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Honda CRF250R 2005, Owner'S Manual

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Honda CRF250R 2005 Owner'S Manual Download Page 3

A Few Words About Safety

Your safety, and the safety of others, is very important.  And operating this motorcycle safely is an important responsibility.  

To help you make informed decisions about safety, this manual contains a section devoted to 

Motorcycle Safety,

as well as a number of Safety Messages

throughout the manual.

Safety Messages are 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 KILLED or SERIOUSLY HURT if you don’t follow instructions.  

You CAN be HURT if you don’t follow instructions. 

Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good
judgement.

Safety Messages

DANGER

WARNING

CAUTION

Summary of Contents for CRF250R 2005

Page 1: ...2005 Honda CRF250R OWNER S MANUAL COMPETITION HANDBOOK ...

Page 2: ... owner s manual before you ride It s full of facts instructions safety information and helpful tips To 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 information that is preceded by a symbol This information is intended to help you avoid damage to your ...

Page 3: ...fety Messages are 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 KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Of course it is not practical or possible to warn you about all hazards associat...

Page 4: ... Speed 48 Clutch System 49 Hot Start Lever 53 Spark Plug 54 Valve Clearance 55 Piston Piston Rings Piston Pin 63 Chassis Suspension 71 Brakes 76 Wheels 80 Tires Tubes 81 Drive Chain 83 Exhaust Pipe Muffler 86 Additional Maintenance Procedures 89 Appearance Care 91 ADJUSTMENTS FOR COMPETITION 93 Front Suspension Adjustments 94 Rear Suspension Adjustments 107 Suspension Adjustments for Track Conditi...

Page 5: ...ions 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 Important Safety Information 2 Important Safety Precautions 2 Accessories Modifications 3 Safety Labels 4 Motorcycle Safety 1 ...

Page 6: ...ake 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 and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilites or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to...

Page 7: ...your CRF in any way that would change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories ...

Page 8: ...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 ...

Page 9: ...Operating Controls 5 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Component Locations 6 ...

Page 10: ...6 Operating Controls Component Locations clutch lever hot start lever front brake lever engine stop button fuel fill cap throttle grip choke knob fuel valve shift lever kickstarter rear brake pedal ...

Page 11: ...et you prepared 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 93 Before Riding Are You Ready to Ride 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection 9 ...

Page 12: ...other adjustments see page 93 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 protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a...

Page 13: ...arburetor throttle operation 47 Tires for damage or improper inflation pressure 81 Spokes for looseness 80 Rim locks for looseness 80 Front and rear suspension for proper operation 71 72 Front and rear brakes check operation 76 Drive chain for correct slack and adequate lubrication 83 Drive chain guide sliders and drive chain rollers for damage or wear 83 Exhaust pipe Muffler inspection removal an...

Page 14: ...10 Before Riding ...

Page 15: ... Instructions This 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 Flooded Engine 13 How to Stop the Engine 14 Break in Guidelines 15 ...

Page 16: ...e first time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death ...

Page 17: ...e throttle 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 in the engine makes kickstarting difficult 6 About a minute after the engine starts push the choke knob back all the way to fully OFF If idling is unstable open the throttle slightly Warm En...

Page 18: ...1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle 1 2 3 times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow result in hard starting Emergency Engine Stop To stop the engine in an emergency press the engine stop button ...

Page 19: ...ying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced ...

Page 20: ...16 Basic Operating Instructions ...

Page 21: ... page 152 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before After Competition Maintenance 26 Between Motos Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Component Locations 28 Seat Removal 29 Fuel Tank Removal 30 Subframe Removal 32 Se...

Page 22: ...ner s manual The 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 good maintenance are especially 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 ...

Page 23: ...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 Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the optional work stand or a maintenance stand to provide support To reduce...

Page 24: ...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 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 Honda par...

Page 25: ...R R R R R 46 53 43 45 54 41 55 36 38 48 63 63 39 42 83 83 84 85 85 77 79 76 49 89 86 71 25 72 73 98 90 80 81 89 R I FORK TUBE SLIDER DAMPER FREQUENCY NOTE Ref Page 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 Every 12 races or about 30 0 hours This maintenance schedule is based upon average riding condition Machin...

Page 26: ...s 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 seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reas...

Page 27: ... to over 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 Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Honda ...

Page 28: ...nt corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 65 Fuel Filter Periodically drain the fuel from the tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 Fuel Contamination Refer to Fuel System in your Owner s Manual page 34 and in this suppl...

Page 29: ...n tight woods can shorten the service life of brake fluid Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Water Pump Inspection Hole After every race check the inspection hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if n...

Page 30: ...above te ground and use the pressure release screws 1 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 while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 1 chain adjuster index marks 1 pressure release screws 1 1 After Competition...

Page 31: ...ly priced cleaning 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 using stiff abrasive brushes on the plastic or rubber parts 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 ...

