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Honda CRF450R 2006, Owner'S Manual

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Honda CRF450R 2006 Owner'S Manual Download Page 34

30

Servicing Your Honda

Fuel Tank Removal

Refer to Safety Precautions on page 19.

Removal
1. Turn the fuel valve OFF.
2. Remove the seat (page 29).
3. Remove the shroud A bolts/collars (1).
4. Remove the shroud B bolts (2) and shrouds

(3).

(1) shroud A bolts/collars
(2) shroud B bolts
(3) shrouds

5. Pull the breather tube (4) out of steering stem

nut.

6. Unhook and remove the fuel tank band (5).
7. Unhook the air cleaner case cover (6).
8. Remove the fuel tank bolt (7).

(4) breather tube
(5) fuel tank band
(6) air cleaner case cover
(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.

(3)

(1)

(2)

(4)

(7)

(6)

(5)

(10)

(8)

(9)

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.

(8) fuel line

(10) fuel valve bolt

(9) fuel valve

10. Remove the fuel valve bolt (10) and fuel

valve.

11. Remove the fuel tank.

Summary of Contents for CRF450R 2006

Page 1: ...2006 Honda CRF450R OWNER S MANUAL COMPETITION HANDBOOK ...

Page 2: ...helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your Honda other property or the environment Unless you are mechanically qualified and have ...

Page 3: ...fety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Of course it is not practical or possible to warn you about all hazards associat...

Page 4: ...ine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 53 Spark Plug 54 Valve Clearance 55 Piston Piston Rings Piston Pin 66 Chassis Suspension 74 Brakes 79 Wheels 83 Tires Tubes 84 Drive Chain 86 Exhaust Pipe Muffler 89 Additional Maintenance Procedures 92 Appearance Care 94 ADJUSTMENTS FOR COMPETITION 97 Front Suspension Adjustments 98 Rear Suspension Adjustments 111 Suspension Ad...

Page 5: ...ns 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 the safety labels on your CRF Important Safety Information 2 Important Safety Precautions 2 Accessories Modifications 3 Safety Labels 4 Motorcycle Safety 1 ...

Page 6: ...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 abilites or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability t...

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

Page 8: ...4 Motorcycle Safety Safety Labels Read this label carefully and don t remove it If the label comes off or becomes hard to read contact your Honda dealer for replacement ...

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

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

Page 11: ...o 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 carburetor and other adjustment see page 97 Before Riding Are You Ready to Ride 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection 9 ...

Page 12: ...other adjustments see page 97 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a...

Page 13: ...for condition 92 Carburetor throttle operation 46 Tires for damage or improper inflation pressure 84 Spokes for looseness 83 Rim locks for looseness 83 Front and rear suspension for proper operation 74 75 Front and rear brakes check operation 79 Drive chain for correct slack and adequate lubrication 86 Drive chain guide sliders and guide rollers for damage or wear 86 87 Exhaust pipe Muffler inspec...

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

Page 15: ... Instructions This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 12 Starting Stopping the Engine 13 Preparation 13 Starting Procedure 13 Flooded Engine 13 How to Stop the Engine 14 Break in Guidelines 15 ...

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

Page 17: ...e carburetor is equipped with an accelerator pump excessive fuel will be charged into the engine and the spark plug will be fouled if the throttle is opened and closed repeatedly Excessive fuel in the engine makes kickstarting difficult 6 About a minute after the engine starts push the choke knob back all the way to fully OFF If idling is unstable open the throttle slightly Warm Engine Starting 1 ...

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

Page 19: ... 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 Break in Guidelines ...

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

Page 21: ...ur Honda dealer s parts depertment Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before After Competition Maintenance 26 Between Motos Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat Removal 29 Fuel T...

Page 22: ...ner s manual The Importance of Maintenance Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to get maximum performance during each moto Careful pre ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF ...

Page 23: ...motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the optional work stand or a maintenance stand to provide support To reduce...

Page 24: ... maintenance schedule are expressed in terms 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 o...

Page 25: ...I I I I I L I I I I 47 53 43 45 54 41 56 37 37 48 68 69 40 41 86 86 87 87 87 80 82 79 49 92 89 74 75 99 102 93 84 92 R L R I R R R R R R I FORK TUBE SLIDER DAMPER FREQUENCY NOTE Ref Page Each race or about 2 5 hours Every 3 races or about 7 5 hours Every 6 races or about 15 0 hours Every 9 races or about 22 5 hours Every 12 races or about 30 0 hours This maintenance schedule is based upon average ...

Page 26: ...or their equivalent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reasse...

Page 27: ...oroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Honda White Lithium Grease or an equivalent is handy for this because any dirt tha...

Page 28: ...sion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 68 Fuel Filter Periodically drain the fuel from the fuel tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 Fuel Contamination Refer to Fuel System in your Owner s Manual page 34 and in this suppleme...

