Honda CRF250X 2007 Owner'S Manual & Competition Handbook Download | Manualshive

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2007
Honda CRF250X
OWNER’S MANUAL & COMPETITION HANDBOOK

FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
If conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway
Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal. The vehicle is equipped with a USDA qualified spark
arrester. Obey local laws and regulations.
It conforms to US EPA and California exhaust emission regulations for off-road motorcycles.

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Summary of Contents for CRF250X 2007

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Page 2: ...tions but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester Obey local laws and regulations It conforms to US EPA and California exhaust emission regulations for off road motorcycles Contents qxd 06 7 4 14 08 ページ1 ...

Page 3: ...CRF beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference Read the Warranties Booklet page 169 throughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities This motorcycle has no cooling fan For this reason engine overheating and coolant loss will occur if the engine is kept idling ...

Page 4: ...rtant safety information in a variety of forms including Safety Labels on the motorcycle Safety Messages 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 instru...

Page 5: ...er 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 74 Chassis Suspension 82 Brakes 86 Wheels 90 Tires Tubes 91 Side Stand 93 Drive Chain 94 Additional Maintenance Procedures 97 Electrical Battery 99 Headlight Taillight 101 Appearance Care 102 ADJUSTMENTS FOR COMPETITION 105 Front Suspension Adjustments 106 Rear Suspension Adjustments 120 Suspension Adjustments for Track Cond...

Page 6: ...e 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 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 001 030 qxd 06 7 4 14 11 ページ1 ...

Page 7: ...Safe Condition It s important to keep your CRF properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your CRF before every ride and perform all recommended maintenance 2 Motorcycle Safety Do not wear loose clothing which could catch on the control levers kickstarter footpegs dri...

Page 8: ...mportant to your safety If you decide to carry cargo you should be aware of the following information Loading Guidelines As discussed on page 2 we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects ...

Page 9: ...ent or modify your CRF in any way that would change its design or operation Such changes could seriously impair your CRF s handling stability and braking making it unsafe to ride We also advice you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your area 4 Motorcycle Saf...

Page 10: ...CRF Some labels warn you of potential hazards that could cause serious injury Othere provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement 001 030 qxd 06 7 4 14 11 ページ5 ...

Page 11: ...6 Motorcycle Safety 001 030 qxd 06 7 4 14 11 ページ6 ...

Page 12: ...perating Controls 7 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 8 001 030 qxd 06 7 4 14 11 ページ7 ...

Page 13: ...peration Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip tripmeter start button choke knob fuel valve shift lever kickstarter rear brake pedal 001 030 qxd 06 7 4 14 11 ページ8 ...

Page 14: ...his 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 105 Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 001 030 qxd 06 7 4 14 11 ページ9 ...

Page 15: ...e page 105 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 helmet increases t...

Page 16: ...tle operation 55 Engine idle speed for stable and proper RPM 134 Tires for damage or improper inflation pressure 91 Spokes for looseness 90 Rim locks for looseness 90 Front and rear suspension for proper operation 82 83 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication 94 Drive chain guide sliders and guide rollers for damage or wear 96 Exhaust pipe M...

Page 17: ...12 Before Riding 001 030 qxd 06 7 4 14 11 ページ12 ...

Page 18: ...nd stop your engine as well as break in guidelines Safe Riding Precautions 14 Side Stand 14 Tripmeter 14 Starting Stopping the Engine 15 Preparation 15 Fuel Valve 15 Starting Procedure 15 Flooded Engine 16 How to Stop the Engine 16 Shifting Gears 17 Braking 18 Parking 19 Post ride Inspection 20 Break in Guidelines 21 001 030 qxd 06 7 4 14 11 ページ13 ...

Page 19: ...e review 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 1 side stand 1 tripmeter 2 tripmeter reset knob 1 2 1 OFF ON Side Sta...

Page 20: ...he hot start lever 3 all the way in and start the engine following step 4 under Normal Air Temperature 2 As soon as the engine starts release the hot start lever NOTICE NOTICE Basic Operating Instructions 15 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON Turning the fuel valve ON before attempting to start the engine allows fuel to...

Page 21: ...lease the hot start lever Using the kickstarter 1 Do not use the choke 2 Shift the transmission into neutral with the throttle fully opened repeat kickstarter operation approximately ten times very slowly to discharge excessive fuel from the engine Close the throttle 3 Pull the hot start lever all the way in and start the engine Do not open the throttle 4 As soon as the engine starts release the h...

Page 22: ...ding after the engine has been warmed and the side stand raised 1 Close the throttle and pull the front brake lever in 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the front brake Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engine will sta...

Page 23: ...y reduce your speed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your CRF When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Ra...

Page 24: ...ing Lower the side stand to support your CRF If you re through riding for the day turn the fuel valve OFF Always choose a level surface to park Basic Operating Instructions 19 001 030 qxd 06 7 4 14 11 ページ19 ...

Page 25: ...F and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your CRF for leaks or damage Be sure to lubricate the drive chain page 96 to prevent rusting 20 Basic Operating Instructions 001 030 qxd 06 7 4 14 11 ページ20 ...

Page 26: ...ntion to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced 001 030 qxd 06 7 4 14 11 ページ21 ...

Page 27: ...22 Basic Operating Instructions 001 030 qxd 06 7 4 14 11 ページ22 ...