Page 32: ...in slider transmission oil drain bolt engine oil drain bolt left side cover clutch lever fuel tank carburetor front brake hose steering head front suspension fuel valve shift lever kickstarter throttle front brake lever spark plug front wheel axle rear brake pedal clutch lever hot start lever front brake lever engine stop button fuel fill cap radiator cap throttle grip ...

Page 33: ...1 seat bolts 3 seat 2 collars Installation 1 Slide the seat front prong 4 onto the seat bracket 5 and the seat rear prong 6 onto the tab 7 by pushing down and forward on the seat in each of these areas 2 Install the collars and tighten the seat bolts 19 lbf ft 26 N m 2 7 kgf m 4 seat front prong 5 seat bracket 6 seat rear prong 7 tab 3 2 1 4 5 7 6 ...

Page 34: ...retor must be disconnected not the fuel line leading to the fuel tank 9 Remove the fuel valve bolt 9 and fuel valve 10 Remove the fuel tank 8 fuel line 9 fuel valve bolt WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 4 2 3 7 5 6 9 8 ...

Page 35: ...e 2 fuel valve bolt 3 fuel line 4 Install the fuel tank bolt 4 5 Hook the air cleaner cover rubber 5 6 Install the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 7 breather tube 8 Install the shrouds 8 and shroud B bolts collars 9 9 Install the shroud A bolts 10 8 shrouds 9 shroud B bolts 10 shrouds A bolts 4 fuel tank bolt 5 air cleaner cover rubber 6 fuel tank band 10 Instal...

Page 36: ... crankcase breather tube 8 fuel tank band 9 air cleaner cover rubber 10 screw 11 air cleaner connecting tube clamp 9 Remove the subframe mounting A bolts 12 and subframe mounting B bolt 13 Then remove the subframe 14 by pulling it straight backward 12 subframe mounting A bolts 13 subframe mounting B bolt 14 subframe Installation 1 Loosely attach the upper and lower ends of the subframe 1 to the ma...

Page 37: ... 10 of the muffler clamp with the cut out 11 of the muffler 12 9 muffler clamp 11 cut out 10 tab 12 muffler 8 Install the new gasket 13 as shown 13 gasket 9 Install the muffler 12 12 muffler 14 muffler B bolt washer 15 muffler A bolt 16 muffler clamp bolt 12 Install the side covers 17 side cover bolts and collars 18 13 Install the seat page 29 17 side cover 18 side cover bolts collars 5 7 6 8 4 11...

Page 38: ...ver 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 3 liter 1 fuel fill cap 3 steering stem nut 2 breather tube 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 un...

Page 39: ...nto an approved gasoline container 2 Remove the fuel tank page 30 3 Remove the fuel filter 1 from fuel tank by removing the bolts 2 Wash the fuel filter in high flash point cleaning solvent 4 Reassemble the fuel filter in the reverse order of removal Make sure the O ring 3 is in place Install the fuel filter in the fuel tank Refill the fuel tank Attach the fuel valve and fuel line and turn the fue...

Page 40: ...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 oil Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent viscosity weight SAE 10W 40 JASO T 903 MA or MB Your motorcycle does not need oil additives Use the recomm...

Page 41: ...rk you do not have to add oil If the oil is below or near the lower level 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 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright posit...

Page 42: ... to damage the O ring then tighten the oil filter cover bolts to the specified forque 9 lbf ft 12 N m 1 2 kgf m 15 Install the left engine guard and left engine guard bolt 16 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69R at oil and filter change 0 70 US qt 0 66R at oil change 17 Install the engine oil filler cap dipstick 18 Check the engine oil level by following the steps ...

Page 43: ...ils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label Type API classification 4 stroke engine oil only Viscosity weight JASO T903 standard others suggested oil transmission oil or 4 st...

Page 44: ... transmission oil filler hole until oil start to flow out of the oil check bolt hole Install the oil check bolt and transmission oil filler cap Repeat step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine at idl...

Page 45: ...ill not provide proper corrosion 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 additional protection against freezing Check the cooling system frequently during freezing weather Checking Adding Coolant Refer to Safety Precautions on page 19 1 With t...

Page 46: ...a Service Manual or consult your Honda dealer for replacing the water pump seal or the engine oil seal Both seals should be replaced at the same time Coolant Replacement Refer to Safety Precautions on page 19 Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page 152 To properl...

Page 47: ...cleaner maintenance can cause poor performance and premature engine wear NOTICE NOTICE Cleaning 1 Remove the seat page 29 2 Loosen the air cleaner retaining bolt 1 3 Align the two access top tabs 2 of the air cleaner 3 and mark 4 of the air cleaner housing by rotating the air cleaner counterclockwise 5 Remove the air cleaner from the air cleaner holder 5 1 air cleaner retaining bolt 2 two access t...