Page 29: ...uch as in tight woods can shorten the service life of brake fluid Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Water 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 ...

Page 30: ...e 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 1 chain adjuster index marks 2 pressure release screws 1 2 After Co...

Page 31: ...onably priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubric...

Page 32: ... speed choke knob spark plug rear brake caliper rear brake fluid reservoir rear brake pedal transmission oil check bolt transmission oil filler cap front suspension rebound damping adjuster front suspension compression damping adjuster rear suspension rebound damping adjuster rear suspension high speed damping adjuster rear suspension low speed damping adjuster clutch lever hot start lever front b...

Page 33: ...sliding it backward Installation 1 Install the seat 2 while aligning the seat front prong 3 with the seat bracket 4 and seat rear prong 5 with the frame 6 2 Install and tighten the seat bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 2 1 4 3 5 6 1 seat bolts 2 seat 3 seat front prong 4 seat bracket 5 seat rear prong 6 frame ...

Page 34: ... Remove the fuel tank bolt 7 4 breather tube 5 fuel tank band 6 air cleaner case cover 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 3 1 2 4 7 6 5 10 8 9 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the en...

Page 35: ... and tighten the fuel tank bolt 4 5 Hook the air cleaner case cover 5 6 Install and hook the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 7 breather tube 8 Install the shroud 8 by aligning it s tab 9 with subframe 10 11 shroud B bolts 12 shroud A bolts collars 4 fuel tank bolt 5 air cleaner case cover 6 fuel tank band 10 Install the seat page 29 10 8 9 8 shroud 10 subframe 9...

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

Page 37: ...st pipe 9 muffler clamp 10 gasket 8 Install the muffler 11 9 Install the muffler clamp 12 by aligning the tab 13 of the muffler clamp with the cut out 14 of the muffler 11 muffler 13 tub 12 muffler clamp 14 cut out 15 muffler B bolt washers 16 muffler A bolt 17 muffler clamp bolt 12 Install the side covers 18 side cover bolts 19 13 Install the seat page 29 18 side covers 19 side cover bolts 6 7 8 ...

Page 38: ...Avoid getting dirt dust or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure Fuel Tank Capacity 1 90 US gal 7 2R 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 bottom of the fil...

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

Page 40: ...cause serious damage to the engine Oil Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label suggested oil Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke engine oil or an equivalent viscosity weight SAE 10W 40 JASO T 903 standard MA or MB Other viscosities shown in the following chart may...

Page 41: ...l If the oil is below or near the lower level mark add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap Repeat steps 1 4 6 Reinsert the engine oil filler cap 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil filler cap ...

Page 42: ...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 16 Install the left engine guard and tighten the left engine guard bolt 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 19 C...

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

Page 44: ...ole add oil slowly through the transmission oil filler hole until oil starts 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 steps 1 4 5 After inspecting the oil level or adding oil tighten the oil check bolt to the specified torque 7 lbf ft 10 N m 1 0 kgf m Replacing Transmission Oil 1 Run the engine for 3 minutes ...

Page 45: ...rovide proper corrosion protection Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Checking Adding Coolant Refer to Safety Precautions on page 19 1 With the engine...

Page 46: ...the Honda Service Manual or consult your Honda dealer for replacing the water seal or the transmission oil seal Both seals should be replaced at the same time Coolant Replacement Refer to Safety Precautions on page 19 Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the Honda Service Manual page 156 To properl...

Page 47: ...leaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality Cleaning 1 Remove the seat page 29 2 Loosen the air cleaner retaining bolt 1 3 Align the two access top tabs 2 of the air cleaner 3 and mark 4 of the air cleaner housing by rotating the air cleaner counterclockwise 4 Remove the air cleaner 3 with the ret...

Page 48: ...ent to prevent dirt intrusion 13 Align the set tab 9 of the air cleaner with the mark 4 of the air cleaner housing by rotating the air cleaner 3 clockwise Tighten the retaining bolt 1 securely 5 Remove the air cleaner 3 from the air cleaner holder 5 1 air cleaner retaining bolt 3 air cleaner 7 hole 5 air cleaner holder 8 air cleaner tab 6 holder tab 6 Wash the air cleaner in clean non flammable cl...

Page 49: ...CRF is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube Draining 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits 2 Reinstall the crankcase breather tube plug 2 1 1 crankcase breather tube plug 2 tube ...

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

Page 51: ... open to fully closed in all steering positions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and...

Page 52: ...ation about high altitude carburetor adjustment see page 147 Idle Speed Adjustment 1 Turn the pilot screw 1 in until it is lightly seated and record the number of turns Turn the pilot screw out the same number of turns 1 1 pilot screw 2 If the engine is cold start it and warm it up 3 minutes Then shut it off 3 Connect a tachometer to the engine 4 Shift the transmission into neutral Start the engin...

