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Honda CRF450R 2017, Owner'S Manual & Competition Handbook

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Honda CRF450R 2017 Owner'S Manual & Competition Handbook Download Page 153

Vehicle Identification

148

Technical Information

Vehicle Identification

The VIN and engine serial number are required 
when you register your CRF. They may also be 
required when ordering replacement parts. You 
may record these numbers in the Quick Reference 
section at the rear of this manual.

The VIN (vehicle identification number) (1) is 
stamped on the right side of the steering head.

The engine number (2) is stamped on the left 
crankcase.

Serial Numbers

(1) VIN

(1)

(2) engine number

(2)

0.(ERRN࣮࣌ࢪ㸰㸮㸯㸴ᖺ㸷᭶㸯᪥ࠉᮌ᭙᪥ࠉ༗ᚋ㸰᫬㸳㸴ศ

Summary of Contents for CRF450R 2017

Page 1: ... You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 26 Before After Competition Maintenance 30 Between Motos Practice Maintenance 30 After Competition Maintenance 31 Service Preparations Maintenance Component Locations 32 Seat 33 Fuel Tank 34 Subframe 36 Service Procedures Fluids Filt...

Page 2: ...2017 Honda CRF450R OWNER S MANUAL COMPETITION HANDBOOK 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 3: ...mation is intended to help you avoid damage to your CRF other property or the environment Unless you are mechanically qualified and have the proper tools you should see your dealer for the service and adjustment procedures discussed in this manual An official Honda Service Manual for your CRF is available page 160 It is the same manual your dealer uses If you plan to do any service on your CRF bey...

Page 4: ... the manual Safety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or S...

Page 5: ...rack Conditions 138 Personal Fit Adjustments 139 Control Positioning 139 Handlebar Position Width Shape 139 TIPS 141 Transporting Your Motorcycle 142 Storing Your Honda 143 Preparation for Storage 143 Removal from Storage 143 You the Environment 144 Troubleshooting 145 TECHNICAL INFORMATION 147 Vehicle Identification 148 Serial Numbers 148 Specifications 149 Torque Specifications 150 Nuts Bolts Fa...

Page 6: ...d recommendations to help you ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF Important Safety Information 2 Important Safety Precautions 2 Accessories Modifications 3 Safety Labels 4 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 7: ...me to Get to Know Your CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perf...

Page 8: ...ld change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride Accessories Modifications WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 9: ...bels 4 Motorcycle Safety Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for replacement For Canada Safety Labels 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 10: ...ion carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 MIL Malfunction Indicator Lamp 7 MIL Blink Pattern 7 Current DTC Freeze DTC 7 Circuit Inspection 8 DTC Index 9 Mode Indicator 10 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 11: ...trols Operation Component Locations front brake lever clutch lever engine mode select button engine stop button MIL mode indicator throttle grip shift lever fast idle knob engine idle speed kickstarter rear brake pedal 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 12: ...nking lasts for 0 4 seconds One long blink is the equivalent of 10 short blinks For example when one long blink is followed by two short blinks the MIL is 12 one long blink 10 blinks plus two short blinks When the ECM stores more than one DTC the MIL will indicate them by blinking in the order from the lowest number to highest number The DTC is indicated in two ways according to the failure status...

Page 13: ...d to poorly connected or corroded connections Check the following connections Remember circuit inspection is not a cure all for other problems in your engine s PGM FI system Circuit Inspection 1 MAP sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 CKP sensor connector 7 ECM connector 7 4 3 2 6 1 5 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 14: ...a Service Manual page 160 for troubleshooting of the PGM FI symptom DTC Index MIL blinks Function Failure Symptom Fail safe function 1 MAP sensor circuit malfunction Poor performance driveability 2 MAP sensor performance problem Poor performance driveability 7 ECT sensor circuit malfunction Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IAT sensor circui...

Page 15: ...ntly selected mode by blinking the mode number once when the engine is started The mode indicator indicates a selected mode when you operate the engine mode select button page 122 If the mode indicator stays on or does not come on when it should have your dealer check it for problems 1 mode indicator blue 2 engine mode select button 2 1 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 16: ...o ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension and other adjustments see page 121 Are You Ready to Ride 12 Is Your Motorcycle Ready to Ride 13 Pre ride Inspection 13 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 17: ...stments see page 121 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 i...