Page 48: ... 1 8 6 3 1 7 5 11 Install the assembly into the air cleaner housing keeping the two access top tabs 2 up 12 Carefully position the sealing flange of the element to prevent dirt intrusion 13 Align the set tab 9 of the air cleaner with the mark 4 of the air cleaner housing by rotating the air cleaner clockwise Tighten the retaining bolt 1 securely 1 air cleaner retaining bolt 3 air cleaner 7 hole 5 ...

Page 49: ...CRF is ridden in the rain or 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 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube 2 1 ...

Page 50: ...n the lock nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 31 If you can t get the freeplay within the specified range contact your Honda dealer 5 6 1 Pull the rubber dust cover 2 back 2 Loosen the upper lock nut 3 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction...

Page 51: ... open to fully 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 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...

Page 52: ...te idle speed adjustment For information about high altitude carburetor adjustment see page 143 Idle Speed Adjustment Refer to Safety Precautions on page 19 1 Turn the pilot screw 1 in until it is lightly seated and record the number of turns Turn the pilot screw out the same number of turns 2 If the engine is cold start it and warm it up three minutes Then shut it off 3 Connect a tachometer to th...

Page 53: ... the freeplay again If the adjuster is threaded out near its limit and the correct freeplay cannot be reached turn the adjuster in direction until it seats lightly and then turn it out one turn in direction Make the adjustment with the integral cable adjuster Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freepl...

Page 54: ...l page 40 2 Remove the rear brake pedal 1 by removing its pivot bolt 2 1 rear brake pedal 2 pivot bolt 3 Remove the five clutch cover bolts 3 and clutch cover 4 3 clutch cover bolts 4 clutch cover 4 Remove the five clutch spring bolts 5 and clutch springs Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps 5 Remove the clutch pressure plate 6 5 clutch spring bolts 6 clutch pressur...

Page 55: ...nstall the eight clutch discs 2 and seven clutch plates alternately starting with a clutch disc 1 clutch plates 2 clutch discs 3 Apply grease to the clutch lifter rod 3 4 Insert the clutch lifter rod into the mainshaft 5 Install the clutch lifter 4 onto the rod 3 clutch lifter rod 4 clutch lifter 6 Install the clutch pressure plate 5 7 Install the five clutch springs and bolts 6 8 Tighten the bolt...

Page 56: ...vot bolt 11 with Honda Lithium Grease and tighten the pivot bolt to the specified torque 27 lbf ft 37 N m 3 8 kgf m Connect the brake pedal return spring 12 if it was removed 9 O ring 11 pivot bolt 10 rear brake pedal 12 return spring 12 Fill the crankcase with transmission oil page 40 12 10 11 9 ...

Page 57: ...freeplay 1 16 1 8 in 2 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster clockwise will increase free play and turning it counterclockwise will decrease free play After adjustment tighten the lock nut 3 lock nut increase 4 cable adjuster decrease 1 2 4 3 ...

Page 58: ...e the spark plug 2 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Push the engine stop button and disengage the clutch by pulling the lever in Coast to a stop 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 ten minutes before taking a plug read...

Page 59: ...er bolts 3 and cylinder head cover 4 3 cylinder head cover bolts 4 cylinder head cover 1 crankshaft hole cap 2 Remove the spark plug 2 2 spark plug 2 1 4 3 1 2 cont d Refer to Safety Precautions on page 19 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance w...

Page 60: ...gear lock bolt 3 crankshaft clockwise until aligning the punch mark 4 on the primary drive gear with the index mark 5 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear lock bolt clockwise again and align the punch mark with the index mark The inspection must be made when ...

Page 61: ...tensioner lifter cover bolt 2 sealing washer 3 Make a tensioner shaft stopper tool 3 out of a thin piece of steel 0 8 mm thick using the diagram 4 Turn the tensioner shaft clockwise with the stopper tool 3 until it stops in order to retract the tensioner fully Then insert the stopper tool fully to hold the stopper in the fully retracted position 3 stopper tool 2 1 12 0 mm 7 0 mm 8 5 mm 3 5 mm 3 3 ...

Page 62: ... of wire to 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 7 Remove the valve lifters 7 Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust right or left Do not let the valve lifters and shims fal...

Page 63: ...est 3 000 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 thickness Make sure of the correct shim thickness by measuring the shim with the micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface ...

Page 64: ...ation 1 Install 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 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the camshaft and outer surface of the each the valve lifters 3 3 Install the valve lifters and camsha...

Page 65: ...2 intake cam lobes 10 Insert the feeler gauge 16 between the intake valve lifter and cam lobe If the feeler gauge cannot be inserted the shim is caught between the valve lifter and the valve retainer Remove the camshaft holders place the shim correctly and reinstall the camshaft holders Valve Clearances IN 0 005 0 001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 16 feeler gauge 11 11 10 12 16 16...

