Honda CRF250R Owner'S Manual Download

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Contents

31KRN720

CRF250R

MOM 15406 (1504)

Contents

MOTORCYCLE SAFETY............................. 1

Important Safety Information ........................... 2

Important Safety Precautions ........................ 2

Accessories & Modifications ........................... 3
Safety Labels .................................................... 4

INSTRUMENTS & CONTROLS .................. 5

Operation Component Locations ...................... 6
MIL (Malfunction Indicator Lamp) ................. 7

MIL Blink Pattern ......................................... 7
Current DTC/Freeze DTC ............................. 7
Circuit Inspection .......................................... 8
DTC Index..................................................... 9

Mode Indicator ............................................... 10

BEFORE RIDING......................................... 11

Are You Ready to Ride? ................................ 12
Is Your Motorcycle Ready to Ride? ............... 13

Pre-ride Inspection ...................................... 13

BASIC OPERATING INSTRUCTIONS .... 15

Safe Riding Precautions .............................. 16

Starting & Stopping the Engine ...................... 17

Fast Idle Knob ............................................. 17
Preparation .................................................. 17
Starting Procedure ....................................... 17
How to Stop the Engine .............................. 18

Break-in Guidelines ........................................ 19

SERVICING YOUR HONDA ......................21
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 Competition Maintenance  .....30

Between Motos & Practice Maintenance.....30
After Competition Maintenance ..................32

Service Preparations

Maintenance Component Locations ............... 33
Seat .................................................................. 34
Fuel Tank ........................................................ 35
Subframe ......................................................... 38

Service Procedures

Fluids & Filters
Fuel System ..................................................... 40
Engine Oil  .......................................................49
Transmission Oil  .............................................52
Coolant ............................................................ 54
Air Cleaner ......................................................56
Crankcase Breather  .........................................58

Engine
Throttle ............................................................ 59
Engine Idle Speed  ........................................... 61
Clutch System  .................................................62
Spark Plug  .......................................................67
Valve Clearance  ..............................................68
Piston/Piston Rings/Piston Pin ........................ 77

Appearance Care .......................................... 130

Summary of Contents for CRF250R

Page 1: ...idelines 19 SERVICING YOUR HONDA 21 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 Competition Maintenance 30 Between Motos Practice Maintenance 30 After Competition Maintenance 32 Service Preparations Maintenance Component Locations 33 Seat 34 Fuel Tank 35 ...

Page 2: ...Fork Height Angle 151 Wheelbase 151 Gearing 152 Tire Selection for Track Conditions 153 Personal Fit Adjustments 154 Control Positioning 154 Handlebar Position Width Shape 154 TIPS 155 Transporting Your Motorcycle 156 Storing Your Honda 157 Preparation for Storage 157 Removal from Storage 157 You the Environment 158 Troubleshooting 159 TECHNICAL INFORMATION 161 Vehicle Identification 162 Serial Nu...

Page 3: ...2016 Honda CRF250R OWNER S MANUAL COMPETITION HANDBOOK ...

Page 4: ...on is intended 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 procedures discussed in this manual An official Honda Service Manual for your CRF is available page 174 It is the same manual your dealer uses If you plan to do any service on your CRF beyond ...

Page 5: ...ages 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 possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN...

Page 6: ...t 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 Important Safety Information 2 Important Safety Precautions 2 Accessories Modifications 3 Safety Labels 4 ...

Page 7: ... 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 and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ab...

Page 8: ...ny 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 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 9: ...Safety Labels 4 Motorcycle Safety Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for replacement ...

Page 10: ...s Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 MIL Malfunction Indicator Lamp 7 MIL Blink Pattern 7 Current DTC Freeze DTC 7 Circuit Inspection 8 DTC Index 9 Mode Indicator 10 ...

Page 11: ...nt Locations 6 Instruments Controls clutch lever engine stop button front brake lever throttle grip MIL engine mode select button mode indicator fast idle knob engine idle speed shift lever kickstarter rear brake pedal ...

Page 12: ...engine speed is over 5 500 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 blinks For example when one long blink is followed by two short blinks the MIL is 12 one long blink 10 blinks plus two short blinks When the ECM stores more than one DTC the MIL wil...

Page 13: ...ften related 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 sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 No 1 No 2 CKP sensor connector 7 ECM connector 1 5 4 6 2 3 7 ...

Page 14: ...of the PGM FI symptom DTC Index MIL blinks Function 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 Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IAT sensor circuit malfunction Engine operates normally 12 Inje...

Page 15: ...hould light for a few seconds and then go off when the engine is started The mode indicator indicates a selected mode when you operate the engine mode select button page 134 If the mode indicator stays on or does not come on when it should have your dealer check it for problems 1 mode indicator 2 engine mode select button 2 1 ...

Page 16: ...ready 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 other adjustments see page 133 Are You Ready to Ride 12 Is Your Motorcycle Ready to Ride 13 Pre ride Inspection 13 ...

Page 17: ...ng damper and other adjustments see page 133 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 WARNIN...

Page 18: ... Throttle operation 59 Tires for damage or improper inflation pressure 116 Spokes for looseness 115 Rim locks for looseness 115 Left fork air pressure 136 Front and rear suspension for proper operation 87 88 Front and rear brakes check operation 111 Drive chain for correct slack and adequate lubrication 118 119 Drive chain sliders and drive chain rollers for damage or wear 118 119 Exhaust pipe Muf...

Page 19: ...nstructions 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 Preparation 17 Starting Procedure 17 How to Stop the Engine 18 Break in Guidelines 19 ...

Page 20: ... the Important Safety Precautions 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 Safe Riding Precautions ...

Page 21: ...smission 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 kick through to the bottom with a rapid continuous motion 4 About a minute after the engine starts push the fast idle knob back all the way to fully OFF If idling is unstable open the throttle slightl...

Page 22: ...into 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 emergency push and hold the engine stop button How to Stop the Engine 1 throttle 2 engine stop button 1 2 ...

Page 23: ...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 The front suspension will feel stiff until after break in approximately 1 hour this is normal ...

Page 24: ...a The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 26 Before After Competition Maintenance 30 Between Motos Practice Maintenance 30 After Competition Maintenance 32 Service Preparations Maintenance Component Locations 33 Seat 34 Fuel Tank 35 Subframe 38 Service Procedures Fluids Filters Fuel System 40 Eng...

Page 25: ...lly 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 Maintenance Schedule in this section WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow ...