Page 28: ...otorcycle repair establishment or individual using parts that are certified to EPA standards An optional tool kit may be available Check with your Honda dealer s parts department Before You Service Your Honda The Importance of Maintenance 24 Maintenance Safety 25 Important Safety Precautions 25 Maintenance Schedule 26 General Competition Maintenance 29 Before After Competition Maintenance 33 Betwe...

Page 29: ...den over rough off road terrain To help you properly care for your CRF this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your CRF to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to help you avoid a ...

Page 30: ...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 a side stand or an optional workstand to provide support To reduce the possibility of ...

Page 31: ...oking required service we urge you to develop a convenient way to record the number of days and or distance traveled USA miles Canada kilometers 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 parts or ...

Page 32: ...PRESSOR SYSTEM ENGINE IDLE SPEED RADIATOR COOLANT COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM TRANSMISSION OIL DRIVE CHAIN DRIVE CHAIN SLIDER BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION SPARK ARRESTER NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS FREQUENCY ITEMS NOTE mi km Month 100 150 1 600 1 000 6 1 200 2 000 12 I L every 300 mi 500 km or...

Page 33: ...ROCKET BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS NOTE 1 NOTE 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 55 60 51 53 61 48 66 44 44 134 76 76 47 49 94 96 96 96 95 95 87 89 86 56 97 62 82 83 32 84 111 98 154 156 90 91 97 I I C I I I I I I I I L ...

Page 34: ...ivalent 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 reassembly check a...

Page 35: ...ver 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 Pro Honda W...

Page 36: ...er to Fuel System in your Owner s Manual page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the fuel tank remove and clean the fuel valve and fuel filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 42 Loosen the carburetor drain screw and examine the fuel that flows out of th...

Page 37: ...er Leakage Check Hole After every race check the leakage check hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged water seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced Fork Oil Performanc...

Page 38: ...the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi 0 kPa 0 kgf cm2 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 2 pressure release screw 1 2 After Competition Maintenance It is ...

Page 39: ...able 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 to all metal parts If you decide to ...

Page 40: ...tery rear suspension high speed damping adjuster rear suspension low speed damping adjuster rear brake caliper main fuse rear brake fluid reservoir rear brake pedal transmission oil check bolt transmission oil filler cap front suspension rebound damping adjuster rear suspension rebound damping adjuster front suspension compression damping adjuster clutch lever hot start lever front brake lever fue...

Page 41: ...t Installation 1 Install the seat while aligning the seat front prong 3 with the seat bracket 4 and seat rear prong 5 with the tab 6 of the frame 2 Install and tighten the seat mounting bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 2 1 3 5 6 4 36 Servicing Your Honda 3 seat front prong 4 seat bracket 5 seat rear prong 6 tab 031 060 qxd 06 7 4 14 13 ページ36 ...

Page 42: ...reather tube 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt 9 Disconnect the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 8 fuel line 10 fuel valve bolt 9 fuel valve WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine an...

Page 43: ...over rubber 5 6 Install the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 8 Install the shrouds 8 and shroud B bolts collars 9 Tighten the shroud B bolts to the specified torque 3 7 lbf ft 5 N m 0 5 kgf m 9 Install the shroud A bolts collars 10 8 shroud 9 shroud B bolts collars 10 shroud A bolts collars 4 fuel tank bolt 6 fuel tank band 5 air cleaner cover rubber 7 breather t...

Page 44: ...Honda 39 7 Loosen the subframe mounting upper bolt 17 and remove the subframe mounting lower bolts 18 17 subframe mounting upper bolt 18 subframe mounting lower bolts 8 Lift the subframe 19 as shown Tighten the subframe mounting upper bolt to the specified torque 22 lbf ft 30 N m 3 1 kgf m 1 right side cover bolt 3 collar 2 seat mounting bolt 4 right side cover 2 Open the air cleaner housing cover...

Page 45: ...bolts Installation 1 Loosen the subframe mounting upper bolt 1 2 Loosely attach the lower ends of the subframe 2 to the mainframe while connecting the air cleaner connecting tube to the carburetor Then align the subframe with the rear wheel and tighten the subframe mounting lower bolts 3 and subframe mounting upper bolt to the specified torque upper bolts 22 lbf ft 30 N m 3 1 kgf m lower bolt 36 l...

Page 46: ...ted gasoline Avoid getting dirt dust or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure Fuel Tank Capacity 2 19 US gal 8 3R 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 until the level reaches the bott...

Page 47: ...oint 1 from fuel tank by removing the bolts 2 3 fuel filter 4 O ring 4 3 42 Servicing Your Honda 1 fuel joint 2 bolts 1 2 4 Wash the fuel filter 3 in high flash point cleaning solvent 5 Check that the O ring 4 is in good condition and install it onto the fuel joint Install the fuel filter in the fuel tank by tightening the bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Refill the fuel tan...

Page 48: ... Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label suggested oil Pro Honda GN4 4 stroke oil or an equivalent viscosity weight SAE 10W 30 JASO T 903 standard MA Your CRF does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label ...

Page 49: ...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 position on a level surface...

Page 50: ...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 16 Install the left engine guard and bolt then tighten them 17 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 18 Install the engine oil filler cap dipstick 19 Check the engine oil level by following the steps i...

Page 51: ...nergy conserving service label on the container They may affect lubrication and clutch performance API classification 4 stroke engine oil only Viscosity weight JASO T903 standard others suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label SG or higher except oils labeled as energy conserving on the...

Page 52: ...start to flow out of the oil check bolt hole Tighten the oil check bolt with a new sealing washer 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 9 lbf ft 12 N m 1 2 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine at idle for 3 minute...