Page 66: ...ole packing 1 from the cylinder head cover Install the spark plug hole packing to the spark plug hole 2 1 spark plug hole packing 2 spark plug hole 2 Install the cylinder head cover packing 3 into the groove of the cylinder head cover 4 3 cylinder head cover packing 4 cylinder head cover 3 Tighten the cylinder head cover 5 and cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0...

Page 67: ...or page 117 7 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 page 88 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 8 Disconnect the spark plug cap 4 9 Remove any dirt around the spark plug base 4 spark plug cap 5 spark plug 11 Position the piston at top dead center on the compression stroke page 55 Remove the cam shaft holders page 57 12 Loosen the r...

Page 68: ...e nuts in a criss cross pattern in 2 or 3 steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase 16 Remove the cylinder head nuts washers 12 and cylinder head 13 NOTICE 12 cylinder head nuts washers 13 cylinder head 17 Remove the dowel pins 14 cylinder head gasket 15 and cam chain guide 16 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 1...

Page 69: ...arts 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 the piston Do not damage the piston Always support the piston when pressing out the pin Do not let the clips fall into the crankcase Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the pis...

Page 70: ...he 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 and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail NOTICE top ring oil ring mark top ring oil ring side rail side rail spacer CamShaft Holders Cylinde...

Page 71: ...pin clips 5 Use new pin clips Never reuse old clips Do not let the clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out Cylinder Installation 1 Clean off any gasket material from the gasket surface of the crankcase being careful not to let any material fall into the c...

Page 72: ...he piston rings and cylinder walls NOTICE 3 cam chain 4 cylinder 5 piston rings 6 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 crankcase guide hole 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder head gasket 2 Do not let the dowel...

Page 73: ...nder head nuts in a criss cross pattern in 2 or 3 steps 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 hanger nuts 8 of the frame side and engine hanger nut 9 of the engine side Tighten the engine hanger nut to the specified torque frame side 25 lbf ft 34 N m 3 5 kg...

Page 74: ...exhaust pipe 15 exhaust pipe joint nuts 9 10 11 12 13 14 15 10 Install the cylinder head cover page 62 Connect the spark plug cap 12 12 Install the carburetor page 121 13 Install the subframe and muffler page 32 14 Install the fuel tank page 31 and the seat page 29 15 Pour a fresh recommended coolant mixture page 41 slowly into the radiator filler hole up to the filler neck Capacity 1 06 US qt 1 0...

Page 75: ...performance of your CRF s front suspension 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 Adjustment Guidelines page 112 Make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you t...

Page 76: ...ncrement or turns described in page 108 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 adjust it by turning all the compression and rebound adjusters according to the procedures described in page 108 After adjusting the adjusters simultaneously suspension may be fine tuned b...

Page 77: ...and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 1 outer tube 6 guide bushing 5 dust seal 7 slider 3 Pour the fork oil from the outer tube 1 Pour the fork oil from the oil hole 9 of the fork damper 1 outer tube 9 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork oil wil...

Page 78: ... oz 368 cm3 Maximum oil capacity 14 0 US oz 414 cm3 Slightly stiffer as it nears full compression Slightly stiffer as it nears full compression Minimum oil capacity 10 8 US oz 318 cm3 1 scribe mark aftermarket parts No mark factory products 3 scribe mark Optional Stiffer 0 47 kgf mm Fork Spring Standard oil capacity 12 6 US oz 374 cm3 Maximum oil capacity 14 2 US oz 420 cm3 Slightly stiffer as it ...

Page 79: ...Check that the O ring 10 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring 2 fork damper 10 o ring 7 Tighten the fork damper using the special tool to the specified torque 25 lb ft 34 N m 3 5 kgf m 10 2 ...

Page 80: ... 1 lock nut 3 piston 2 adjuster 1 Loosen the lock nut 1 2 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pullin...

Page 81: ... brake system and it must be bled Refer to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 79 Worn brake pads should be replaced ...

Page 82: ...curely to the specified torque 1 1 lbf ft 1 5 N m 0 15 kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 4 bolts 5 reservoir cap diaphragm 6 upper level mark 1 Remove the bolts 4 reservoir cap and diaphragm 5 2 Fill the reservoir wit...

Page 83: ...ake disc 2 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 replaced 4 rear brake caliper 6 brake disc 5 brake pads Other Inspections Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Make sure the...

Page 84: ...erform the recommended 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 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Front Spoke 2 7 lbf ft 3 68 N m 0 38 kgf m Rear Spoke 2 7 lbf ft 3 7 N m 0 38 kgf m Rim Loc...

Page 85: ...ary install a new cap 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 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 particul...

Page 86: ...oper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual Front 80 100 21 51M Rear 100 90 19 57M Type bias ply tube Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched an...