Page 26: ...t 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 an optional workstand or a maintenance stand to provide support To reduce the possibility of a...

Page 27: ...erms 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 Honda Genuine Pa...

Page 28: ...s 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 40 FUEL PUMP FILTER NOTE 6 R 44 THROTTLE OPERATION I 60 AIR FILTER NOTE 1 C 56 CRANKCASE BREATHER I 58 SPARK PLUG I 67 VALVE CLEARANCE NOTE 4 I 68 76 ENGINE OIL NOTE 3 I R 49 ENGINE OIL FILTER NOTE 3 R 50 ENGINE IDLE SPEED I 61 PIST...

Page 29: ... Genuine Parts or their equivalents when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surfaces 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 reassemb...

Page 30: ...ructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Pro Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 56 Use the Honda Genuine air cleaner or an equivalent air cleaner specified for your model ...

Page 31: ...ng or other damage It makes good racing sense Spokes Check spoke tension frequently between the first few rides As the spokes spoke nuts and rim contact points seat in the spokes may need to be retightened Once past this initial seating in period the spokes should hold their tension Still be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular...

Page 32: ... to maintain proper suspension performance and minimize component wear Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file Be aware that filing them too sharp will reduce boot sole lifespan Sharpen only the points of the teeth Filing the grooves deeper will weaken the footpegs Be sure the pegs are free to pivot freely and that the pivot...

Page 33: ...ance while engine is running Injury to your fingers or hands may result After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad wear Suspend the front wheel above the ground and us...

Page 34: ... rebound and compression damping adjuster to the standard settings Do not adjust the left fork air pressure to less than the minimum calculated value or more than the maximum calculated value 1 inner chamber air valve 2 outer chamber air valve 3 balance chamber air valve Air fork pump 07AMJ KRNA100 USA only Air fork pump adapter 07AMJ KRNA110 USA only 1 3 Left fork 2 Left Fork Recommended Setting ...

Page 35: ... drive chain clean and lubricate it pages 119 120 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 hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning brushes are ava...

Page 36: ...d adjuster crankcase breather tube A left front suspension balance chamber air valve left front suspension inner chamber air valve left front suspension outer chamber air valve right front suspension compression damping adjuster steering damper adjuster right front suspension rebound damping adjuster transmission oil check bolt engine oil drain bolt rear brake pedal rear brake fluid reservoir rear...

Page 37: ...lation 1 Install the seat while aligning the seat front slit 1 with the front seat bracket 2 and seat prong 3 with the seat stopper plate 4 2 Install and tighten the seat mounting bolts 5 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat mounting bolts 2 seat 2 1 1 seat front slit 4 seat stopper plate 2 front seat bracket 5 seat mounting bolts 3 seat prong 1 3 2 4 5 ...

Page 38: ... in the same manner 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 fuel tank band 9 and air cleaner rubber 10 10 Remove the fuel tank bolt and collar 11 11 Remove the clamp A 12 from the throttle cable 13 and fuel pump wire 14 12 Unhook the fuel feed hose 15 from the clamp B 16 1 shroud A bolts and c...

Page 39: ...l pump wire 6 3 Install the fuel tank 7 on the frame 4 Install the collar and fuel tank bolt 8 5 Hook the air cleaner rubber 9 and the fuel tank band 10 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 15 fuel feed hose 18 fuel tank st...

Page 40: ...d the rear so that the shrouds and the tabs 18 on the air cleaner housing covers are aligned 11 Install the shroud B bolts 19 collars and shroud A bolts 20 Tighten the shroud B bolts to the specified torque 3 8 lbf ft 5 2 N m 0 5 kgf m 12 Install the seat page 34 11 breather tube 13 hose clamp 12 steering stem nut 14 shroud hooks 15 recesses 16 shrouds 17 frame 12 11 13 15 14 17 16 16 shrouds 18 a...

Page 41: ... Remove the subframe 9 Installation 1 Loosely attach the upper and lower ends of the subframe to the main frame and loosely install all subframe bolts 2 Tighten the subframe upper bolts 1 and subframe lower bolts 2 to the specified torque subframe upper bolts 24 lbf ft 32 N m 3 3 kgf m subframe lower bolts 36 lbf ft 49 N m 5 0 kgf m 1 rear fender mounting bolts and nuts 2 rear fender 3 air cleaner...

Page 42: ... hole in the subframe and then install the rear fender mounting bolts and nuts 6 5 Hook the fuel tank band 7 6 Install the air cleaner mounting bolts 8 7 Install the left and right mufflers page 122 8 Install the seat page 34 3 air cleaner case 4 subframe bosses 5 rear fender 6 rear fender mounting bolts and nuts 4 3 3 6 5 7 fuel tank band 8 air cleaner mounting bolts 7 8 ...

Page 43: ...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 filler neck 4 Fuel Tank Capacity 1 66 US gal 6 3 ℓ Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill ca...

Page 44: ...eft side of the frame 3 Remove the fuel quick connect fitting cover 1 from the 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 Place a shop towel 6 over the fuel quick connect fitting Fuel Pressure Relieving 1 fuel pump connector A 2 stay 2 1 Fuel Line Replacement 1 fuel quick connect fitting cover 2 fuel pump 3 ...

Page 45: ...el joints 8 with plastic bags 12 Connection 1 Install the rubber cover 1 onto the fuel joint 2 of the fuel pump as shown 2 Be sure that the slide retainer 3 is completely pulled up before connecting the quick connect fitting Do not bend or twist the fuel feed hose Do not reuse the kinked or damaged fuel hose Do not use gloves or a shop towel while installing the quick connect fitting WARNING Gasol...

Page 46: ...e retainer is firmly locked into place check visually and by pulling the connector housing 5 Install the setting rubber 5 clamp 6 and bolt 7 by aligning the clamp tab 8 with the groove 9 of the stay 6 Install the fuel quick connect fitting cover 10 Be sure the rubber cover 1 is properly installed between the fuel quick connect fitting cover and fuel pump 7 Increase the fuel pressure page 48 2 fuel...

Page 47: ...p plate 10 6 Remove the fuel pump unit 11 and O rings 12 Be careful not to damage the fuel pump unit 7 Disconnect the fuel pump wire terminals 13 from the fuel pump base 14 Be careful not to damage the wires when disconnecting the fuel pump wire terminals Fuel Pump Filter Replacement WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop t...