Page 53: ...freeze to less than 40 will not provide proper corrosion protection NOTICE 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 ...

Page 54: ...ee the Honda Service Manual for troubleshooting of leaks 2 Check the water hoses 1 for cracks deterioration and radiator hose clamp for looseness 3 Check the radiator mount for looseness 4 Make sure the siphon hose 2 is connected and not clogged 5 Check the radiator fins for clogging 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If ...

Page 55: ...olant change 2 quick fastener 6 seat mounting bolt 3 air cleaner housing cover 7 left side cover 4 left side cover bolt 8 reserve tank cap 5 collar 9 UPPER level line 6 Bleed air front the system as follows Shift the transmission into neutral Start the engine and let it idle 2 3 minutes Snap the throttle three four times to bleed air from the system Stop the engine and if necessary add coolant up ...

Page 56: ...ce can cause poor performance and premature engine wear NOTICE Cleaning 1 To open the air cleaner housing cover 1 turn the quick fastener 2 counterclockwise 3 Pull the air cleaner element 5 out from the air cleaner holder 6 1 air cleaner housing cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 and air cleaner assembly 4 as shown 5 air cleaner element 8 hole 6 air cleaner holder 9 a...

Page 57: ...stall the tab 7 of the holder in the hole 8 of the air cleaner tab 9 9 Install the air cleaner assembly into the air cleaner housing 3 air cleaner retaining bolt 10 access tab 11 mark 52 Servicing Your Honda 10 11 3 10 Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner element with the mark 11 of the air cleaner housing by rota...

Page 58: ...the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube 2 1 031 060 qxd 06 7 4 14 13 ページ53 ...

Page 59: ...e throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 38 If you can t get the freeplay within the specified range contact your Honda dealer 5 6 1 Pull the 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 will increase freeplay 4 Tighten ...

Page 60: ...ositions 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 corrosion 1 Servicing Your Honda 55 03...

Page 61: ...able end adjuster in direction until it seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the...

Page 62: ...lutch springs 9 clutch pressure plate 6 Remove the clutch lifter assembly 10 and clutch lifter rod 11 7 Remove the eight clutch discs seven clutch plates judder spring and spring seat 12 Turn the lifter bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing plate does not turn smoothly 10 clutch lifter...

Page 63: ... the clutch center as shown Coat the clutch discs 3 and plates 4 with clean engine oil 2 Install the clutch disc A larger I D disc 5 onto the clutch outer Stack the seven clutch plates and seven clutch discs alternately 1 spring seat 4 clutch plates 2 judder spring 5 clutch disc A 3 clutch discs 3 Insert the clutch lifter rod into the mainshaft 4 Install the clutch lifter assembly 6 onto the rod 6...

Page 64: ...ll the crankcase with transmission oil page 47 Servicing Your Honda 59 16 12 13 14 15 11 5 Install the clutch pressure plate 7 6 Install the five clutch springs and clutch spring bolts 8 7 Tighten the bolts in a crisscross pattern in two or three steps to the specified torque 9 lbf ft 12 N m 1 2 kgf m 7 clutch pressure plate 8 clutch spring bolts clutch springs 8 Install a new O ring 9 in the groo...

Page 65: ... 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 in direction will increase freeplay and turning it in direction will decrease freeplay After adjustment tighten the lock nut 3 lock nut increase 4 adjuster decrease 60 Servicing Your Honda 1 2 4 3 031 060 qxd 06 7 4 14 13 ページ60 ...

Page 66: ...e If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 03 0 04 in 0 8 0 9 mm 3 sealing gasket 4 spark plug gap 3 4 Servicing Your Honda 61 Standard IMR8C 9H NGK or VUH24D DENSO Optional IMR9C 9H NGK or VUH27D DENSO 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Push the engine stop button and disengage the clutch...

Page 67: ...ce 1 seat mounting bolt 3 collar 2 side cover bolt 4 right side cover 2 Loosen the muffler clamp bolt 5 3 Remove the muffler A bolt washer 6 muffler B bolt 7 and muffler 8 5 muffler clamp bolt 7 muffler B bolt 6 muffler A bolt washer 8 muffler 1 4 2 3 6 8 7 5 Muffler Removal 1 Remove the seat mounting bolt 1 side cover bolt 2 collar 3 and right side cover 4 62 Servicing Your Honda 061 083 qxd 06 7...

Page 68: ... A 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 6 muffler B bolt 8 muffler clamp bolt 7 muffler A bolt washer 9 right side cover 11 side cover bolt 10 collar 12 seat mounting bolt 7 Install the right side cover 9 collar 10 and side cover bolt 11 8 Install the seat mounting bolt 12 and tighten ...

Page 69: ...o 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 63 Exhaust Pipe Removal 1 Remove the muffler page 62 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 1 2 3 3 2 1 061 083 qxd 06 7 4 14 20 ページ64 ...

Page 70: ...onment 1 Allow the engine and muffler 1 to cool 2 Remove the bolts 2 spark arrester 3 and gasket 4 from the muffler 1 muffler 3 spark arrester 2 bolts 4 gasket 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of brakes and holes Replace if necessary Check the gasket Replace if necessary 4 A...

Page 71: ...er head cover 4 3 cylinder head cover bolts rubber seals 4 cylinder head cover 1 crankshaft hole cap 1 2 4 3 1 Refer to Safety Precautions on page 25 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 when the engine is cold at the intervals specified in the...

Page 72: ...lockwise until aligning the punch mark 3 on the primary drive gear with the mark 4 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 bolt clockwise again and align the punch mark with the mark The inspection must be made when the piston is at the top of the compression st...