Page 18: ...r damage or improper inflation pressure 107 Spokes for looseness 106 Rim locks for looseness 106 Front and rear suspension for proper operation 85 101 Front and rear brakes check operation 102 Drive chain for correct slack and adequate lubrication 109 110 Drive chain sliders and drive chain rollers for damage or wear 109 110 Exhaust pipe Muffler for looseness 112 Every possible part for looseness ...

Page 19: ...14 Before Riding 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ BLANK PAGE ...

Page 20: ...s section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 16 Starting Stopping the Engine 17 Fast Idle Knob 17 Preparation 17 Starting Procedure 17 How to Stop the Engine 18 Break in Guidelines 19 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 21: ... as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Safe Riding Precautions WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colorless odorless gas can quickly cause unconsciousness and lead...

Page 22: ...gh to the bottom with a rapid continuous motion 4 About a minute after the engine starts push the fast idle knob back all the way to fully OFF If idling is unstable open the throttle slightly Warm Engine Starting 1 Shift the transmission into neutral 2 Kick start the engine Do not open the throttle Starting the engine excessively changed with fuel by throttle blipping or other reasons 1 Shift the ...

Page 23: ... Shift the transmission into neutral 2 Push and hold the engine stop button 1 until the engine stops completely Emergency Engine Stop To stop the engine in an emergency push and hold the engine stop button How to Stop the Engine 1 engine stop button 1 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 24: ...extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 25: ...20 Basic Operating Instructions 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ BLANK PAGE ...

Page 26: ...available Check with your dealer s parts department Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 26 Before After Competition Maintenance 30 Between Motos Practice Maintenance 30 After Competition Maintenance 31 Service Preparations Maintenance Component Locations 32 Seat ...

Page 27: ...ecause your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection ...

Page 28: ...d exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using an optional workstand or a maintenance stand to provide support To reduce the possibility of a fire or explos...

Page 29: ... and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only Honda Genuine Parts or their ...

Page 30: ...ces or about 15 0 hours Every 9 races or about 22 5 hours Every 12 races or about 30 0 hours Ref Page FUEL LINE NOTE 6 I R 38 FUEL PUMP FILTER NOTE 6 R 42 47 THROTTLE OPERATION I 57 AIR FILTER NOTE 1 C 53 54 CRANKCASE BREATHER I 55 SPARK PLUG I 64 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 65 73 ENGINE OIL NOTE 3 NOTE 5 I R 49 ENGINE OIL FILTER NOTE 3 R 49 50 ENGINE IDLE SPEED I 58 PISTON AND PI...

Page 31: ...r their equivalents when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surfaces O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reass...

Page 32: ...unning condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Air Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Pro Honda Foam Air Filter Sealer or an equivalent is handy for this because any dirt that penetrates this sealing area will sho...

Page 33: ...rol Remove the throttle control every few rides clean the inside of the throttle pipe and handlebar thoroughly Inspect the cable carefully for kinks or other damage that may restrict throttle control in anyway Move the handlebar from lock to lock to be sure there is no cable interference Make certain the throttle operation is perfect after servicing and inspecting Engine Mounting Bolts and Nuts Ma...

Page 34: ...the engine A small amount of coolant weeping from the bleed hole is normal See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil seal Both seals should be replaced at the same time Suspension Linkage Lubrication Disassemble clean inspect and lubricate all suspension linkage pivot bearings with molybdenum disulfide grease containing more than 3 molybde...

Page 35: ...n parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel ...

Page 36: ...an and lubricate it pages 110 111 Be sure the chain is wiped clean and is dry before lubricating the chain Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning brushes are available from vari...

Page 37: ...adjuster rear suspension low speed compression damping adjuster front suspension compression damping adjuster both left and right fast idle knob engine idle speed engine oil filter crankcase breather tube drive chain front brake caliper engine oil fill cap air cleaner rear suspension spring pre load adjuster spark plug engine oil drain bolt rear brake pedal rear brake fluid reservoir rear brake ca...