Page 48: ...18 from the fuel pump base 14 and remove the O ring 19 Wipe the spilled out fuel immediately 11 Remove the fuel pump stopper 20 and damper rubber 21 12 Remove the fuel pump assembly 22 with fuel pump filter 23 O ring 24 from the fuel pump unit holder 25 13 Check the fuel pump filter 23 for clog damage or deterioration and replace it if necessary 14 Remove the fuel pump filter from the fuel pump as...

Page 49: ...hooks 16 with the grooves 17 in the fuel pump base tabs 18 If the gap between the hooks and tabs is more than 0 04 in 1 0 mm replace the fuel pump unit Be sure that the hooks are completely seated 7 Connect the fuel pump red 19 and black 20 wire terminals to the fuel pump base terminals 21 Push the wire terminals until they stop as shown Be careful not to damage the wires 8 Apply 0 02 oz 0 5 g max...

Page 50: ... of the conical spring washers are upside 13 Tighten the fuel pump mounting bolts to the specified torque in the specified sequence as shown 8 lbf ft 11 N m 1 1 kgf m 14 Connect the fuel pump connector B 35 15 Install the stopper cable 32 to the hook 36 of the frame while holding the fuel tank 26 16 Connect the fuel line page 42 17 Increase the fuel pressure page 48 24 O ring new 26 fuel tank 25 f...

Page 51: ...e selector switches 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 the fuel pump for about 3 5 seconds and fuel pressure will rise 9 Turn the PUMP selector switch OFF Check that there is no leakage in the fuel line 10 Make sure that the battery harnes...

Page 52: ...engine 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 the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classe...

Page 53: ...ipstick 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 dipstick 1 from the left crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the engine oil drain bolt 2 and sealing washer 3 5 With the engine stop button pushed repeat kickstarter op...

Page 54: ... oil filter or a filter of equal quality specified for your model NOTICE If the oil filter is not installed properly it will cause serious engine damage 13 Apply engine oil to a new O ring and install it to the oil filter cover 14 Install the oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 9 lbf ft 12 N m 1 2 kgf m 15 Fill the...

Page 55: ...or 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 shown in the following chart may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stro...

Page 56: ...ry 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 the transmission oil fill cap 1 from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 5 After the oil h...

Page 57: ...only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Refer to Important Safety Precautions on page 23 1 Position your CRF on an optional workstand or equivalent support so that it is securely held in place in an upright position 2 With the engine cold remove the radiator cap 1 and check coolant level The coolant level is correct...

Page 58: ...leed 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 dealer for replacing the mechanical seal or oil seal Both seals should be replaced at the same time Refer to Important Safety Precautions on page 23 Coolant should be replaced by your dealer unless you have the proper tools and service data and a...

Page 59: ...p 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 or an air cleaner of equal quality NOTICE Using the wrong air cleaner may result in premature engine wear Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs lo...

Page 60: ...ir cleaner element and holder Install the holder tabs in the holes of the air cleaner element 8 Apply 0 05 0 19 oz 1 5 5 5 g of Pro Honda White Lithium Grease or equivalent to the air cleaner housing contact area of the air cleaner element 9 Install the air cleaner assembly 2 into the air cleaner housing by aligning its tabs 8 with the stay 9 of the air cleaner housing 10 Carefully position the se...

Page 61: ...see deposits in the transparent section of the crankcase breather tubes If the drain tube overflows the air filter may become contaminated with engine oil causing poor engine performance 1 Remove the crankcase breather tube plugs 1 from the crankcase breather tubes 2 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plugs Draining 1 crankcase breather tube plugs ...

Page 62: ...not be reached turn the adjuster all the way in and back out one turn Tighten the lock nut 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 adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the throttle body It is also used if you cannot get the...

Page 63: ... 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 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 corrosi...

Page 64: ...eed adjustment When pushed in the fast idle knob acts as the idle adjustment screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed 1 If the engine is cold start it and warm it up 3 minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift the transmission into neutral Start the engine 4 Keep the motorcycle in a...

Page 65: ...irection 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 in 10 20 mm Tighten the lock nut 6 Adjust the cable end adjuster for minor adjustment page 63 Inspection Check freeplay 1 Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range Im...

Page 66: ... stall 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 does not work properly the cable may be kinked or worn or the clutch discs may be worn Inspect the clutch discs and plates page 65 Check that the clutch lever assembly is positioned properly the end...

Page 67: ...e bearing 9 and washer 10 by removing the clip 11 Turn the needle bearing with your finger The needle bearing should turn smoothly and quietly Replace the needle bearing and washer if the needle bearing does not turn smoothly 7 Remove the eight clutch discs seven clutch plates judder spring and spring seat 12 Clutch Disc Plate Removal 1 clutch cover bolt A 3 clutch cover 2 clutch cover bolts B 1 3...

Page 68: ...nd plates replace the clutch springs 1 Install the spring seat 1 and judder spring 2 onto the clutch center as shown Coat the clutch discs with engine oil 2 Install the clutch disc A larger I D disc 3 onto the clutch outer Stack the seven clutch plates 4 and seven clutch discs B 5 alternately 3 Apply engine oil to the needle bearing 6 Install the needle bearing and washer 7 onto the clutch lifter ...

Page 69: ...bf ft 12 N m 1 2 kgf m 9 Apply engine oil to a new O ring 14 and install it in the groove of the clutch cover 15 10 Install the cover by tightening the clutch cover bolt A 16 and clutch cover bolts B 17 in a crisscross pattern in two or three steps to the specified torque 7 lbf ft 10 N m 1 0 kgf m 11 Fill the crankcase with transmission oil page 53 10 clutch lifter rod 11 clutch lifter assembly 12...

Page 70: ...e feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 024 0 028 in 0 60 0 70 mm 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Press and hold 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 ...

Page 71: ...ld The valve clearance 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 pages 34 35 2 Disconnect the breather tube 1 and spark plug cap 2 3 Remove the cylinder head cover bolts rubber seals 3 and cylinder head cover 4 1 Remove the crankshaft hole cap 1 2 Remo...

Page 72: ...when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arm 5 If it is free an indication that the valves are closed and that the piston is on the compression stroke If it is tight and the valves are open rotate the primary drive gear bolt 360 and realign the punch mark with the index mark 1 Set the piston at TDC on the compression stroke pa...

Page 73: ...e condenser stay mounting bolts 1 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 lifter 5 Turn the tensioner stopper clockwise and lock the cam chain tensioner lifter by pushing the handle 6 into the notch on the cam chain tensioner lifter 1 feeler gauge 4 exhaust rocker arm 5 exhaust valve shims EX 0 008 0 00...