Page 73: ...Tensioner stopper 070MG 0010100 3 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 1 2 3 3 68 Servicing Your Honda 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 061 083 qxd 06 7 4 14 20 ページ68 ...

Page 74: ...case Be careful not let the set rings of the camshaft holders fall into the crankcase 4 camshaft holder bolts 6 camshaft 5 camshaft holders 6 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 fall into the crankcase NOTICE 7 valve lifters 7 Remove the shims 8 4 4 6...

Page 75: ...m 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 a micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits result...

Page 76: ...1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to outer surface of the each valve lifters Install the valve lifters 3 3 Rotate the primary drive gear bolt 4 crankshaft clockwise and align the punch mark 5 with the mark 6 7 cam sprocket 9 cylinder head 8 timing marks 10 cam chain 11 camshaft holders 12 camshaft holder bolts 2 2 1 4 5 6 12 12 11 Servicing Your H...

Page 77: ...mm 13 feeler gauge 7 Remove the stopper tool 14 from the cam chain tensioner lifter 14 stopper tool 8 Install a new sealing washer 15 and tighten the cam chain tensioner lifter cover bolt 16 15 sealing washer 16 cam chain tensioner lifter cover bolt 13 13 14 15 16 Crankshaft Hole Cap Installation Coat a new O ring 1 with engine oil and install it onto the crankshaft hole cap 2 Apply grease to the ...

Page 78: ...r head cover packing 3 for damage or deterioration replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 3 cylinder head cover packing 4 cylinder head cover 4 cylinder head cover 7 cylinder head cover bolts 8 direct ignition coil 9 breather tube 6 Install the fuel tank and the seat pages 36 38 2 1 3 4 Servicing Your Honda 73 7 4 8 9 3 Check th...

Page 79: ...he air supply pipe bolt 3 PAIR control valve bolts nuts 4 and PAIR control valve 5 1 air suction hose 4 PAIR control valve bolts nuts 2 vacuum hose 5 PAIR control valve 3 air supply pipe bolt 10 Disconnect the direct ignition coil 5 11 Remove any dirt around the spark plug base 5 direct ignition coil 12 Remove the cylinder head cover page 66 13 Remove the spark plug 6 6 spark plug 14 Position the ...

Page 80: ...nd cylinder head 14 Loosen the nuts in a criss cross pattern in two or three steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase NOTICE 13 cylinder head nuts washers 14 cylinder head 20 Remove the dowel pins 15 cylinder head gasket 16 and cam chain guide 17 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 15 dowel pins 17 cam chain guid...

Page 81: ... crankcase to keep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the piston pin after 15 0 hours of running 4 Spread each piston ring 4 and remo...

Page 82: ...ails Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring 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 top ring mark side rail oil ring side rail spacer Servicing ...

Page 83: ...Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 6 NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 piston cut out Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt from entire the engine 2 Clean off any gasket ma...

Page 84: ... cam chain 5 piston rings 4 cylinder 7 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the 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 pins fall into the crankcase NOTICE 1 dowe...

Page 85: ...or three steps NOTICE NOTICE 4 Install the cylinder bolt 5 cylinder head bolts 6 and tighten them to the specified torque 7 lbf ft 10 N m 1 0 kgf m 3 cylinder head 4 cylinder head nuts washers 5 cylinder bolt 6 cylinder head bolts 7 engine hanger plate 8 engine hanger nuts bolts of the frame side 9 engine hanger nut bolt of the engine side 3 4 6 5 9 8 7 80 Servicing Your Honda 5 Install the engine...

Page 86: ...air supply pipe bolt 15 11 Tighten the PAIR control valve nuts and air supply pipe bolt to the specified torque 7 lbf ft 10 N m 1 0 kgf m 12 Connect the vacuum 16 and air suction 17 hoses 13 Install the exhaust pipe page 64 14 Install the carburetor page 133 15 Install the subframe and muffler pages 40 63 16 Install the fuel tank and the seat pages 36 38 17 Fill the cooling system with the recomme...

Page 87: ...uspension 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 125 Make all rebound and compression 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 become confu...

Page 88: ...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 121 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and rebound dampi...

Page 89: ...uide bushing 6 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 Drain the fork oil from the outer tube 1 Drain 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 will...

Page 90: ... scribe marks 6 Check taht the O ring 10 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring 1 outer tube 10 O ring 2 fork damper 7 Temporarily install the fork damper 2 to the outer tube 1 After installing the fork leg page 117 tighten the fork damper to the specified torque Actual 25 lbf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 lbf ft 31 N m 3 2 kgf m...

Page 91: ...ckwise 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 the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake s...

Page 92: ...e 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 89 Worn brake pads should be replaced If th...

Page 93: ...0 1 kgf m Adding Rear Brake Fluid Spilled brake fluid will severely damage instrument lenses and 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 re...

Page 94: ...caliper Rear Brake Pads Inspect the brake pads 4 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 brake pads 6 brake disc 5 rear brake caliper Other Inspections Check that the front brake lever and rear brake pedal assemblies are positioned properly and the securing bolts are tight Make sure there...

Page 95: ...perform the recommended service in the Maintenance Schedule pages 27 and 28 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rims 2 spokes 3 rim lock 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Spoke 2 7 lbf ft 3 68 N m 0 4 kgf m Rim Lock 9 lbf ft 12 N m 1 2 kgf m 3 Check w...

Page 96: ...s 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 particular riding condition make ch...

