to raise both tires off the ground 9 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 10 St...

Page 153: ...cleaning solvents away 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...

Page 154: ...rive chain too tight 2 Check the tire pressure p 95 Faulty valve core Punctured tire 3 Check the engine speed change accordingly when clutch is engaged Clutch slipping Improperly adjusted clutch lever...

Page 155: ...re Faulty CKP sensor Loose or disconnected ignition system wires Faulty engine stop button Faulty regulator rectifier Faulty condenser CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INC...

Page 156: ...data Vehicle Identification 150 Serial Numbers 150 Specifications 151 Torque Specifications 152 Nuts Bolts Fasteners 152 Oxygenated Fuels 155 Competition Logbook 156 Optional Parts List 158 Spare Part...

Page 157: ...our 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 The VIN vehicle identification number 1 is stam...

Page 158: ...Item English Metric Engine Type Liquid cooled 4 stroke Cylinder arrangement Single 6 30 inclined from vertical Bore and stroke 3 78 x 2 44 in 96 0 x 62 1 mm Displacement 27 43 cu in 449 7 cm3 Compress...

Page 159: ...olts 7 10 1 0 3 Water pump cover bolts 7 10 1 0 4 Transmission oil check bolt 9 12 1 2 5 Crankshaft hole cap 11 15 1 5 NOTE 1 6 Oil filter cover bolts 7 10 1 0 7 Cylinder head bolts 38 51 5 2 NOTE 2 8...

Page 160: ...r nuts 40 54 5 5 Front engine hanger plate nuts 19 26 2 7 11 Lower engine hanger nut 40 54 5 5 12 Cylinder head hanger bolts 40 54 5 5 13 Cylinder head hanger plate bolts 24 32 3 3 14 Rear suspension...

Page 161: ...k center bolt 41 55 5 6 NOTE 3 33 Fork center bolt lock nut 21 29 3 0 34 Disc cover bolts 10 13 1 3 35 Fork protector socket bolts 5 2 7 0 0 7 NOTE 5 36 Left right muffler clamp bolt 15 20 2 0 37 Driv...

Page 162: ...ed under the name Gasohol MTBE Methyl Tertiary 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 contain...

Page 163: ...nterval maintenance repairs running 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 B...

Page 164: ...Technical Information 157 Date Running Time Location Event Comments Suspension Settings Steering Damper Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this...

Page 165: ...minum Drive chain size link D I D 520 DMA4 120RB RK520TXZ 120RJ Handlebar lower holder 0 1 in 3 mm offset Optional no offset TOOLS Remarks Pin spanner A To adjust spring preload two spanners required...

Page 166: ...dle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipmen...

Page 167: ...low O Orange FREE Bu Blue Lb Light blue PUSH G Green Lg Light green COLOR Bl W R Y R Red P Pink W White Gr Gray FUEL PUMP ENGINE STOP SWITCH REGULATOR RECTIFIER CONDENSER NO 1 CKP SENSOR FRAME GROUND...

Page 168: ...tion 161 Consumer Information This section contains information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 162 Contacting Honda 163 Your Honda Dealer 164...

Page 169: ...tion for various systems on Honda motorcycles scooters ATVs MUVs and PWCs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful...

Page 170: ...ny differences at the dealership level If you wish to comment on your experiences with your CRF or with your dealer please send your comments to the following address Motorcycle Division American Hond...

Page 171: ...Honda Genuine Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable...

Page 172: ...ion 165 The Honda Rider s Club USA only The Honda Rider s Club of America HRCA sponsors local riding chapters at Authorized Honda Dealerships across the country You can log on to the HRCA Clubhouse we...

Page 173: ...tments 138 cleaner air 55 cleaning appearance care 109 clutch system adjustment 61 competition logbook 156 consumer information 161 contacting Honda 163 controls 5 coolant 53 customer service 164 cyli...

Page 174: ...ion component locations 6 optional parts list 158 sprockets 139 oxygenated fuels 155 pads brake 93 parts optional 158 personal fit adjustments 141 pinging engine 39 plug spark 66 pre load rear suspens...

Page 175: ...12 guidelines 132 rear 127 throttle freeplay 58 inspection 59 tires air pressure 95 flat 95 selection 96 tools 159 torque specifications engine 152 frame 153 154 transmission oil 51 transporting 144 t...

Page 176: ...Memo 169...

Page 177: ...equencies for each race or about 2 5 hours every 3 races or about 7 5 hours every 6 races or about 15 0 hours every 9 races or about 22 5 hours and every 12 races or about 30 0 hours Pre ride Inspecti...

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