Page 74: ...ngs carefully 6 Slide the left camshaft bearing 10 and remove the camshaft 11 by removing the cam chain 12 Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase NOTICE Do not let the cam chain fall into the crankcase 7 Remove the intake valve lifters 13 Keep the intake valve lifters and shims separate so you can easily identify the originally installed loc...

Page 75: ... 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 a micrometer Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 2 900 mm NOTICE Do not lap the intake and exhaust valves They are titanium and have a thin oxide coating Lapping will damage this coat...

Page 76: ... valve lifter 3 in their original location into the cylinder head 4 4 Make sure the piston is at TDC page 68 5 Place the camshaft 5 with the intake cam lobes 6 facing up and align the timing marks 7 on the cam sprocket 8 with the surface 9 of the cylinder head Install the cam chain 10 over the sprocket without rotating the camshaft 6 Slide the left camshaft bearing 11 Camshaft Installation 1 shims...

Page 77: ... and seating surface Tighten the camshaft holder bolts A 17 and B 18 to the specified torque 12 lbf ft 16 N m 1 6 kgf m Tighten the camshaft holder bolts in a crisscross pattern in two or three steps 11 Remove the tensioner stopper 19 from the cam chain tensioner lifter 12 Install a new sealing washer 20 and tighten the cam chain tensioner lifter cover bolt 21 12 dowel pins 13 camshaft holders 14 ...

Page 78: ...nces by inserting a feeler gauge 24 Valve Clearance 1 Install the spark plug page 67 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 hole cap to the specified torque 11 lbf ft 15 N m 1 5 kgf m 22 condenser stay 23 condenser stay mounting bolts IN 0 005 0 001 in 0 12 0 03 mm EX 0 0...

Page 79: ... 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 the cylinder head cover 2 and tighten the cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Connect the spark plug cap 7 and breather tube 8 6 Install the fuel tank and seat pages 34 36 Cylinder Head Cover Instal...

Page 80: ...on the compression stroke page 68 9 Remove the camshaft holders camshaft valve lifters and shims page 70 10 Disconnect the ECT sensor connector 1 11 Loosen the radiator hose clamp screw 2 and disconnect the radiator hose 3 12 Disconnect the crankcase breather tube A 4 from the air cleaner connecting tube 13 Disconnect the IAT sensor connector 5 14 Release the crankcase breather tube B 6 from the c...

Page 81: ...y and support it with a suitable strap 19 Remove the cylinder head hanger bolts 15 Remove the cylinder head hanger plate bolts 16 left cylinder head hanger plate 17 and right cylinder head hanger plate 18 10 air cleaner case 11 rear shock absorber upper nut and bolt 10 11 12 insulator band screw 13 throttle body 14 insulator 14 13 12 15 cylinder head hanger bolts 16 cylinder head hanger plate bolt...

Page 82: ...the dowel pins 23 and cylinder head gasket 24 NOTICE Do not let the dowel pins and cam chain fall into the crankcase 24 Remove the cam chain guide 25 from the cylinder 26 1 Remove the cylinder bolt 1 and cylinder 2 NOTICE Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder 19 cylinder head A bolts 20 cylinder bolt 21 cylinder head B bolts and washers 22 cylinder h...

Page 83: ...s 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 piston pin every 6 races or about every 15 0 hours of running Spread each piston ring 1 and remove by lifting it up at a point just opposite the gap NOTICE Do not damage the piston ring by spreading the e...

Page 84: ...de rails 2 to the piston 3 4 Install the top ring 4 to the piston with RNM mark 5 side facing up NOTICE Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation 5 After installing the piston 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 ga...

Page 85: ...de 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 surface Apply engine oil to the piston outer surface and piston pin hole inner surface Install the piston pin and new piston pin clips 7 NOTICE Use new pin clips Never reuse old clips Do not let the clips fa...

Page 86: ...E Do not let the dowel pins fall 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 cylinder over the piston rings by hand while compressing the piston rings NOTICE Do not damage the piston rings and cylinder walls 6 Temporarily tighten the cylinder bolt...

Page 87: ...ad 5 Apply engine oil to all cylinder head B bolt threads and seating surface Install the washers and cylinder head B bolts 7 Install the cylinder bolt 8 and cylinder head A bolts 9 6 Tighten the washers and cylinder head B bolts to the specified torque in a crisscross pattern in two or three steps 33 lbf ft 45 N m 4 6 kgf m NOTICE Do not let the washers fall into the crankcase 7 Tighten the cylin...

Page 88: ...s 0 43 0 04 in 11 0 1 0 mm 10 Set the rear shock absorber 17 and install the rear shock absorber upper bolt 18 and nut 19 as shown Tighten the rear shock absorber upper nut to the specified torque 32 lbf ft 44 N m 4 5 kgf m 11 Install the air cleaner connecting tube 20 along with air cleaner case to the throttle body Tighten the air cleaner connecting tube band screw 21 so the distance between the...

Page 89: ...ankshaft hole cap page 75 19 Install the cylinder head cover page 76 20 Install the spark plug page 67 21 Install the exhaust pipe page 124 22 Install the subframe page 38 and left and right mufflers page 122 23 Install the fuel tank and seat pages 34 36 24 Fill and bleed the cooling system page 157 Check for the following compression leaks abnormal engine noise secondary air leaks exhaust gas lea...

Page 90: ...per fork oil replacement Use HP Fork Oil SS 19 or an equivalent which contains special additives to assure maximum 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 145 Make all rebound...

Page 91: ...ments in one click or 1 4 turn increments Adjusting two or 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 rebound adjusters according to the procedures described in page 141 After adjusting the adjusters simultaneously suspension may be fine tuned by ...

Page 92: ... upper pinch bolts 3 6 When the fork is ready to be disassembled loosen the air cylinder unit 5 and or fork damper 6 using a lock nut wrench 7 but do not remove them yet Lock nut wrench 07WMA KZ30100 NOTICE Do not use an adjustable wrench to loosen the fork cap assembly fork damper and air cylinder unit it may damage them 7 Remove the disc cover 8 by removing disc cover socket bolts 9 from the lef...

Page 93: ...ifficulty in fitting the brake disc between the brake pads 11 Loosen the fork bridge lower pinch bolts 18 when loosening the lower bolts make sure to hold the fork tube so it dose not fall 12 Pull the fork legs down and out 13 Clean the fork assembly especially the sliding surface 19 of the slider and fork dust seal 20 14 Measure the length 21 between the axle holder and outer tube and record it b...