Page 53: ...nd adjuster increase freeplay decrease freeplay 5 Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay 3 8 13 16 in 10 20 mm at the tip of lever Tighten the lock nut 1 2 3 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns Cable end adjuster 4 5 4 lock nut 5 integral cable adjuster increase freeplay decrease ...

Page 54: ...nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the adjustment 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 throttle Your CRF should move smoothly and accelerate gradually If you can t get proper adjustment...

Page 55: ...Remove the clutch pressure plate 6 5 clutch spring bolts springs 6 clutch pressure plate 6 Remove the washer 7 needle bearing 8 clutch lifter 9 and clutch lifter rod 10 7 Remove the eight clutch discs and seven clutch plates 11 Assemble the clutch lifter needle bearing and washer Turn the needle bearing with your finger The needle bearing should turn smoothly and quietly Replace the needle bearing...

Page 56: ...7 clutch pressure plate 8 clutch springs and bolts 2 1 3 6 4 5 8 7 9 10 10 Install a new O ring 9 in the groove of the clutch cover 10 11 Install the clutch cover by tightening the six cover bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m 3 Apply grease to the clutch lifter rod 3 4 Insert the clutch lifter rod into the mainshaft 5 Apply engine oil to the needle bearing 4 and washer 5 and i...

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

Page 58: ...nd the spark plug base 4 Remove the spark plug 2 1 spark plug cap 2 spark plug 5 Check the electrode for wear or deposits the sealing gasket 3 for damage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 039 0 043 in 1 0 1 1 mm 3 ...

Page 59: ...4 and cylinder head cover 5 3 cylinder head cover A bolt 4 cylinder head cover B bolts 5 cylinder head cover 1 crankshaft hole cap 2 Remove the spark plug 2 2 spark plug 1 2 5 3 4 1 2 cont d Refer to Safety Precautions on page 19 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Che...

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

Page 61: ...er tool fully to hold the stopper in the fully retracted position 3 stopper tool 1 2 3 3 Measure the decompressor arm clearance by inserting a feeler gauge 1 between the decompressor arm adjusting screw 6 and right side rocker arm 7 1 feeler gauge 6 decompressor arm adjusting screw 7 right side rocker arm DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured rig...

Page 62: ...amshaft holder assembly bolts 7 in a crisscross pattern in 2 3 steps Remove the camshaft holder assembly bolts camshaft holder assembly 8 intake valve lifters 9 and shims 10 As you remove the camshaft holder assembly the intake valve lifter and the intake valve shim may be sticking in the camshaft holder assembly Keep the intake valve lifters and the shims so as to allow identification of the orig...

Page 63: ...ickness in intervals of 0 025 mm 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with the micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust val...

Page 64: ...ach valve lifters 3 1 2 2 3 Install the valve lifters into the camshaft holder assembly 4 3 valve lifters 4 camshaft holder assembly 4 3 4 Install the camshaft holder assembly onto the cylinder head with the intake cam lobes 5 facing up as illustrated below Apply the oil to the camshaft holder assembly bolt threads and seating surface Tighen the camshaft holder assembly bolts 6 to the specified to...

Page 65: ...ket 10 cam sprocket 11 timing mark 12 mark 13 cam chain 13 10 12 11 7 Clean and apply a locking agent to the cam sprocket bolt threads coating width 0 26 in 6 5 mm from tip Temporarily install the cam sprocket bolt 14 by aligning the bolt holes of the cam sprocket and camshaft Rotate the primary drive gear bolt crankshaft clockwise one turn and tighten the sprocket bolt 14 to the specified torque ...

Page 66: ...12 on the camshaft holder assembly If the timing mark doesn t align with the mark remove the cam sprocket Then realign the valve timing 15 8 punch mark 9 index mark 11 timing marks 12 mark 8 12 9 11 10 Measure the intake valve clearance and exhaust valve clearance Valve Clearance IN 0 006 0 001 in 0 16 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 11 Install the new sealing washer 17 and cam chain tensio...

Page 67: ...0 03 mm 1 feeler gauge 3 shim 2 right side rocker arm 2 Pull out the feeler gauge between the right side rocker arm and shim 2 3 1 3 Loosen the lock nut 4 and decompressor arm adjusting screw 5 Insert the feeler gauge 1 between the adjusting screw and right side rocker arm 6 DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0...

Page 68: ...at 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 1 O ring 2 crankshaft hole cap 1 2 Cylinder Head Cover Installation 1 Remove the spark plug hole packing 1 from the cylinder head cover Install the spark plug hole packing to th...

Page 69: ...r A bolt 6 and cylinder head cover B bolts 7 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 cylinder head cover 6 cylinder head cover A bolt 7 cylinder head cover B bolts 8 spark plug cap 9 breather tube 6 5 7 8 9 6 Install the fuel tank and seat page 31 5 Connect the spark plug cap 8 and breather tube 9 ...