Page 97: ...place the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Front Rear Type 80 100 21 51M DUNLOP 100 100 18 59M DUNLOP bias ply tube D742F D756 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 tire...

Page 98: ...5 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with grease 1 084 103 qxd 06 7 4 14 59 ページ93 ...

Page 99: ...to neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm Excessive chain slack may allow the drive chain to damage the engine cases NOTICE Adjustment 1 Loosen the rear axle nut 1 2 Loosen the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decreace slack or cloc...

Page 100: ... rings or other wise appears unserviceable 3 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 0 53 in 13 4 mm the drive chain must be replaced Replacement Chain Size link DID520MXV 116 4 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sprockets with a badly...

Page 101: ...rive chain rollers Replace them if below the service limit Service Limit UPPER ROLLER 1 1 in 29 mm LOWER ROLLER 1 2 in 31 mm 2 Replace the roller if necessary as follows Install the upper drive chain roller Green 1 and lower drive chain roller Black 2 as shown Tighten the drive chain roller bolt and nut to the specified torque Upper roller bolt 9 lbf ft 12 N m 1 2 kgf m Lower roller nut 9 lbf ft 1...

Page 102: ...ark Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant If the clutch lever hot start lever and throttle operation is not smooth replace the cable Be sure the throttle returns freely from fully open to fully closed automatically in all steering positions 1 3 2 2...

Page 103: ...in bolt Transmission oil drain bolt Air supply pipe bolt ENGINE Torque lbf ft N m kgf m 7 15 7 11 9 7 7 9 7 23 12 12 7 10 21 10 15 12 10 10 12 10 31 16 16 10 1 0 2 1 1 0 1 5 1 2 1 0 1 0 1 2 1 0 3 2 1 6 1 6 1 0 2 exhaust pipe joint nuts 3 coolant drain bolt 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts 13 air supply pipe bolt 13 5 4 6 2 3 9 8 1 7 10 11 12 RIGHT SIDE LEFT ...

Page 104: ...ttery we recommend disconnecting the battery cables negative cable first NOTICE You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging on page 100 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label WARNING The battery gives off explosive hydrogen gas ...

Page 105: ...ckle charger 1 for home charging These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charge connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage 1 trickle charger 1 08...

Page 106: ...usting screw Taillight The taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service This model is equipped with an electric starter and battery for easy engine starting There is a possibility of damage to the lighting system if the battery is carelessly removed Never kick start the engine without the battery connected If it becomes necessary to ...

Page 107: ...ion 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 Pro Honda Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quic...

Page 108: ...rodes 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 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 Do not ...

Page 109: ...104 Servicing Your Honda 104 129 qxd 06 7 4 14 24 ページ104 ...

Page 110: ... your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 106 Rear Suspension Adjustments 120 Suspension Adjus...

Page 111: ...d air pressure in the fork legs by using 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 your CRF on an optional warkstand or equivalent support with the front wheel off the ground 2 Remove the pressure release screw 1 3 Check that the O ring 2 is in go...

Page 112: ...k Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a 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 co...

Page 113: ...rk protectors 19 Remove the brake caliper bolts 20 and brake caliper 21 The fork protector bolts and brake caliper bolts have a locking agent applied 5 7 6 8 9 14 15 12 14 13 6 handlebar holder nuts washers mounting rubbers 7 handlebar 5 Loosen the upper pinch bolts 8 6 Loosen the fork damper 9 using the lock nut wrench but do not remove it yet Do not use an adjustable wrench to loosen the fork da...

Page 114: ...ock nut wrench 28 Gently slide the outer tube down onto the lower end of the slider 29 30 24 31 26 25 24 23 28 26 29 26 27 26 32 16 fork protector bolts 19 fork protectors 17 tripmeter cable clamp bolts 20 brake caliper bolts 18 brake hose clamp bolts 21 brake caliper 11 Loosen the fork leg lower pinch bolts 22 then pull the fork legs down and out 17 19 16 20 20 21 18 22 Do not support the brake c...

Page 115: ... to the fork cap Be careful not to damage the lock nut and fork center bolt hole NOTICE 33 axle holder 37 push rod 36 lock nut 26 Remove the fork damper assembly 38 from the fork assembly 39 Remove the fork from the vise Remove the fork spring 40 from the fork 38 fork damper assembly 40 fork spring 39 fork assembly 33 35 36 34 33 37 36 38 40 39 17 Temporarily install the fork damper to the outer t...

Page 116: ...1 1 2 2 2 2 4 6 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 5 US oz 192 cc 6 8 Imp oz 3 Remove the fork cap assembly 1 from the fork damper 2 Be careful not to damage the fork cap bushing Do not disassemble the fork cap assembly Replace the fork cap as an assembly if it ...

Page 117: ...on and pump the fork damper piston rod 4 to 3 9 in 100 mm slowly several times 2 3 1 10 Tighten the fork cap assembly 1 while holding the cut out of the fork damper 2 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 2 fork damper 9 Apply fork oil to the bushing 5 and new O ring 6 on the fork cap assembly 1 Extend the fork damper piston rod to maximum holding it instal...

Page 118: ...9 US oz 175 cm3 of fork fluid to be left in the chamber 13 Blow the extra oil off to the fork damper spring chamber 8 by pumping the fork damper piston rod to full stroke 15 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 16 If you can not use compressed air remove the pressure release screw 10 on the fork cap 11...

Page 119: ...inutes at 20 C 1 outer tube slider 2 Tighten the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3 Using compressed air blow all oil off the fork spring 3 Install the fork spring Install the fork damper assembly 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 fo...