Page 38: ...while aligning the seat front prong 1 with the slot 2 of the fuel tank and seat center prongs 3 with the seat support base slots 4 2 Install and tighten the seat mounting bolts 5 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat mounting bolts 2 seat 1 2 1 1 seat front prong 4 seat support base slots 2 slot 5 seat mounting bolts 3 seat center prongs 1 3 5 4 2 5 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳...

Page 39: ...nks or other damage Do not support the fuel tank by the fuel feed hose 13 NOTICE The fuel tank is made of titanium material Since the fuel tank has not been painted it might be discolored with mud and dust To remove mud or dust use a sponge or soft cloth and a stainless steel kitchen detergent then rinse well clean water After washing rinse with plenty of water and dry with a clean cloth 1 shroud ...

Page 40: ...the shroud 7 toward the down so that the shroud tab 8 and the slot 9 on the air cleaner housing cover 10 is aligned 6 Install the shroud C bolt 11 B bolt 12 and shroud A bolt 13 Tighten the shroud A and B bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Tighten the shroud C bolt to the specified torque 3 8 lbf ft 5 2 N m 0 5 kgf m The right and left shrouds can be installed in the same mann...

Page 41: ...ather tube 6 and IAT sensor connector 7 7 Loosen the air cleaner connecting tube clamp screw 8 8 Remove the subframe lower bolts 9 and upper bolts 10 Remove the subframe 5 while disconnecting the air cleaner connecting tube 11 1 seat support base mounting bolts 2 washers 3 collars 4 seat support base 1 2 3 4 3 2 4 seat support base 5 subframe 6 breather tube 7 IAT sensor connector 8 air cleaner co...

Page 42: ...ween the clamp ends is 0 30 0 06 in 7 5 1 5 mm 4 Connect the breather tube 6 and IAT sensor connector 7 5 Install the seat support base 8 6 Install and tighten the collars 9 washers 10 and seat support base mounting bolts 11 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 7 Install the left and right mufflers page 113 8 Install the seat page 33 1 subframe upper bolts 2 subframe lower bolts Left ...

Page 43: ...ill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck 4 Fuel Tank Capacity 1 66 US gal 6 3 ℓ Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert th...

Page 44: ...move the fuel quick connect fitting cover 1 from the fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary 5 Remove the bolt 4 clamp and setting rubber 5 6 Place a shop towel 6 over the fuel quick connect fitting Fuel Pressure Relieving 1 fuel pump connector 1 Fuel Line Replacement 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick connect fitting 4 bolt 5 c...

Page 45: ...Connection 1 Install the rubber cover 1 onto the fuel joint 2 of the fuel pump as shown 2 Be sure that the slide retainer 3 is completely pulled up before connecting the quick connect fitting Do not bend or twist the fuel feed hose Do not reuse the kinked or damaged fuel hose Do not use gloves or a shop towel while installing the quick connect fitting WARNING Gasoline is highly flammable and explo...

Page 46: ...place check visually and by pulling the connector housing 5 Install the setting rubber 5 clamp 6 and bolt 7 by aligning the clamp tab 8 with the groove 9 of the stay 6 Install the fuel quick connect fitting cover 10 Be sure the rubber cover 1 is properly installed between the fuel quick connect fitting cover and fuel pump 7 Increase the fuel pressure page 47 2 fuel joint 3 slide retainer 4 connect...

Page 47: ...move the fuel pump mounting nuts 6 fuel pump mounting cup nut 7 stopper cable guide 8 stopper cable 2 washer 9 collars 10 conical spring washers 11 and fuel pump plate 12 while holding the fuel tank Fuel Pump Filter Replacement 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...

Page 48: ...9 Release the hooks of the fuel pump unit holder from the grooves 20 in the fuel pump base tabs while pushing the holder against the base and slightly spreading the base tabs Be careful not to damage the hooks and tabs 10 Remove the fuel pump unit holder assembly 21 from the fuel pump base 17 and remove the O ring 22 Wipe the spilled out fuel immediately 11 Remove the fuel pump stopper 23 and damp...