Page 70: ... exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 7 Disconnect the spark plug cap 4 and remove the ignition coil nut 5 ignition coil bolts 6 and ignition coil 7 8 Remove any dirt from around the spark plug base 4 spark plug cap 6 ignition coil bolts 5 ignition coil nut 7 ignition coil 8 spark plug 11 Position the piston at top dead center on the compression stroke page 55 Remove the ca...

Page 71: ...er head bolts 17 15 Loosen the cylinder bolt 18 17 cylinder head bolts 18 cylinder bolt 16 Remove the cylinder head nuts washers 19 and the cylinder head 20 Loosen the nuts in a criss cross pattern in 2 or 3 steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase NOTICE 19 cylinder head nuts washers 20 cylinder head 17 Remove the dowel pins 21 cylinder head gask...

Page 72: ... Place clean shop towels in the 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 30 0 hours of running 4 Spr...

Page 73: ...tall the spacer first then install the side rails 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 mark top ring s...

Page 74: ... 5 Use new pin clips Never reuse old clips Do not let the clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out Cylinder Installation 1 Clean off any gasket material from the gasket surface of the crankcase being careful not to let any material fall into the crankcase ...

Page 75: ...e piston rings and cylinder walls NOTICE 4 cam chain 6 piston rings 5 cylinder 6 Install the cam chain guide 7 and fit the cam chain guide tab 8 in the cylinder cut out 9 Push the guide until it bottoms in the crankcase guide hole 7 cam chain guide 8 cam chain guide tab 9 cylinder cut out Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder head gasket 2 Do not let the dowel pins...

Page 76: ... 7 lbf ft 10 N m 1 0 kgf m 3 cylinder head 4 cylinder head nuts washers 7 left engine hanger plate 8 right engine hanger plate 9 engine hanger B bolts 10 engine hanger A bolt 11 fuel hose guide 12 engine hanger nut 4 4 3 6 5 10 11 7 9 5 cylinder bolt 6 cylinder head bolts 5 Install the left engine hanger plate 7 right engine hanger plate 8 and engine hanger B bolts 9 and tighten the engine hanger ...

Page 77: ...k plug cap 13 14 20 15 18 17 19 16 10 Install the cylinder head cover page 64 11 Install the ignition coil 15 ground terminal 16 ignition coil bolts 17 and ignition coil nut 18 Connect the primary wire 19 and spark plug cap 20 12 Install a new exhaust pipe gasket 21 exhaust pipe 22 and exhaust pipe joint nuts 23 and tighten to the specified torque 15 lbf ft 21 N m 2 1 kgf m 21 exhaust pipe gasket ...

Page 78: ...ur 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 116 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 b...

Page 79: ...ncrement or turns described in page 112 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 112 After adjusting the adjusters simultaneously suspension may be fine tuned b...

Page 80: ... fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube Amount of fork oil left in the fork within damper and spring unit cc minute C F 30 86 20 68 10 50 0 32 5 27 29 4 28 2 30 6 10 15 3 16 5 21 2 22 4 20 10 6 11 8 16 5 18 8 35 9 4 10 6 15 3 16 5 55 8 3 9 4 12 9 16 5 85 7 9 8 2 11 8 15 3 145 7 9 8 2 11 8 14 1 3 2 1 1 4 5 6 7 1 1 9 1 Recommen...

Page 81: ...l capacity 12 9 US oz 380 cm3 Maximum oil capacity 13 9 US oz 412 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 7 US oz 316 cm3 2 scribe marks aftermarket parts No mark factory products 3 scribe marks Optional Stiffer 0 48 kgf mm Fork Spring Standard oil capacity 12 5 US oz 369 cm3 Maximum oil capacity 13 6 US oz 401 cm3 Slig...

Page 82: ...2 is in good condition Apply the recommended fork oil to the O ring Temporarily install the fork damper 2 to the outer tube 1 After installing the fork leg page 119 tighten the fork damper to the specified torque 25 lbf ft 34 N m 3 5 kgf m 1 outer tube 2 fork damper 10 O ring 10 1 2 ...

Page 83: ... 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 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake l...

Page 84: ... the brake system and it must be bled Refer to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 82 Worn brake pads should be repla...

Page 85: ... torque 0 7 lbf ft 1 0 N m 0 1 kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 5 bolts 6 reservoir cap 7 set plate 8 diaphragm 9 upper level mark 1 Remove the bolts 5 reservoir cap 6 set plate 7 and diaphragm 8 2 Fill the reservoir...

Page 86: ...c 2 front brake caliper Rear Brake Pads Inspect the 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 ...