Page 94: ...ider when removing the fork damper 4 Drain the fork oil from the outer tube 3 Drain the fork oil from the oil holes 9 of the fork damper 5 Drain the fork oil by turning the outer tube 3 upside down About 0 2 US oz 7 cm3 of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 68 F 20 C Pour the drained oil into a suitable container and dispose of it in an approve...

Page 95: ...e reading 51 lbf ft 69 N m 7 0 kgf m using a 20 in 50 cm long deflecting beam type torque wrench When using the lock nut wrench use a 20 in 50 cm long deflecting beam type torque wrench with 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 8 Clean the threads of the fork protec...

Page 96: ...rom the outer tube using a lock nut wrench 6 Gently slide the outer tube down onto the lower end axle holder 7 NOTICE The outer tube 8 can drop on the slider 9 and damage the fork dust seal 10 To avoid damage hold both the outer tube and slider when removing the fork damper 3 Drain the fork oil from the outer tube slider 11 and oil holes 12 of the fork damper 4 Temporarily install the fork damper ...

Page 97: ...nut is removed the piston rod will fall in the fork damper and you may not reassemble the fork damper 9 Remove the push rod 15 from the fork damper piston rod 10 Remove the fork damper assembly 16 from the fork assembly 17 Remove the fork from the vise Remove the O ring 18 from the fork damper assembly NOTICE Do not attempt to separate the fork assembly and drop the axle holder out from the outer ...

Page 98: ...by pumping the fork damper piston rod several times 4 Clean the fork cap and fork damper threads 4 5 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper 5 while covering the oil holes by hand Recommended Oil HP Fork Oil SS 19 Recommended Amount 10 2 US oz 303 cm3 6 Pump the fork damper piston rod 2 slowly several times to bleed the air from the fo...

Page 99: ...mper piston rod sliding surface for damage 11 Cover the fork damper piston rod end with shop towel 10 to prevent fork damage Hold the fork damper in an upright position and pump the fork damper piston rod 2 to 3 9 in 100 mm slowly several times 12 Cover the oil holes 11 with shop towel to prevent blow out of fork oil Blow the extra oil off from the fork damper oil chamber 3 by pumping the fork dam...

Page 100: ...armful to the environment 15 Install and tighten the pressure release screw to the specified torque 1 0 lbf ft 1 3 N m 0 1 kgf m 1 Drain the fork oil from the fork assembly 1 by placing it upside down About 0 2 US oz 7 cm3 of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 68 F 20 C To properly dispose of drained fluids refer to You the Environment o...

Page 101: ...olt installation 9 Tighten the fork center bolt lock nut 2 to the fork center bolt 6 closely by hand Tighten the fork center bolt lock nut to the specified torque 21 lbf ft 28 N m 2 9 kgf m 10 Apply locking agent to the fork center bolt threads Install the fork center bolt 6 to the axle holder and tighten it to the specified torque 51 lbf ft 69 N m 7 0 kgf m 11 Measure the length between the axle ...

Page 102: ...e recommended fork oil to the O ring 16 Pull up the fork assembly 1 slowly and install the fork damper assembly into the outer tube 17 Clean the threads of the fork protector socket bolts 10 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protector 11 and fork protector socket bolts Tighten the fork protector socket bolts to the specified torque 5 2 lbf ft 7 N m...

Page 103: ...he balance chamber by pressing the valve center When releasing air pressure from the balance chamber the fork will be extended Spraying a small amount of fork oil from the balance chamber air valve is normal when releasing air pressure from the balance chamber This will not affect the fork performance 7 Hold the outer tube 6 then remove the air cylinder unit 7 from the outer tube using a lock nut ...

Page 104: ...en filling to the standard maximum or minimum oil capacity 11 Check that the O ring 12 on the air cylinder unit 7 is in good condition Apply the recommended fork oil to the O ring Temporarily install the air cylinder unit to the outer tube 6 After installing the fork leg page 107 tighten the air cylinder unit to the specified torque using a lock nut wrench Actual 56 lbf ft 76 N m 7 7 kgf m Torque ...

Page 105: ... Chamber Air Pressure When applying air pressure to the balance chamber the fork will be shortened 15 Install and tighten the balance chamber valve cap to the specified torque 0 4 lbf ft 0 5 N m 0 1 kgf m 16 Clean the threads of the fork protector socket bolts 1 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protector 2 and fork protector socket bolts Tighten t...

Page 106: ...nter When releasing air pressure from the balance chamber the fork will be extended Spraying a small amount of fork oil from the balance chamber air valve is normal when releasing air pressure from the balance chamber This will not affect the fork performance 7 Press the fork cap 6 and remove the stopper ring 7 8 Place a shop towel 8 over the fork cap 9 Slide the outer tube down slowly several tim...

Page 107: ... air valve 4 and check that there is no air leakage Install the valve cap Air fork pump 07AMJ KRNA100 USA only Air fork pump adapter 07AMJ KRNA110 USA only Outer Chamber Air Pressure When applying air pressure to the outer chamber the fork will be extended 20 Apply air pressure to the balance chamber through the balance chamber air valve 5 and check that there is no air leakage Air fork pump 07AMJ...

Page 108: ...ter When releasing air pressure from the inner chamber the fork will be shortened 5 Release the air pressure from the outer chamber by pressing the outer chamber air valve 4 center When releasing air pressure from the outer chamber the fork will be shortened 6 Place a shop towel over the balance chamber air valve 5 Release the air pressure from the balance chamber by pressing the valve center When...

Page 109: ...t there is no air leakage Air fork pump 07AMJ KRNA100 USA only Air fork pump adapter 07AMJ KRNA110 USA only Balance Chamber Air Pressure When applying air pressure to the balance chamber the fork will be shortened 13 Install and tighten the balance chamber valve cap to the specified torque 0 4 lbf ft 0 5 N m 0 1 kgf m 14 Clean the threads of the fork protector socket bolts 1 and axle holder thorou...

Page 110: ...er unit and or fork damper 3 Tighten fork cap assembly 5 to the specified torque 22 lbf ft 30 N m 3 1 kgf m 4 For ease of releasing air pressure after the right fork is installed loosen the fork bridge lower pinch bolts and position the outer tube so that the fork air pressure release screw is in front of the compression damping adjuster Align the groove 6 in the outer tube with the top surface of...