Page 120: ...ing rod 9 with the push rod Tighten the fork center 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 fork 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 fork center bolt 9 Tighten the loc...

Page 121: ... Optional Softer 0 40 kgf mm Fork Spring Standard oil capacity 11 9 US oz 353 cm3 Maximum oil capacity 13 7 US oz 404 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 4 US oz 308 cm3 No mark factory products 3 scribe marks 2 scribe marks aftermarket parts or Optional Stiffer 0 44 kgf mm Fork Spring Standard oil capacity 11 9 US ...

Page 122: ...ormed outer tubes must be replaced NOTICE 13 lower pinch bolts 17 upper pinch bolts 12 4 1 cont d 13 lower pinch bolts 13 4 14 16 15 1 4 fork damper assembly 14 lock nut wrench 18 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 Align 15 the to...

Page 123: ...liper 26 Install and tighten the axle nut 32 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m Tighten the left axle pinch bolts 33 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 32 axle nut 33 left axle pinch bolts 27 Install the handlebar 34 mounting rubbers washers and handlebar holder nuts 35 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 30 31 29...

Page 124: ... specified torque 15 Ibf ft 20 N m 2 0 kgf m To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 32 Install the tripmeter cable 41 and tighten the lock nut securely NOTICE 33 Install the disc cover 42 and tighten the bolts 43 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m 42 disc cover 43 bolts 34 Turn the rebound damp...

Page 125: ...ring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 62 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place your CRF on an optional workstand or equivalent support with the rear wheel off the ground 2 Loosen the connecting tube clamp screw and subframe mounting upper bolt a...

Page 126: ...uster 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 can be adj...

Page 127: ...he 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 center of the rear fender mounting bolt to the center of the chain adjuster ...

Page 128: ...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 4 to 1 0 in 10 to 25 mm If the rear of your CRF sags less than 0 4 in 10 mm from its own weight the spring is too stiff for your weight It is not compressed enough even though you have th...

Page 129: ...t springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress 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 compression and reboun...

Page 130: ...cially 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 of the above adjus...

Page 131: ...nsion 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 stiff Test softer ...

Page 132: ...el too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer 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 2 If it still fee...

Page 133: ...gine 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 mixture must be delivered to t...

Page 134: ...etered 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 the venturi past...

Page 135: ...olt 4 2 band 3 rear suspension upper mounting nut 4 rear suspension upper mounting bolt 6 Lift the subframe to the upright position page 39 7 Loosen the intake band screw 5 5 intake band screw 8 Disconnect the throttle position sensor connector 6 Remove the carburetor 6 throttle position sensor connector 9 Remove the hot start cable holder 7 7 hot start cable holder 2 3 4 5 6 7 WARNING Gasoline is...

Page 136: ...w 6 When installing the link arm set torx screw apply a locking agent to the link arm set torx screw threads 4 Remove the throttle valve 7 throttle valve roller 8 and floating valve 9 6 link arm set torx screw 8 throttle valve roller 7 throttle valve 9 floating valve 2 1 3 5 4 6 7 9 7 8 10 Remove the throttle drum cover bolt 8 and throttle drum cover 9 8 throttle drum cover bolt 9 throttle drum co...

Page 137: ...nto the accelerator pump cover 12 make sure the U ring s flatside faces down away from the float bowl 17 12 accelerator pump cover 15 spring 13 U ring 16 diaphragm 14 O ring 17 float bowl 7 Remove the holder screw 18 throttle stop screw holder 19 float bowl screws 20 tube guides 21 and float bowl 17 17 float bowl 18 holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 8 R...

Page 138: ...ws 1 5 lbf ft 2 1 N m 0 2 kgf m accelerator pump cover screws 1 5 lbf ft 2 1 N m 0 2 kgf m carburetor top cover bolts 1 5 lbf ft 2 1 N m 0 2 kgf m jet needle holder assembly 1 5 lbf ft 2 1 N m 0 2 kgf m leak jet 0 2 lbf ft 0 3 N m 0 03 kgf m rink arm set torx screw 1 5 lbf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 lbf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 lbf ft 2 1 N m 0 2 kgf m th...

Page 139: ... it up 3 minutes and then shut it off 2 Connect a tachometer to the engine 3 Shift into neutral Start the engine 4 Keep the motorcycle in an upright position 5 Adjust idle speed with the throttle stop screw 1 Idle speed 1 700 100 rpm 1 throttle stop screw 1 4 air vent hoses 5 overflow hose 4 4 5 4 130 139 qxd 06 7 4 14 28 ページ134 ...

Page 140: ... 90 110 mm range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the outer tube 1 with the top of the upper fork clamp 2 STANDARD POSITON Wheelbase Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure...

Page 141: ...nd 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 a change in speed...

Page 142: ...cceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound 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 on the transmis...

Page 143: ...sed 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 forward either 3 mm using optional handlebar lower holders or 6 mm by rotating the...

Page 144: ...ul advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 140 Storing Your Honda 141 You the Environment 143 Troubleshooting 144 130 139 qxd 06 7 4 14 28 ページ139 ...

Page 145: ...ach the lower ends of two straps to the tie down hooks on your CRF Attach to 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 could damage the...

Page 146: ...r to get your CRF running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the engine oil and filter page 44 3 Change the transmission oil page 47 4 Drain the fuel tank a...