Page 87: ...perform the recommended service in the Maintenance Schedule page 21 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rim 3 rim lock 2 spoke 1 Inspect the wheel rims 1 and spokes 2 for damages 2 Tighten any loose spokes and rim locks 3 to the specified torque Spoke front 2 7 lbf ft 3 68 N m 0 4 kgf m rear 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Lock 9 lb...

Page 88: ...stall a new cap Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular rid...

Page 89: ... 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 Front Rear Type 80 100 21 51M DUNLOP 110 90 19 62M DUNLOP D742F D756 bias ply tube 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 a...

Page 90: ...in slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links...

Page 91: ...ckwise lightly until it touches the axle plate Then while holding the adjusting bolt with a wrench tighten the lock nut to the specified torque 20 lbf ft 27 N m 2 8 kgf m Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda Chain Lube or an equivalent or SAE 80 or 90 gear oil is recommended Satura...

Page 92: ...imit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service Replacement chain D I D 520DMA2 Service limit 10 20 in 259 0 mm MEASURE A SPAN OF 17 PINS 16 PITCHES 6 Lubricate the drive chain 7 Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends aga...

Page 93: ...deformation A damaged exhaust pipe and muffler may reduce engine performance Muffler Removal 1 Remove the seat bolt 1 side cover bolt 2 and right side cover 3 1 seat bolt 3 right side cover 2 side cover bolt 2 Loosen the muffler clamp bolt 4 3 Remove the muffler A bolt 5 muffler B bolt washers 6 and muffler 7 4 muffler clamp bolt 6 muffler B bolt washers 5 muffler A bolt 7 muffler 1 3 2 7 6 5 4 ...

Page 94: ...ler 6 tab 5 muffler clamp 7 cut out 5 Tighten the muffler B bolt washers 8 and muffler A bolt 9 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 6 Tighten the muffler clamp bolt 10 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 8 muffler B bolt washers 10 muffler clamp bolt 9 muffler A bolt 11 right side cover 13 seat bolt 12 side cover bolt 1 2 3 4 7 6 5 8 9 10 13 11 12 7 Install the right ...

Page 95: ...d tighten to the specified torque 15 lbf ft 21 N m 2 1 kgf m 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 90 Exhaust Pipe Removal 1 Remove the muffler page 89 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 2 1 3 2 3 1 ...

Page 96: ...Tighten the front bolts first 1 handlebar 2 handlebar upper holders 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 Be certain that the throttle cables have no kinks or other damage 1 2 2 Stand in front of your CRF grab the fork at the axle look at the steer...

Page 97: ...ft hole cap Oil filter cover Cylinder bolt Cylinder head bolts Exhaust pipe joint nuts Torque lbf ft N m kgf m 7 7 7 7 11 9 7 7 15 10 10 10 10 15 12 10 10 21 1 0 1 0 1 0 1 0 1 5 1 2 1 0 1 0 2 1 1 cylinder head cover bolts 2 clutch cover bolts 3 water pump cover bolts 4 transmission oil check bolt 5 crankshaft hole cap 9 exhaust pipe joint nuts 1 cylinder head cover bolts 6 oil filter cover bolts 7...

Page 98: ...teering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your motorcycle You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and r...

Page 99: ...s manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mi...

Page 100: ...96 Servicing Your Honda ...

Page 101: ...by installing the optional fork springs of a similar rate Front Suspension Adjustments 98 Front Suspension Air Pressure 98 Front Suspension Damping 98 Fork Springs 99 Front Suspension Disassembly 99 Damper Oil Change 102 Fork Assembly 105 Rear Suspension Adjustments 111 Rear Suspension Spring Pre Load 111 Rear Suspension Damping 112 Rear Suspension Race Sag 113 Suspension Adjustments for Track Con...

Page 102: ...ng the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place an optional workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pres...

Page 103: ...k springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 ...

Page 104: ... loosen the front axle pinch bolts 10 on both forks Pull the front axle shaft 11 out of the wheel hub and remove the front wheel 9 axle nut 11 front axle shaft 10 axle pinch bolts 9 Remove the fork protector bolts 12 brake hose clamp bolts 13 and fork protectors 14 Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause...

Page 105: ...olt 20 Push out the fork center bolt from the axle holder of the slider by pushing the fork damper 21 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as shown if you do not have the special tool 24 23 20 26 27 28 33 mm 12 2 mm cont d The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold ...

Page 106: ...31 from the fork damper 25 Remove the special tool or mechanic s stopper tool 29 between the axle holder 27 and lock nut 30 while applying pressure to the fork cap Be careful not to damage the lock nut and fork center bolt hole NOTICE 27 axle holder 30 lock nut 29 stopper tool 31 push rod 26 Remove the fork damper assembly 32 from the fork assembly 33 Remove the fork from the vise Remove the fork ...