Page 111: ...r and tighten the front brake caliper mounting bolts to the specified torque 22 lbf ft 30 N m 3 1 kgf m 10 Aligntheuppersurfaceofthebrakehoseprotector 12 stay A 13 and stay B 14 and assemble them Install and tighten them to the left fork protector using the brake hose clamp bolts 15 11 Clean the surfaces where the axle and axle clamps contact each other Apply grease to each dust seal lips of the f...

Page 112: ...ten the handlebar holder nuts to the specified torque 32 lbf ft 44 N m 4 5 kgf m 15 Install the number plate page 126 16 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 17 While keeping the forks parallel alternately tighten the right axle pinch bolts 22 to the specified torque 15 lbf ft 20 N m 2 0 kgf m NOTICE To avoid damage w...

Page 113: ...ket bolts 24 to the specified torque 10 lbf ft 13 N m 1 3 kgf m 19 Turn the rebound damping 25 and compression damping 26 adjusters back to their original settings 23 disc cover 24 disc cover socket bolts 25 rebound damping adjuster 26 compression damping adjuster 24 23 Left fork Right fork 26 25 ...

Page 114: ...d from the system 1 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 counterclockwise 3 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m 4 Apply silicone grease to the contacting areas of the adjuster Th...

Page 115: ... Make 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 above the LOWER mark 1 If the level is at or below the LOWER mark check the brake pads for wear page 114 Worn brake pads should be replaced If the pads are not worn have your brake system inspected...

Page 116: ... m 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 the reservoir is horizontal first Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended br...

Page 117: ...s 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 lever and rear brake pedal assemblies are positioned properly page 111 and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings B...

Page 118: ...It 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 7 lbf ft 3 7 N m 0 4 kgf m Rim Locks 9 lbf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see an official Honda Service Manual for inspection instructions See an official Honda...

Page 119: ...t 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 condition make changes a little at a time Take time to inspect your tires and wheels before you ride Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a b...

Page 120: ...speed 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 Installing improper 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...

Page 121: ...k 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 NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear Replace the drive cha...

Page 122: ...gn the index 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 adjust as necessary 5 Turn the adjusting bolt counterclockwise until it touches the axle plates lightly Then tighten the chain adjuster lock nuts to the specified torque while holding the a...

Page 123: ... 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 measured shift the transmission into neutral again before proceeding with inspection and service 8 Lubricate the drive chain page 119 9 Pass the chain over the sprockets and join the ends of the chain with...

Page 124: ... 1 Remove the seat page 34 2 Remove the side covers 1 and air cleaner housing covers 2 by removing the bolts 3 The procedure is the same for the both right and left side 3 Loosen the left muffler clamp bolt 4 4 Remove the left muffler mounting bolt 5 washer 6 and left muffler 7 Exhaust Pipe Muffler Inspection Muffler Removal 1 side covers 3 bolts 2 air cleaner housing covers 4 left muffler clamp b...

Page 125: ...t muffler 5 Install the washer B 7 right muffler mounting B bolt 8 washer A 9 with the tab side facing outside and right muffler mounting A bolt 10 6 Tighten the right muffler clamp bolt 11 to the specified torque 15 lbf ft 20 N m 2 0 kgf m 8 right muffler clamp bolt 9 right muffler mounting A bolt 10 washer A 11 right muffler mounting B bolt 12 washer B 13 right muffler 8 11 12 13 10 9 Muffler In...

Page 126: ...t to the specified torque 19 lbf ft 26 N m 2 7 kgf m 12 Tighten the left muffler clamp bolt 16 to the specified torque 15 lbf ft 20 N m 2 0 kgf m 13 Install the air cleaner housing covers 17 and side covers 18 and then tighten the bolts 19 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 14 Install the seat page 34 8 right muffler mounting B bolt 10 right muffler mounting A bolt 4 right muffler 1...

Page 127: ...ighten the nuts yet 3 Install the right muffler page 122 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 right muffler clamp bolt right muffler mounting A bolt and B bolt page 122 6 Install the left muffler page 123 Exhaust Pipe Removal 1 exhaust pipe joint nuts 2 exhaust pipe 3 gasket 2 1 3 Exhaust Pipe Instal...

Page 128: ...ing before 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 cause you to pass over the best adjustment Test ride after each adjustment If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Unlock the ...

Page 129: ...er plate page 125 2 Remove the steering damper mounting bolts 1 collar 2 connector stay 3 and steering damper 4 1 Check the damper rod 1 operation The damper rod is fully extended and compressed by hand Release the damper rod then check that it extends to its maximum length If the damper rod does not extend to its maximum length refer to an official Honda Service Manual for disassembly and inspect...

Page 130: ...g toward the front side 3 Install the connector stay 4 collar 5 and steering damper mounting bolts 6 Be sure to install the collar with its wide flange side facing toward the steering head pipe side Align the connector stay tab 7 with the steering head pipe lug 8 4 Tighten the steering damper mounting bolts to the specified torque 15 lbf ft 20 N m 2 0 kgf m 5 With your CRF on a box or an optional ...

Page 131: ...r 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 is aligned with the paint mark 3 3 Check the torque of the handlebar upper holder bolts 4 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first Periodically disconnect the throttle and clutch cab...

Page 132: ...t 7 10 1 0 8 Engine oil drain bolt 12 16 1 6 9 Cylinder bolt 7 10 1 0 10 Oil filter cover bolts 9 12 1 2 11 Cylinder head A bolts 7 10 1 0 12 Drive sprocket bolt 23 31 3 2 13 Transmission oil drain bolt 12 16 1 6 14 Cylinder head B bolts 33 45 4 6 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts ...

Page 133: ... 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 Pro Honda Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Allow the engine muffler brakes and other high temperature parts to cool before washing 1 Rinse your...

Page 134: ...o 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 detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame NOTICE Do not use steel wool to clean the frame as it could damage ...

Page 135: ...or softer rear spring The need for either optional rear spring may need to be balanced by adjusting the left fork air pressure and oil capacity Engine Mode Select Button 134 Current Mode 134 Mode Selection 134 Front Suspension Adjustments 135 Right Front Suspension Air Pressure 135 Front Suspension Damping Right Fork 136 Fork Springs Left Fork 136 Rear Suspension Adjustments 140 Rear Suspension Sp...

Page 136: ...de select button indicate a selected mode by the number of times the indicator blinks 1 Start the engine 2 With your CRF stopped and the throttle closed push and hold the engine mode select button for 1 or more second Make sure that the fast idle knob is pushed in page 17 If the fast idle knob is pulled out the engine mode will not change 3 Release the engine mode select button The mode indicator ...