Page 147: ...fuel tank with recommended fuel page 41 4 Charge the battery page 100 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capacity 1 27 US qt 1 20R at disassembly 1 19 US qt 1 13R at draining Remove the radiator reserve tank cap and fill the reserve tank to the upper level line Bleed air from the system 6 Per...

Page 148: ...ay see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning 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 other toxic wast...

Page 149: ...enough P 51 CLOGGED INCORRECT LOW WEAK OR INTERMITTENT SPARK NOT CLOGGED CORRECT CORRECT GOOD SPARK 3 Check carbureator jets for clogging 4 Check valve timing 5 Try spark test 6 Test cylinder compression Contaminants in the fuel Cam sprocket not installed properly Faulty carbon or wet fouled spark pulg P 61 Faulty ignition control module Faulty alternator Faulty direct ignition coil Broken or shor...

Page 150: ...ing Care of the Unexpected Taking Care of the Unexpected 145 This section gives practical advice to help you problems If a Fuse Blows 146 If Your Battery Is Low or Dead 147 140 180 qxd 06 7 4 14 29 ページ145 ...

Page 151: ...ight side cover 3 Disconnect the wire connector 5 of the starter magnetic switch 6 4 Pull main fuse 7 out If it is blown 8 install the spare main fuse 9 5 wire connector 6 starter magnetic switch 7 main fuse 8 blown fuse 9 spare main fuse 5 Reconnect the wire connector If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Replacing a fuse with...

Page 152: ... greater amperage of an automobile battery when the car engine is running can damage your CRF s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer Taking Care of the Unexpected 147 140 180 qxd 06 7 4 14 29 ページ147 ...

Page 153: ...148 Taking Care of Unexpected 140 180 qxd 06 7 4 14 29 ページ148 ...

Page 154: ... technical data Vehicle Identification 150 Specifications 151 Torque Specifications 154 High Altitude Carburetor Adjustment 157 Emission Control Systems 158 Oxygenated Fuels 160 Competition Logbook 161 Optional Parts List 163 Spare Parts Equipment 164 Wiring Diagram 165 140 180 qxd 06 7 4 14 29 ページ149 ...

Page 155: ...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 streering head RIGHT SIDE 1 VIN The engine number 2 is stamped on the left crankcase LEFT SIDE 2 engine number 1 2 140 180 qxd 06 7 4 14 29 ページ150 ...

Page 156: ... mm Exhaust 0 011 0 001 in 0 28 0 03 mm Engine oil capacity at draining at draining and oil filter change at disassembly at disassembly Transmission oil capacity at draining Type Identification number Main jet Jet needle Piston valve FCR02B 130 NLAT Slow jet Pilot screw opening Float level Idle speed Liquid cooled 4 stroke 42 2 1 4 turns out 1 700 100 rpm Type Metric 0 66 R 0 69 R 0 85 R 0 67 R 0 ...

Page 157: ...ng ICM Electric Kickstarter Battery 12V 4 Ah Light Head light 12V 35 W Fuse Main fuse 15 A Left foot operated return system 1 N 2 3 4 5 IMR8C 9H VUH24D IMR9C 9H VUH27D 15 2 cu in 0 70 US qt 0 73 US qt 0 90 US qt 0 71 US qt 0 79 US qt 249 cm3 at disassembly Cooling system capacity at draining 1 19 US qt 1 27 US qt Single disc brake 60 6 in2 391 1 cm2 Overall length Overall width Overall height Whee...

Page 158: ... 0 001 in 0 12 0 03 mm Exhaust 0 011 0 001 in 0 28 0 03 mm Engine oil capacity at draining at draining and oil filter change at disassembly at disassembly Transmission oil capacity at draining Type Identification number Main jet Jet needle Piston valve FCR02B 130 NLAT Slow jet Pilot screw opening Float level Idle speed Liquid cooled 4 stroke 42 2 1 4 turns out 1 700 100 rpm Type Metric 0 66 R 0 69...

Page 159: ...pe joint nuts Coolant drain bolt Crankshaft hole cap Clutch cover bolts Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket bolt Engine oil drain bolt Transmission oil drain bolt Air supply pipe bolt Torque Remarks lbf ft N m kgf m 7 15 7 11 9 7 7 9 7 23 12 12 7 10 21 10 15 12 10 10 12 10 31 16 16 10 1 0 2 1 1 0 1 5 1 2 1 0 1 0 1 2 1 0 3 2 1 6 1 6 1 0 NOTE 1 NOTE 2 NOTE 2 Trans...

Page 160: ...27 13 0 7 Front axle pinch bolts 15 20 2 0 6 Front axle nut 65 88 9 0 NOTE 2 NOTE 1 2 NOTE 1 2 NOTE 1 2 13 Shock absorber upper nuts lower 32 32 44 44 4 5 4 5 NOTE 2 NOTE 2 9 Chain adjuster lock nuts 20 27 2 8 NOTE 3 NOTE 2 5 Handlebar holder nuts 32 44 4 5 4 Handlebar upper holder bolts 16 22 2 2 3 Fork lower pinch bolts 15 20 2 0 2 Fork upper pinch bolts 16 22 2 2 1 Steering stem nut 80 108 11 0...

Page 161: ...rocket nuts Seat mounting bolts 15 24 19 21 32 26 2 1 3 3 2 7 NOTE 2 40 Side stand mounting bolts upper lower 41 42 43 44 Shroud B bolts Fuel joint bolts Brake lever adjuster lock nut Brake pedal adjuster lock nut 40 29 54 39 5 5 4 0 39 Fork air pressure release screw 0 9 1 2 0 1 3 7 7 4 4 4 4 5 10 5 9 5 9 0 5 1 0 0 6 0 6 38 Rear brake reservoir cap bolts 0 7 1 0 0 1 37 Front brake reservoir cap s...