Page 107: ...damage the fork cap bushing If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 1 fork cap 7 bushing 2 fork damper 8 O ring 4 2 2 5 2 2 6 1 65 1 85 in 42 47 mm 2 8 2 1 7 8 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper as shown Oil Level 1 65 1 85 in 42 47...

Page 108: ...use 5 9 US oz 173 cm3 of fork fluid to be left in the chamber 12 Screw in the lock nut 9 to the fork damper piston rod 6 fully 1 fork cap 3 lock nut wrench 2 fork damper 2 3 1 10 Tighten the fork cap 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 11 Hold the fork damper 2 in an upright position and pump the fork pisto...

Page 109: ...20 minutes 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 Blow out the oil completely off the fork spring 3 using the compressed air Install the fork spring Install the fork damper assembly 4 to the outer tube slider 1 1 outer tube slider 4 fo...

Page 110: ...he center bolt fully by hand NOTICE 2 lock nut 7 O ring 5 stopper tool 8 center bolt 6 push rod 9 adjusting rod 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 lock nut 8 center bolt 9 Tighten the lock nut 2 to the center bolt 8 closely by hand Tighten the ...

Page 111: ...oz 311 cm3 Optional Softer 0 44 kgf mm Fork Spring Standard oil capacity 12 9 US oz 380 cm3 Maximum oil capacity 13 9 US oz 412 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 7 US oz 316 cm3 2 scribe marks aftermarket parts No mark factory products 3 scribe marks Optional Stiffer 0 48 kgf mm Fork Spring Standard oil capacity 1...

Page 112: ...m the outer tubes Deformed outer tubes must be replaced NOTICE 13 lower pinch bolts 17 upper pinch bolts 12 4 1 13 17 13 13 fork lower pinch bolts 17 Tighten the fork damper 4 to the specified torque using the lock nut wrench 14 Actual 25 lbf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using a 20 in 50 cm long torque wrench When using the lock nut wrench use a 20 inc...

Page 113: ...rotector bolts 19 fork protectors 20 brake hose clamp bolts 21 caliper mounting bolts 22 brake caliper 23 front axle nut 24 left axle pinch bolts 20 22 19 18 21 18 24 23 cont d 25 Install the handlebar 25 mounting rubbers 26 washers and handlebar holder nuts 27 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 25 handlebar 26 mounting rubbers 27 washers handl...

Page 114: ...he right fork pinch bolts 32 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 32 axle pinch bolts To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 30 Clean the threads of the disk cover bolts and axle holder thoroughly Apply locking agent to the bolt threads Install the disc cover 33 and tighten the bolts 34 to the sp...

Page 115: ...ough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 89 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear whe...

Page 116: ... speed damping adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 1 2 2 turns and the punch marks are aligned Low Speed Damping The low speed damp...

Page 117: ...sion tuning the proper rear spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the center of the rear fender mounting bolt to the center of the ch...

Page 118: ...oaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF With the spring pre load set to obtain the proper race sag the rear suspension should sag 0 4 to 1 0 in 10 to 25 mm If the rear of your CRF sags more than 1 0 in 25 mm from its own weight the spring is too stiff for your weight It is not compressed enough even th...

Page 119: ...iffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compre...

Page 120: ...on large bumps especially downhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because...

Page 121: ...ng makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is...

Page 122: ...bumps Entire travel too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment ...

Page 123: ...vered to the cylinder when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A l...

Page 124: ...Circuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture enters the venturi through the bypass 3 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...

Page 125: ...or Removal 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by loosening the drain screw 1 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 drain screw 3 Tighten the drain screw 2 1 1 straght section 2 clip 1 con...

Page 126: ...tor band screw 8 Disconnect the throttle position sensor connector 5 9 Remove the carburetor 5 throttle position sensor connector 10 Remove the hot start cable holder 6 6 hot start cable holder 11 Remove the throttle drum cover bolt 7 and throttle drum cover 8 7 throttle drum cover bolt 8 throttle drum cover 12 Remove the throttle cables 9 by loosening the throttle cable lock nut 10 9 throttle cab...

Page 127: ...le valve 3 Remove the link arm set screw 6 When installing the link arm set screw apply a locking agent to the link arm set screw threads 4 Remove the throttle valve 5 throttle valve roller 7 and floating valve 8 5 throttle valve 7 throttle valve roller 6 link arm set screw 8 floating valve When installing the floating valve 8 onto the throttle valve 5 make sure the floating valve s flat side face...

Page 128: ...at bowl 8 Remove the pump rod 20 Clean the pump rod and rod passage 21 Install the pump rod into the link lever 22 Push the rod forcibly into the link lever until it snaps into place 20 pump rod 22 link lever 21 rod passage 23 float level 24 float level gauge 25 carburetor intake 9 Measure the float level 23 with the float level gauge 24 during float tab just contacting the float valve and the car...