Page 87: ...between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm 1 drive chain slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several 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 Excessive chain slack m...

Page 88: ...adjusting bolt with a wrench tighten the lock nut to the specified torque 20 lbf ft 27 N m 2 8 kgf m 6 7 8 7 6 6 1 2 3 5 4 Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda Chain Lube or an equivalent or SAE 80 or 90 gear oil is recommended Saturate each chain joint so that the lubricant penetr...

Page 89: ...chain with the master 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 the direction of forward wheel rotation 8 Recheck chain slack and adjust as necessary More About Drive Chain The master link is the most critical element of drive chain security M...

Page 90: ...aust pipe and muffler may reduce engine performance Muffler Removal 1 Remove the seat bolt 1 collars 2 side cover bolt 3 and right side cover 4 1 seat bolt 3 side cover bolt 2 collars 4 right side cover 2 Loosen the muffler clamp bolt 5 3 Remove the muffler A bolt 6 muffler B bolt washer 7 and muffler 8 5 muffler clamp bolt 7 muffler B bolt washer 6 muffler A bolt 8 muffler 2 1 4 3 2 7 8 6 5 ...

Page 91: ...r A bolt 6 and muffler B bolt washer 7 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 6 Tighten the muffler clamp bolt 8 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 4 muffler 7 muffler B bolt washer 6 muffler A bolt 8 muffler clamp bolt 9 right side cover 11 side cover bolt 10 collars 12 seat bolt 3 4 1 2 5 4 6 8 7 10 12 9 11 10 7 Install the right side cover 9 collar 10 and side cover ...

Page 92: ...d tighten to the specified torque 15 lbf ft 21 N m 2 1 kgf m 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 87 Exhaust Pipe Removal 1 Remove the muffler page 86 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 2 1 3 1 2 3 ...

Page 93: ...steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer Handlebar Inspection 1 Remove the handlebar pad 2 Check the handlebar 1 for bends or cracks 3 Check that the handlebar has not moved from its proper position by inspecting the punch mark 4 Tighten the front bolts first 5 Check the torque of the upper holde...

Page 94: ...sion oil check bolt Clutch cover Cylinder bolt Oil filter cover Cylinder head bolt Drive sprocket Torque lbf ft N m kgf m 7 15 7 11 7 7 7 9 7 23 10 21 10 15 10 10 10 12 10 31 1 0 2 1 1 0 1 5 1 0 1 0 1 0 1 2 1 0 3 2 1 cylinder head cover 2 exhaust pipe joint nuts 3 water pump cover 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover 7 cylinder bolts 8 oil filter cover 9 cylinder head...

Page 95: ...or steering 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 surface 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 Hondabrite and rins...

Page 96: ...s manual for lubricating 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 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 mi...

Page 97: ...s to determine if 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 firmer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 94 Rear Suspension Adjustments 107 S...

Page 98: ...sing the pressure release 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 an optional workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pr...

Page 99: ...rk springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1...

Page 100: ...upper pinch bolts 6 fork damper 6 Remove the disc cover 7 by removing the disc cover bolts 8 7 disc cover 8 disc cover bolts 7 Remove the front axle nut 9 and loosen the front axle pinch bolts 10 on both forks Pull the front axle shaft 11 out of the wheel hub and remove the front wheel 9 axle nut 11 front axle shaft 10 axle pinch bolts 8 Remove the fork protector 12 and brake caliper 13 Do not sup...

Page 101: ...ops 12 Measure the length 17 between the axle holder and outer tube and record it before disassembling the fork 18 outer tube 20 lock nut wrench 19 fork damper 21 slider lower end 14 Pour the fork oil from the outer tube Pour the fork oil from the oil hole 22 of the fork damper 22 oil hole 15 Temporarily install the fork damper to the outer tube 16 Set the lower end axle holder 23 of the slider in...

Page 102: ...ork center bolt 26 lock nut 22 Remove the push rod 27 from the fork damper 23 Remove the special tool or mechanic s stopper tool between the axle holder 23 and lock nut 26 while applying pressure to the fork cap Be careful not to damage the lock nut and fork center bolt hole NOTICE 23 axle holder 26 lock nut 25 tool 27 push rod 24 Remove the fork damper assembly 28 from the fork assembly 29 Remove...

Page 103: ...ul not to damage the fork cap bushing 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 2 fork damper 4 fork assembly 4 2 2 5 2 2 6 1 65 1 85 in 42 47 mm 2 2 4 7 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper 2 as shown Oil Level 1 65 1 85 in 42 47 mm 5 ...

Page 104: ...mper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 15 If you can not use compressed air remove the pressure release screw 10 on the fork cap 11 Hold the fork damper up side down for 10 minutes and drain the oil from the fork damper spring chamber 6 7 8 2 8 9 11 10 13 Drain the extra oil from the fork damper spring chamber 8 oil hole 9 By doing this...