Page 162: ...igh altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made When the carburetor has been modified for h...

Page 163: ...vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles reader pipes or any other component ...

Page 164: ...dle speed adjustment with the throttle stop screw The exhaust emission control system is separate from the crankcase emission control system Secondary Air Injection System The exhaust emission control system consists of a secondary air injection system The secondary air injection system introduces filtered air into the exhaust gases in the exhaust port The secondary air injection system helps impr...

Page 165: ...ertiary 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 performance problems It ...

Page 166: ...me on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many hours of running 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 may choose to record your time the same way aircraft operators do but without the benefit of an electric...

Page 167: ...ion Date Running Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Competition Logbook 140 180 qxd 06 7 4 14 29 ページ162 ...

Page 168: ... Teeth Aluminum 116 Optional no offset 52 Teeth Aluminum 116 Handlebar lower holder Drive chain size link Standard 3 mm offset DID 520MXV 120ZB TOOLS Remarks For checking tire air pressure Pin spanner A Workstand To adjust spring pre load two spanners required For maintenance Air gauge ENGINE Remarks Cooling system assembly Orange Red and Black 280 lbf in 5 00 kgf mm 291 2 lbf in 5 20 kgf mm White...

Page 169: ...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 purchased from your Honda dealer Clutch Center Holder 07724 00...

Page 170: ...Technical Information 165 Wiring Diagram 140 180 qxd 06 7 4 14 29 ページ165 ...

Page 171: ...166 Technical Information 140 180 qxd 06 7 4 14 29 ページ166 ...

Page 172: ...ains information about contacting Honda and how to get an official Honda service manual Authorized Manuals 168 Warranty Coverage 169 Warranty Service 170 Contacting Honda 171 Your Honda Dealer 172 The Honda Rider s Club USA only 173 140 180 qxd 06 7 4 14 29 ページ167 ...

Page 173: ... the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form USA only Canada See your Honda dealer to order authorized manuals 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...

Page 174: ...ize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the prope tools and service information and be mechanically qualified Failures that occur...

Page 175: ...results of the inspection If the problem is covered under warranty your dealer will perforn the warranty repairs for you If you have questions about waranty coverage or the nature of the repair it is best to talk to the service manager of your Honda dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling of ...

Page 176: ...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 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following information...

Page 177: ...ries 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 USA only the Honda...

Page 178: ...usive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for successful completion of a Motorcycle Safety Foundation training course Separate complimentary training from the Specialty Vehicle Institute of America for purchasers of new ATVs One full year of Honda Red Rider magazine six issues Discounts from HRCA...

Page 179: ...ntenance Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids Filters Fuel System 41 Engine Oil 43 Transmission Oil 46 Coolant 48 Air Cleaner 51 Crankcase Breather 53 Engine Throttle 54 Clutch System 56 Hot Start Lever 60 Spark Plug 61 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 74 Chassis...

Page 180: ...on Control Systems 158 Oxygenated Fuels 160 Competition Logbook 161 Optional Parts List 163 Spare Parts Equipment 164 Wiring Diagram 165 CONSUMER INFORMATION 167 Authorized Manuals 168 Warranty Coverage 169 Warranty Service 170 Contacting Honda 171 Your Honda Dealer 172 The Honda Rider s Club USA only 173 TABLE OF CONTENTS 174 INDEX 176 QUICK REFERENCE 140 180 qxd 06 7 4 14 29 ページ175 ...

Page 181: ...ed 134 removal 130 care appearance 102 chain drive 94 chassis adjustments 135 choke knob 15 cleaner air 51 cleaning appearance care 102 clutch system adjustment 56 consumer information 167 competition logbook 161 contacting Honda 171 controls operating 7 coolant 48 cylinder removal 76 damping adjustments front 106 rear 121 dealer your Honda 172 diagram wiring 165 drive chain 94 engine flooded 16 i...

Page 182: ...ts list 163 sprockets 163 oxygenated fuels 160 pads brake 89 parts optional 163 personal fit adjustments 138 pinging engine 41 plug spark 61 pre load rear suspension 120 pre ride inspection 11 protective apparel 2 rear suspension inspection 83 Rider s Club Honda 173 riding apparel 2 basic operation 13 before 9 important safety information 2 safety precautions 2 safety a few words about Safety Mess...

Page 183: ...spection 55 tires air pressure 91 inspection 91 replacement 92 tools 164 torque specifications 98 154 156 transporting 140 tripmeter 14 troubleshooting 144 tubes replacing 91 valve fuel 15 valve clearance 66 vehicle identification no VIN 150 warranty coverage 169 service 170 washing your motorcycle 102 weight limit 3 wheels 90 wiring diagram 165 W V T 140 180 qxd 06 7 4 14 29 ページ178 ...

Page 184: ...Memo 179 140 180 qxd 06 7 4 14 29 ページ179 ...

Page 185: ...be D742F Front Type 100 100 18 59 M DUNLOP D756 Rear Tire Pressure cold Spark Plug Pro Honda GN4 4 stroke oil or an equivalent Transmission oil Pro Honda GN4 4 stroke oil or an equivalent The maintenance schedule pages 27 28 lists service frequencies for about 2 5 hours about 7 5 hours about 22 5 hours and about 30 0 hours about 15 0 hours Check the items listed on the Pre ride Inspection checklis...

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