Page 129: ... 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 After installing the carburetor adjust the throttle cable 1 free play and hot start cable 2 free play After installing the carburetor check the throttle sensor connector 3 for correct routing as necessary After installing the carburetor check the air vent hoses 4 and overflow hose ...

Page 130: ...opening Slow jet Jet needle Needle clip position Main jet Float level Identification number Standard settings 1 1 2 turns out 42 NCYQ 4th groove 168 0 31 in 8 0 mm FCR00E Adjustments for Altitude Temperature All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture Condition cold temperature warm temperature dry air hig...

Page 131: ...track has a very long straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is hotter than 113 degrees F After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CRF If larger jetting changes...

Page 132: ...3 turns out the next larger slow jet is needed If you are under 1 turn out the next smaller slow jet is needed 1 pilot screw Adjustment Procedure 1 Warm up the engine 2 Make 2 3 laps of a course with the standard setting or corrected jetting page 126 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening Verify carburetion by removing the spark plug and...

Page 133: ...uretor top and carburetor top bolts 16 Install the fuel tank page 31 10 jet needle holder 12 throttle valve 11 jet needle 17 Start the engine If the engine idle speed is too high or too low or engine is not idling adjust the engine idle speed page 48 18 Repeat steps 4 16 until the engine gives maximum power with the correct spark plug reading It is always better to jet a little rich than a little ...

Page 134: ... appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain indicate rich jetting NOTICE Condition Normal Overheating Lean Wet Rich Spark Plug Appearance Dark brown to light tan color with dry electrode Light gray or white color Wet or sooty Mi...

Page 135: ... 90 100 mm range Fork Height Angle The position of the fork tubes in the clamps is adjustable Standard Position The standard position 1 align the top of the outer tube 2 not the top of the fork cap with the top of the upper fork clamp 3 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 yo...

Page 136: ...od 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 a ch...

Page 137: ...y will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands...

Page 138: ...ither is depressed when sitting or standing comfortably on your CRF Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved forward either 3 mm using optional handlebar lower holders or 6 mm ...

Page 139: ... on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 136 Storing Your Honda 137 Preparation for Storage 137 Removal from Storage 137 You the Environment 138 Troubleshooting 139 ...

Page 140: ...railer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and ...

Page 141: ...radiator cap and drain bolt 1 bolt 3 coolant drain bolt 2 right engine guard 4 water pump 7 Lubricate the drive chain 8 Inflate the tires to their recommended pressures 9 Place your CRF on the optional Honda workstand or equivalent to raise both tires off the ground Removal from Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the ...

Page 142: ...ing solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and o...

Page 143: ...nition system wires Faulty engine stop button Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing Valve stick open POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Disconnect fuel line at carburetor and check for clogging P 34 UNRESTRICTED FUEL FLOW FUEL FLOW RESTRICTED CLOGGED DIRTY INCORRECT LOW WEAK OR INTERMITTENT SPARK NOT CLOGGED CORRECT CORRECT GOOD SPARK...

Page 144: ...140 Tips ...

Page 145: ...dimensions capacities and other technical data Vehicle Identification 142 Specifications 143 Torque Specifications 144 High Altitude Carburetor Adjustment 147 Oxygenated Fuels 148 Competition Logbook 149 Optional Parts List 151 Spare Parts Equipment 152 Wiring Diagram 153 ...

Page 146: ...You may record these numbers in the Quick Reference section at the rear of the manual The Vin vehicle identification number 1 appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 1 vin The frame number 2 is stamped on the right side of the steering head RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 engine number 1...

Page 147: ...r disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet standard Jet needle standard Piston valve FCR00E 168 NCYQ Needle clip position standard Slow jet standard Pilot screw opening Float level Idle speed Liquid cooled 4 stroke Single 8 inclined from vertical 4th groove 42 1 1 2 turns out 1 700 100 rpm Type Metric 660 cm3 690 cm3 850 cm3 590 cm3...

Page 148: ... ENGINE Cylinder head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap Oil filter cover Cylinder bolt Cylinder head bolts Exhaust pipe joint nut Drive sprocket bolt Torque Remarks lbf ft N m kgf m 7 7 7 7 11 9 7 7 15 23 10 10 10 10 15 12 10 10 21 31 1 0 1 0 1 0 1 0 1 5 1 2 1 0 1 0 2 1 3 2 1 9 5 4 2 3 1 8 6 10 7 ...

Page 149: ...r Swingarm pivot nut Fork fork damper fork cap Rear shock arm nuts swingarm side shock link side Rear shock link nuts Frame side Shock spring lock nut Kickstarter arm bolt Torque Remarks lbf ft N m kgf m 80 16 15 16 32 65 15 94 20 47 44 40 19 32 32 65 25 22 39 39 39 32 28 108 22 20 22 44 88 20 128 27 64 59 54 26 44 44 88 34 30 53 53 53 44 38 11 0 2 2 2 0 2 2 4 5 9 0 2 0 13 1 2 8 6 5 6 0 5 5 2 7 4 ...