Page 105: ...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 Wipe the oil completely off the fork spring 3 Install the fork spring Install the fork damper 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 fork spring 1 Amount of fork oil left in the fork without damper and spring unit cc minute C F 30 86 20 68 10 50 0 32...

Page 106: ...bolt fully by hand NOTICE 2 lock nut 7 O ring 5 stopper tool 8 fork 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 specification check the lock nut and center bolt installation 2 lock nut 8 center bolt 9 Tighten the lock nut 2 to the fork center bolt 8 closely by hand Tighten the ...

Page 107: ...Standard oil capacity 12 4 US oz 368 cm3 Maximum oil capacity 14 0 US oz 414 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 8 US oz 318 cm3 No mark factory products 1 scribe mark 1 scribe mark aftermarket parts or Optional Stiffer 0 47 kgf mm Fork Spring Standard oil capacity 12 6 US oz 374 cm3 Maximum oil capacity 14 2 US oz ...

Page 108: ... of the upper fork clamp Temporarily tighten the fork lower pinch bolts 13 and then tighten the fork damper 4 to the specified torque using a special tool 25 Ibf ft 34 N m 3 5 kgf m For ease of releasing air pressure after the forks are installed loosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adjusters 17 Tighten th...

Page 109: ... onto the left fork leg clamp inner surface Tighten the axle nut 16 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m 16 axle nut 21 Align the brake caliper 17 and hose with the left fork leg making sure that the brake hose is not twisted 22 Clean the threads of the caliper mounting bolts 18 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the slid...

Page 110: ...own several times to seat the axle and check front brake operation 27 Tighten the left axle pinch bolts 26 alternately first While keeping the forks parallel alternately tighten the right axle pinch bolts to the specified torque 14 Ibf ft 20 N m 2 0 kgf m 26 axle pinch bolts To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surf...

Page 111: ...t throttle break in time about 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 86 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off t...

Page 112: ...mping adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 3 4 2 1 4 turns and the punch marks are aligned Low Speed Damping The low speed damping c...

Page 113: ...for any suspension tuning the proper rear spring pre load 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 To calculate the proper adjustment it is necessary to measure between two fixed points from the top of the most rearward point of the subframe do...

Page 114: ...ded dimension step 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 should sag 0 39 to 0 98 in 10 to 25 mm If the rear of your CRF sags more than 0 98 in 25 mm from its own weight the spring is too stiff for your weight It is not compressed enough even t...

Page 115: ...iffer aftermarket 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 the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compre...

Page 116: ...on large bumps especially 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 damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because...

Page 117: ...ng makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desire compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is ...

Page 118: ...bumps Entire travel 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 low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment ...

Page 119: ...o 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 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mix...

Page 120: ...rcuit 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 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 air passage 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters t...

Page 121: ...al 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by removing the float bowl plug 1 WARNING Gasoline is highly flammable and explosive You can be burmed or seriously injured when handing fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 float bowl plug 3 Install the float bowl plug 2 1 1 straight section 2 clip 1...

Page 122: ...ensor connector 10 Remove the hot start cable holder 6 6 hot start cable holder 11 Disconnect the rear suspension 7 upper mounting nut 8 7 rear suspension 8 upper mounting nut 12 Remove the throttle drum cover bolt 9 and throttle drum cover 10 9 throttle drum cover bolt 10 throttle drum cover 13 Loosen the lock nut 11 adjusters 12 and disconnect the throttle cables 13 from the throttle drum 14 Rem...

Page 123: ...r 5 jet needle 6 throttle valve 3 Remove the link arm set screw 7 When installing the link arm set screw apply a locking agent to the link arm set screw threads 4 Remove the throttle valve 8 throttle valve roller 9 and floating valve 10 7 link arm set screw 9 throttle valve roller 8 throttle valve 10 floating valve When installing the floating valve 10 onto the throttle valve 8 make sure the float...

Page 124: ...bowl 18 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws 22 tube guides 8 Remove the pump rod 23 Clean the pump rod and rod passage 24 Install the pump rod into the link lever 25 Push the rod forcibly into the link lever until it snaps into place 23 pump rod 25 link lever 24 rod passage 26 float level 27 float level gauge 28 carburetor intake 10 Remove the leak jet ...

Page 125: ...etor reverse the removal procedures After installing the carburetor adjust the throttle cable 1 free play and hot start cable 2 free play After installing the carburetor check the air vent hoses 3 and overflow hose 4 for kinking or pinching and correct routing as necessary 1 throttle cables 2 hot start cable 3 air vent hoses 4 overflow hose 2 1 3 3 4 3 4 ...