Page 137: ...cles from the sealed cartridge to provide more consistent damping Do not dispose of the fork see your dealer Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race For this reason release built up air pressure in the ...

Page 138: ...n and rebound damping can be increased by turning the adjuster clockwise NOTICE Always start with position 1 when adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the compression and rebound adjusters are firmly located in a detent and not between positions The CRF uses a pneumatic spring in the fork The fork spring rate can...

Page 139: ...mp 07AMJ KRNA100 USA only Air fork pump adapter 07AMJ KRNA110 USA only When releasing air pressure from the inner chamber the fork will be shortened When applying air pressure to the inner chamber the fork will be extended Do not adjust the inner chamber air pressure to a level that is outside the minimum or maximum level Inner chamber air pressure 156 psi 1 075 kPa 11 0 kgf cm2 Outer chamber air ...

Page 140: ...n releasing air pressure from the outer chamber the fork will be shortened When applying air pressure to the outer chamber the fork will be extended Do not adjust the outer chamber air pressure to a level that is outside the minimum or maximum level The correct cold outer chamber air pressures are Standard 12 psi 80 kPa 0 8 kgf cm2 The higher or lower outer chamber air pressure affects the entire ...

Page 141: ...nce chamber air pressure Air fork pump 07AMJ KRNA100 USA only Air fork pump adapter 07AMJ KRNA110 USA only When applying air pressure to the balance chamber the fork will be shortened Do not adjust the balance chamber air pressure to a level that is outside the minimum or maximum level The correct cold balance chamber air pressures are Standard 156 psi 1 075 kPa 11 0 kgf cm2 Increasing the balance...

Page 142: ... 1 and turning the adjusting nut 2 Each complete turn of the adjusting nut changes the spring length by 0 06 in 1 5 mm 5 After adjustment hold the adjusting nut and tighten the shock spring lock nut to the specified torque 32 lbf ft 44 N m 4 5 kgf m Refer to the following pages for the installation procedure of the removed parts air cleaner case and air cleaner connecting tube page 85 Cylinder Hea...

Page 143: ...r The low speed compression adjuster has 13 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4 positions To adjust to the standard position 1 Turn the adjuster clockwise harder until it will no longer turn lightly seat Turn the adjuster counterclockwise softer until it clicks This click is position 1 2 Set the adjuster position 10 10th click and adjust it until ...

Page 144: ...h 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 upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to measure the...

Page 145: ...ed 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 bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevent...

Page 146: ...ight line stability In a muddy event stiffer front suspension setting and stiffer aftermarket rear shock spring 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 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 probab...

Page 147: ...build up increases your CRF s weight If the suspension is too stiff soft on part of travel adjust according to the Adjustments for Too Soft Stiff On Part Of Travel chart on next page Recommended Setting Inner chamber air pressure Outer chamber air pressure Balance chamber air pressure Compression damping adjuster Rebound damping adjuster Soft 149 psi 1 025 kPa 10 5 kgf cm2 10 psi 70 kPa 0 7 kgf cm...

Page 148: ...g in one click increments Stiff suspension Initial travel too stiff Stiff on small bumps while riding at full throttle in a straight line Stiff on small cornering bumps Front end wanders while riding at full throttle in a straight line Increase the left fork balance chamber air pressure in increments of 3 6 psi 25 kPa 0 3 kgf cm2 within maximum pressure If initial travel is still stiff after incre...

Page 149: ...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 further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 ...

Page 150: ...elain 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 porcelain insulator and center electrode indicate lean air fuel mixture Wet or black sooty streaks on the porcelain indicate rich air fuel mixture NOTICE An improperly tightened spark plug can damage the en...

Page 151: ... the adjuster to the standard setting proceed as follows Turn the adjuster clockwise harder until it will no longer turn lightly seats Turn the adjuster counterclockwise softer until it clicks This click is position 1 The standard position is position 9 12 9 12th click Damping can be increased by turning the adjuster clockwise NOTICE Always start with position 1 when adjusting damping Do not turn ...

Page 152: ... 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 Action Steering is wobbling on large bumps Adjust the steering damper adjuster to a stiffer setting Steering is wobbling on a sand track Adjust the steering damper adjuster to a stiffer setting Steering is heavy when corner...

Page 153: ... 0 115 0 mm range The position of the fork in the clamp is not adjustable Align the groove in the outer tube with the top surface with the top of the upper fork bridge Standard Position The groove 1 in the outer tube is aligned with the top surface of the upper fork bridge 2 Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing l...

Page 154: ...om 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 clutch to compensate downshifting may be too drastic...

Page 155: ...n 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 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 pla...

Page 156: ...CRF Position the handlebar so that both gripping the bar and operating the controls are comfortable while both seated and standing while riding straight ahead and turning Tighten the forward handlebar upper holder bolts first The handlebar position may be moved rearward either 0 1 in 3 mm using optional handlebar lower holders or 0 2 in 6 mm by rotating the standard holders 180 degrees Refer to an...

Page 157: ...ce on how to transport and store your CRF as well as three troubleshooting flow charts Transporting Your Motorcycle 156 Storing Your Honda 157 Preparation for Storage 157 Removal from Storage 157 You the Environment 158 Troubleshooting 159 ...

Page 158: ...wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on truck bed or trailer rail 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 compr...

Page 159: ... 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 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 11 Cover your CRF with a porous material Avoid using plastic or similar non breathing co...

Page 160: ...w 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 coolant 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 container...

Page 161: ...e chain too tight 2 Check the tire pressure P 116 Faulty valve core Punctured tire 3 Check the engine speed change accordingly when clutch is engaged Clutch slipping Improperly adjusted clutch lever freeplay P 62 Worn clutch discs plates P 65 Warped clutch discs plates P 65 Weak clutch springs Sticking clutch lifter Additive in transmission oil 4 Check the engine speed increase Dirty air cleaner e...

Page 162: ...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 INCORRECT CORRECT INCORRECT CORRECT INCORRECT WEAK OR INTERMITTENT SPARK POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Check the ignition timing Faulty ECM Faulty CKP sensor 2 Remove the air cle...

Page 163: ... data Vehicle Identification 162 Serial Numbers 162 Specifications 163 Torque Specifications 164 Nuts Bolts Fasteners 164 Oxygenated Fuels 167 Competition Logbook 168 Optional Parts List 170 Spare Parts Equipment 171 Spare Parts 171 General Tools 171 Honda Special Tools 171 Chemical Products 171 Other Products 171 Wiring Diagram 172 ...