Page 49: ...to a new O ring 5 Install a new O ring to the fuel pump assembly 2 3 Install the fuel pump assembly with fuel pump filter into the fuel pump unit holder 6 while routing the fuel pump yellow 7 and green 8 wires through the holder grooves 9 as shown 4 Install a new damper rubber 10 to the fuel pump filter as shown Install fuel pump stopper 11 25 fuel pump assembly 26 fuel pump unit holder 27 O ring ...

Page 50: ...s 22 with the fuel pump unit grooves 23 Check the dust seal lug 24 which is located the index mark 25 of the fuel pump base 13 9 Apply small amount of engine oil to a new O ring 26 Install a new O ring into the between the collar A 27 and collar B 28 of the fuel pump unit 29 10 Install the fuel pump unit 29 into the fuel tank 30 with its hose joint facing forward Be careful not to damage the fuel ...

Page 51: ...o the specified torque in the specified sequence as shown 8 lbf ft 11 N m 1 1 kgf m 14 Install the harness band clip 42 to the stopper cable guide 38 15 Install the stopper cable 37 to the hook 43 of the frame while holding the fuel tank 30 16 Connect the fuel line page 40 17 Increase the fuel pressure page 47 24 dust seal lug 31 fuel pump plate 32 fuel pump plate groove 33 fuel pump unit lug 24 3...

Page 52: ...rate the kickstarter starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion The engine will start up by increasing the fuel pressure If the engine does not start check all connector connections and or refer to an official Honda Service Manual page 160 for troubleshooting of the PGM FI symptom Fuel Pressure Increasing 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ...

Page 53: ...playing a circular API energy conserving or resource conserving service label on the container They may affect lubrication Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil...

Page 54: ...ark add the recommended oil until it reaches the upper level mark Do not overfill Reinstall the engine oil fill cap dipstick Repeat steps 1 5 6 Check that the O ring 4 is in good condition and replace it if necessary 7 Reinstall the engine oil fill cap dipstick 1 8 Check for oil leaks 1 Remove the engine guard A bolts washers 1 B bolt washer 2 collars 3 and engine guard 4 2 Run the engine at idle ...

Page 55: ... crankcase and install a new oil filter with the rubber seal 13 facing out away from the engine You should see the OUT SIDE mark 14 on the filter body near the seal Use a new Honda Genuine oil filter or a filter of equal quality specified for your model NOTICE If the oil filter is not installed properly it will cause serious engine damage 13 Apply engine oil to a new O ring and install it to the o...

Page 56: ...t 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 Refer to Important Safety Precautions on page 23 1 Position your CRF on an optional workstand or equivalent support so that it is securely held in place in an upri...

Page 57: ...time 7 Check the radiator air passages for clogging or damage Straighten bent fins 6 and remove insects mud or other obstructions with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surface Radiator should be replaced by your dealer unless you have the proper tools and service data and are mechanically qualified Refer to a...

Page 58: ...mance requirements Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality NOTICE Using the wrong air cleaner may result in premature engine wear Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling NOTICE Improper or lack of proper air cleaner maintenance can ca...

Page 59: ...tabs in the holes of the air cleaner element 8 Apply 0 05 0 19 oz 1 5 5 5 g of Pro Honda Foam Air Filter Sealer or equivalent to the air cleaner element contact area of the air cleaner housing 9 Install the air cleaner assembly 2 into the air cleaner housing stay 8 with the UP mark tab 9 facing up 10 Carefully position the sealing flange of the element to prevent dirt intrusion 11 Install and tigh...

Page 60: ... the transparent section of the crankcase breather tube If the breather tube overflows the air filter may become contaminated with engine oil causing poor engine performance 1 Remove the crankcase breather tube plug 1 from the crankcase breather tube 2 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plug Draining 1 crankcase breather tube plug 2 crankcase breat...

Page 61: ...r all the way in and back out one turn Tighten the lock nut securely Make the adjustment with the lower adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the throttle body It is also used if you cannot get the proper adjustment with the upper adjuster 1 Loosen the lock nut 1 2 Turn the adjuster 2 in direction ...