Page 126: ...rd 170 1 1 2 42 NCYQ 2nd 170 1 1 2 42 NCYQ 2nd 168 1 1 2 42 NCYQ 2nd 168 1 1 4 42 NCYQ 2nd 165 1 1 4 42 NCYQ 2nd 165 7 499 ft to 5 000 ft PS SJ JN NC MJ 1 3 4 42 NCYQ 3rd 175 1 3 4 42 NCYQ 3rd 172 1 3 4 42 NCYQ 3rd 170 1 1 2 42 NCYQ 2nd 170 1 1 2 42 NCYQ 2nd 168 1 1 2 42 NCYQ 2nd 168 1 1 4 42 NCYQ 2nd 165 4 999 ft to 2 500 ft PS SJ JN NC MJ 2 42 NCYQ 4th 175 1 3 4 42 NCYQ 3rd 175 1 3 4 42 NCYQ 3rd...

Page 127: ...n the track has a very long straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is hotter than 113 degrees F After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CRF If larger jetting c...

Page 128: ...Adjustment Procedure 1 Turn the pilot screw in until it is lightly seated and record the 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 2 3 laps of a course with the standard setting or corrected jetting page 122 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening V...

Page 129: ...ool 9 jet needle 10 throttle valve 17 Change the clip position of jet needle or jet needle as required 18 Reinstall the jet needle jet needle holder carburetor top and carburetor top bolts 19 Install the fuel tank page 31 20 Rotate the carburetor and align the lug 11 on the carburetor with the slot 12 on the intake tube 11 lug 12 slot 21 Tighten the connecting and intake tube band screws 22 Connec...

Page 130: ...d appear clean and colorless 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 indicate rich jetting NOTICE Condition Normal Overheating Lean Wet Rich Spark Plug Appearance Dark brown to light tan color with dry electrode Light gray or white color Wet or sooty M...

Page 131: ...roove in the outer tube with the top surface of the upper fork clamp If you install the optional 20 inch wheel align the top of the fork tube with the top of the upper fork clamp Standard Position The standard position 1 aligns the index groove 2 with the top of the upper clamp 3 Standard Position For Optional Front Wheel If you install the optional 20 inch wheel align the top of the fork tube 5 n...

Page 132: ...ppery during the first few races then changes from 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 use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clut...

Page 133: ...y 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 choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands...

Page 134: ...is depressed when 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 standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved rearward either 3 mm using optional handlebar lower holders or 6 mm by ro...

Page 135: ... 131 Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 132 Storing Your Honda 133 You the Environment 134 Troubleshooting 135 ...

Page 136: ...railer rail Attach the lower ends of two straps to the tie down hooks on your vehicle 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 tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and ...

Page 137: ...hain 7 Remove the spark plug and pour a tablespoon 0 51 0 68 US oz 15 20 cm3 of clean engine oil into the cylinder With the spark plug grounded or the engine stop button pressed in crank the engine several times to distribute the oil then reinstall the spark plug 8 Inflate the tires to their recommended pressures 9 Place your CRF on the optional work stand or equivalent to raise both tires off the...

Page 138: ...ning 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 and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and ...

Page 139: ...ion coil Broken or shorted spark plug wire Faulty ignition pulse generator Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Disconnect fuel line at carburetor and check for clogging P 34 UNRESTRICTED FUEL FLOW FUEL FLOW RESTRICTED CLOGGED DIRTY INCORRECT LOW WEAK OR INTERMITTENT SPARK NOT CLOGGED CORRECT CORREC...

Page 140: ...136 Tips ...

Page 141: ...dimensions capacities and other technical data Vehicle Identification 138 Specifications 139 Torque Specifications 140 High Altitude Carburetor Adjustment 143 Oxygenated Fuels 144 Competition Logbook 145 Optional Parts List 147 Spare Parts Equipment 148 Wiring Diagram 149 ...

Page 142: ...ecord these numbers in the Quick Reference section at the rear of the manual The VIN vehicle identification number 1 appears on the Safety Certification Label attached to the left side of the frame LEFT SIDE 1 vehicle identification number The frame number 2 is stamped on the right side of the steering head RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 ...

Page 143: ...l capacity After draining After draining and oil filter change After disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet standard Jet needle standard Piston valve FCR01B 172 NCYQ Needle clip position standard Slow jet standard Pilot screw opening Float level Liquid cooled 4 stroke Single 10 inclined from vertical 0 70 US qt 0 73 US qt 0 90 US ...

Page 144: ... 10 ENGINE Cylinder head cover Exhaust pipe joint nut Water pump cover Crankshaft hole cap Transmission oil check bolt Clutch cover Cylinder bolt Oil filter cover Cylinder head bolt Drive sprocket Torque Remarks lbf ft N m kgf m 7 15 7 11 7 7 7 9 7 23 10 21 10 15 10 10 10 12 10 31 1 0 2 1 1 0 1 5 1 0 1 0 1 0 1 2 1 0 3 2 8 9 7 10 1 2 3 5 4 6 RIGHT SIDE LEFT SIDE ...