Page 164: ...your CRF They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head The engine number 2 is stamped on the left crankcase Serial Numbers 1 VIN 1 2 engine number 2 ...

Page 165: ...rpressure standard inner chamber 156 psi 1 075 kPa 11 0 kgf cm2 outer chamber 12 psi 80 kPa 0 8 kgf cm2 balance chamber 156 psi 1 075 kPa 11 0 kgf cm2 Item English Metric Engine Type Liquid cooled 4 stroke Cylinder arrangement Single 5 inclined from vertical Bore and stroke 3 02 x 2 12 in 76 8 x 53 8 mm Displacement 15 21 cu in 249 4 cm3 Compression ratio 13 8 1 Valve clearance cold Intake 0 005 0...

Page 166: ... nuts 15 21 2 1 3 Water pump cover bolts 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 NOTE 1 5 Transmission oil check bolt 9 12 1 2 6 Clutch cover bolts 7 10 1 0 7 Coolant drain bolt 7 10 1 0 8 Engine oil drain bolt 12 16 1 6 NOTE 2 9 Cylinder bolt 7 10 1 0 10 Oil filter cover bolts 9 12 1 2 11 Cylinder head A bolts 7 10 1 0 12 Drive sprocket bolt 23 31 3 2 13 Transmission oil drain bolt 12 16 1 6 NOT...

Page 167: ...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 upper 32 44 4 5 NOTE 1 lower 32 44 4 5 NOTE 1 15 Swingarm pivot nut 65 88 9 0 NOTE 1 16 Left fork air cylinder unit 56 76 7 7 balance chamber valve cap 0 4 0 5 0 1 17 Right fork fork cap assembly 22 30 3 1 fork damper 56 76 7 7 18 Rear s...

Page 168: ...69 7 0 NOTE 3 34 Fork center bolt lock nut 21 28 2 9 35 Disc cover socket bolts 10 13 1 3 36 Fork protector socket bolts 5 2 7 0 7 NOTE 5 37 Left right muffler clamp bolt 15 20 2 0 38 Driven sprocket nuts 24 32 3 3 NOTE 1 39 Seat mounting bolts 19 26 2 7 40 Front brake reservoir cap screws 0 7 1 0 0 1 41 Rear brake reservoir cap bolts 0 7 1 0 0 1 42 Right fork air pressure release screw 1 0 1 3 0 ...

Page 169: ...10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol METHANOL methyl or wood alcohol up to 5 by Volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also da...

Page 170: ...gular interval 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 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 guesstimate is close enough for our timekeeping purposes You m...

Page 171: ... Technical Information 169 Date Running Time Location Event Comments Suspension Settings Steering Damper Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use ...

Page 172: ...Drive chain links 49 Teeth Aluminum 116 Standard Optional 48 Teeth Aluminum 50 Teeth Aluminum Drive chain size link D I D 520 DMA4 120RB RK520TXZ 120RJ Handlebar lower holder Standard 0 1 in 3 mm offset Optional no offset TOOLS Remarks Pin spanner A To adjust spring preload two spanners required Workstand For maintenance Air gauge For checking tire air pressure FRAME Remarks Shock spring 297 lbf i...

Page 173: ...e pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment Any special tools for your CRF purchased from your dealer Tensioner Stopper 070MG 0010100 07AMG 001A100 USA only Lock Nut Wrench 07WMA KZ30100 Air fork pump 07AMJ KRNA100 USA only Air fork pump adapter 07AMJ KRNA110 USA only Spoke Wrench 07JMA MR60100 Spoke Wrench 070MA KZ30100 Battery Harness 070MZ MEN010...

Page 174: ...PUSH Bu Blue Lb Light blue FREE FREE G Green Lg Light green COLOR Bl W R Y COLOR Lg R R Red P Pink W White Gr Gray FUEL PUMP ENGINE STOP BUTTON REGULATOR RECTIFIER CONDENSER NO 1 CKP SENSOR FRAME GROUND IGNITION COIL SPARK PLUG ALTERNATOR NO 2 CKP SENSOR ECT SENSOR IAT SENSOR TP SENSOR MAP SENSOR ECM INJECTOR MIL ENGINE MODE SELECT BUTTON LED DARK BLUE ...

Page 175: ...ation 173 Consumer Information This section contains information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 174 Contacting Honda 175 Your Honda Dealer 176 The Honda Rider s Club USA only 177 ...

Page 176: ...ide in conjunction with the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Order On Line www helminc com Order...

Page 177: ...s 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 Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 Mailstop 100 4C 7B Telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsi...

Page 178: ... 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 quality in the accessories and products available from the parts department Your Honda dealer can inform you about competition events in your area You ll also find that your dealer is a source of in...

Page 179: ...tion 177 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 website for more information at www hrca honda com ...

Page 180: ...nce 130 chain drive 118 chassis adjustments 151 cleaner air 56 cleaning appearance care 130 clutch system adjustment 62 competition logbook 168 consumer information 173 contacting Honda 175 controls 5 coolant 54 customer service 173 cylinder system 79 damping adjustments front 135 136 rear 141 steering damper 149 dealer your Honda 176 diagram wiring 172 drive chain 118 R engine flooded 17 idle spe...

Page 181: ...rating instructions 15 operation component locations 6 optional parts list 170 sprockets 152 outer chamber air pressure 138 oxygenated fuels 167 pads brake 114 parts optional 170 personal fit adjustments 154 pinging engine 40 plug spark 67 pre load rear suspension 140 pre ride inspection 13 protective apparel 2 rear suspension adjustment 147 Rider s Club Honda USA only 177 riding apparel 2 basic o...

Page 182: ... rear 88 throttle freeplay 59 inspection 60 tires air pressure 116 flat 116 selection 117 tools 171 torque specifications engine 164 frame 165 166 transmission oil 52 transporting 156 troubleshooting 159 tubes replacing 116 tuning tips 148 valve clearance 68 vehicle identification no VIN 162 washing your motorcycle 130 wheels 115 wiring diagram 172 T V W ...

Page 183: ...ists service frequencies 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 Inspection Check the items listed on the Pre ride Inspection checklist each time before you ride page 13 Fuel Tank Capacity unleaded gasoline pump octane number of 91 or higher tank 1 66 US gal...

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Honda CRF250R, Owner'S Manual

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