Page 150: ...t mounting bolts Front brake reservoir cap screws Rear brake reservoir cap bolts Fork air pressure release screw Torque Remarks lbf ft N m kgf m 7 3 25 22 12 12 27 2 7 2 7 9 9 9 22 36 51 16 10 5 2 15 15 15 24 19 0 7 0 7 0 9 9 9 34 30 16 16 36 3 68 3 7 12 12 12 30 49 69 22 13 7 21 21 21 32 26 1 0 1 0 1 2 1 0 3 5 3 1 1 6 1 6 3 7 0 4 0 4 1 2 1 2 1 2 3 1 5 0 7 0 2 2 1 3 0 7 2 1 2 1 2 1 3 3 2 7 0 1 0 1...

Page 151: ...and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may cause engine overhea...

Page 152: ...ol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performa...

Page 153: ...e repairs running time on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your t...

Page 154: ...ng Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use 150 Technical Information Competition Logbook ...

Page 155: ...mm NCYS Ø2 765 mm NCVS Ø2 765 mm CARBURETOR Remarks Main jet Standard 168 Slow jet Standard 42 158 178 in increments of 2 or 3 38 48 in increments of 2 or 3 Jet Needles Standard needle NCYQ Straight diameter ø2 745 mm Jet needle number standard series TOOLS Remarks FRAME Remarks Driven sprocket Standard Drive chain links 48 Teeth Aluminum 114 Optional Optional 47 Teeth Aluminum 114 49 Teeth Alumin...

Page 156: ...len wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CRF purchased from your Honda dealer Tensioner stopper 070MG 0...

Page 157: ...Technical Information 153 Wiring Diagram ...

Page 158: ...154 Technical Information ...

Page 159: ...Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals 156 Contacting Honda 157 Your Honda Dealer 158 The Honda Rider s Club USA only 159 ...

Page 160: ...6 Calif Add 8 25 Handling 5 00 Charge Grand Total Prices are subject to change without notice and without incurring obligation Orders are mailed within 10 days Please allow adequate time for delivery S H I P T O NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to ...

Page 161: ...es at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following infor...

Page 162: ...ondaline accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information US...

Page 163: ...ong as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Specialty Vehicle Institute of America for ATV owners One f...

Page 164: ...ortance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before After Competition Maintenance 26 Between Motos Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat Removal 29 Fuel Tank Removal 30 Subframe Removal 32 Service Procedures Fluids Filters Fue...

Page 165: ...pension Damping 98 Fork Springs 99 Front suspension Disassembly 99 Damper oil change 102 Fork Assembly 105 Rear Suspension Adjustments 111 Rear Suspension Spring Pre Load 111 Rear Suspension Damping 112 Rear Suspension Race Sag 113 Suspension Adjustments for Track Conditions 115 Suspension Adjustment Guidelines 116 Carburetor Adjustments Tuning Tips 119 Carburetor Components 119 Carburetor Circuit...

Page 166: ...ment 147 idle speed 48 minor adjustments 128 removal 121 care appearance 94 chain drive 86 chassis adjustment for track conditions 133 choke knob 13 cleaner air 43 cleaning appearance care 94 clutch system adjustment 49 consumer information 155 competition logbook 149 contacting Honda 157 controls operating 5 coolant 41 customer service 158 cylinder system 68 damping adjustments front 98 rear 112 ...

Page 167: ...ons 6 optional parts list 151 sprockets 132 oxygenated fuels 148 pads brake 82 parts optional 151 personal fit adjustments 134 pinging engine 34 plug spark 54 pre load rear suspension 111 pre ride inspection 9 protective apparel 2 rear suspension maintenance 111 Rider s Club Honda 159 riding apparel 2 basic operation 11 before 7 important safety information 2 safety precautions 2 safety a few word...

Page 168: ...s 116 transmission oil 39 tuning tips 119 throttle freeplay 46 inspection 47 tires air pressure 84 flat 84 selection 85 tools 152 torque specifications 144 146 transporting 136 troubleshooting 139 tubes replacing 84 valve fuel 13 vehicle identification 142 washing your motorcycle 94 wheels 83 writing diagram 153 W V T ...

Page 169: ...Memo 165 ...

Page 170: ...166 Memo ...

Page 171: ...Memo 167 ...

Page 172: ...heck the items listed on the Pre Ride inspection checklist each time before you ride page 9 unleaded gasoline pump octane number of 91 or higher tank 1 90 US gal 7 2R Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke engine oil or an equivalent Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdem additives 4 stroke engine oil or an equivalent Front 1...

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