Page 145: ...k absorber upper lower Swingarm pivot nut Fork fork damper fork cap Rear shock arm nuts swingarm side shock link side Rear shock link nuts Frame side Shock spring lock nut Kickstarter arm bolt Torque Remarks lbf ft N m kgf m 80 16 15 16 33 65 15 94 20 47 47 47 40 25 33 33 65 25 22 38 38 39 33 28 108 22 20 22 44 88 20 128 27 64 64 64 54 34 44 44 88 34 30 52 52 53 44 38 11 0 2 2 2 0 2 2 4 5 9 0 2 0 ...

Page 146: ...ont rear Muffler clamp bolt Sprocket nuts Seat mounting bolts Front brake reservoir cap screws Rear brake reservoir cap bolts Fork air pressure release screw Torque Remarks lbf ft N m kgf m 7 25 22 12 12 23 2 8 2 8 9 6 22 36 51 16 9 5 1 19 19 15 24 19 0 7 0 7 0 9 9 9 34 30 16 16 31 3 68 3 7 13 30 49 69 22 13 7 26 26 21 32 26 1 0 1 0 1 2 1 0 3 5 3 1 1 6 1 6 3 2 0 38 0 38 1 3 3 1 5 0 7 0 2 2 1 3 0 7...

Page 147: ...educed and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may cause engine ...

Page 148: ...ol 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 containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performa...

Page 149: ...ance 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 Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record you...

Page 150: ...ng Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use 146 Consumer Information Competition Logbook ...

Page 151: ...NCYQ Straight diameter Ø2 745 mm Jet needle number standard series TOOLS Remarks FRAME Remarks Driven sprocket Standard Drive chain links 51 Teeth Aluminum 114 20 inch wheel assembly except brake disk tire tube tire flap rim lock bead stopper front tire 90 100 20 90 100 20 M C Fork height 0 in 0 mm align the top of the fork tube with the top of the upper clamp Optional Optional Optional 50 Teeth A...

Page 152: ...justable wrenches open end box wrenches hex Allen wrench spoke 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 gauge set vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your motorcycle purch...

Page 153: ...Technical Information 149 Wiring Diagram THROTTLE POSITION SENSOR SPARK PLUG ...

Page 154: ...150 Technical Information ...

Page 155: ...Consumer Information This section contains information about 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 USA only 155 ...

Page 156: ... 31KRN610 2005 CRF250R Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation S H I P T O NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation Customer Name Attention Street Address ...

Page 157: ...es 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 USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following infor...

Page 158: ...ondaline accessories USA only and Honda accessories and products Canada only 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 parts department Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information US...

Page 159: ...ong as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Speialty Vehicle Institute of America for ATV owners One fu...

Page 160: ...ransmission Oil 39 Coolant 41 Air Cleaner 43 Crankcase Breather 45 Engine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 53 Spark Plug 54 Valve Clearance 55 Piston Piston Rings Piston Pin 63 Chassis Suspension 71 Front Suspension Inspection 71 Rear Suspension Inspection 72 Fork Oil Change 73 Brakes 76 Wheels 80 Tires Tubes 81 Drive Chain 83 Exhaust Pipe Muffler 86 Additional Mai...

Page 161: ...eed 48 minor adjustments 124 care appearance 91 chain drive 83 chassis adjustment for track conditions 127 choke knob 13 cleaner air 43 cleaning appearance care 91 clutch system adjustment 49 consumer information 151 controls operating 5 component locations 6 28 maintenance 28 operating controls 6 competition logbook 145 contacting Honda 153 controls operating 5 coolant 41 customer service 153 dam...

Page 162: ...sion 39 operating controls 5 instructions 11 optional parts list 147 sprockets 128 oxygenated fuels 144 pads brake 79 parts optional 147 personal fit adjustments 130 pinging engine 34 plug spark 54 pre load rear suspension 107 pre ride inspection 9 rear suspension maintenance 72 Rider s Club Honda 155 riding basic operation 11 before 7 important safety information 2 safety precautions 2 safety imp...

Page 163: ...elines 112 transmission oil 39 tuning tips 115 throttle freeplay 46 inspection 47 tires air pressure 81 flat 81 selection 129 tools 148 torque specifications 140 transporting 132 troubleshooting 135 tubes replacing 81 valve fuel 34 vehicle identification 138 washing your motorcycle 91 wheels 80 writing diagram 149 W V T ...

Page 164: ...5 psi 100 kPa 1 0kgf cm2 standard R0409B 8 NGK optional R0409B 9 NGK D I D 520DMA2 Maintenance Pre ride Inspection Fuel Capacity Engine oil Transmission oil Tires Tire Pressure cold Spark Plug Drive Chain Quick Reference Record important information here Frame No Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr The following is a brief but importan...

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