Page 62: ...ease to sliding surface of the throttle cable ends 1 Slide the dust cover 1 2 Remove the throttle housing bolts 2 3 Remove the throttle housing 3 from the throttle pipe 4 4 Thoroughly lubricate the throttle cable ends 5 with multi purpose grease 5 Install the throttle housing then tighten the throttle housing bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m NOTICE Align the lugs 6 of the wi...

Page 63: ...idle speed adjustment When pushed in the fast idle knob acts as the idle adjustment screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed 1 If the engine is cold start it and warm it up 3 minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift the transmission into neutral Start the engine 4 Adjust idle speed...

Page 64: ...lay 1 Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster Turning the cable end adjuster 1 in direction will increase freeplay and turning ...

Page 65: ...d of the holder 1 is aligned with the paint mark 2 on the handlebar and the securing bolts are tight Check the clutch cable for kinks or signs of wear If necessary have it replaced 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot bolt sliding surface with grease and or clutch cable with commercially available cable lubricant 2 Check the clutch cable for deter...

Page 66: ...bolts in a crisscross pattern in two or three progressive steps 4 Remove the clutch pressure plate 4 5 Check the operation of the bearing 5 with your finger The bearing should turn smoothly and quietly If the operation is not smooth refer to an official Honda Service Manual page 160 for bearing disassembly or see your dealer 6 Remove the clutch lifter 6 first then remove the clutch lifter rod 7 6 ...

Page 67: ...on Check the plate warpage on a surface plate using a feeler gauge Service Limit 0 006 in 0 15 mm Replace the clutch discs and plates as a set Check the clutch spring 3 for wear or damage Measure the thickness of each clutch spring Service Limit 1 917 in 48 70 mm Replace the clutch spring as a set If you feel the clutch slippage when replacing the clutch discs and plates replace the clutch springs...

Page 68: ...prings and bolts 12 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 8 Apply engine oil to a new O ring 13 and install it in the groove of the clutch cover 14 9 Install the cover by tightening the six cover bolts in a crisscross pattern in two or three steps to the specified torque 7 lbf ft 10 N m 1 0 kgf m 10 Install the engine oi...

Page 69: ...t of specifications replace the plug with a new one The recommended spark plug gap is 0 031 0 035 in 0 8 0 9 mm 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Press and hold the engine stop button and disengage the clutch by pulling the lever in Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electrode should appea...

Page 70: ...ormed while the engine is cold The valve clearance will change as engine temperature rises Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and hang the fuel tank to the left of the frame pages 33 34 2 Disconnect the breather tube 1 and spark plug cap 2 3 Remove the cylinder head cover socket bolts 3 rubber seals 4 cylinder head cover 5 and spar...

Page 71: ...n and align the T mark with the index mark Make sure that the decompressor weight 5 is upper position 5 Check the timing marks 6 on the cam sprocket aligns with the camshaft holder mating surface 7 of the cylinder head 6 The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving t...

Page 72: ...rance and exhaust valve clearance need adjustment see Camshaft Removal this page and select the correct shim for each valve 1 Record the intake valve and exhaust valve clearances this page Make sure the piston is at TDC on the compression stroke page 66 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 Valve Clearance Inspection 1 feeler gauge 3 camshaft cam lobes 2 intake ...

Page 73: ...ngs 8 As you remove the camshaft holder set rings may be sticking in the camshaft holder NOTICE Do not let the set rings fall into the crankcase If the set rings are remained on the camshaft holder remove the set rings carefully 5 Slide the left camshaft bearing 9 and remove the camshaft 10 by removing the cam chain 11 Suspend the cam chain with a piece of wire to prevent the chain from falling in...

Page 74: ... 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 exhaust valve seat if carbon deposits result in a calculated dimension of over 3 000 mm NOTICE Do not lap the intake valves They are titanium and have a thin oxide coat...

Page 75: ...denum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 to the following parts camshaft cam lobes plunger whole surface 5 Install the camshaft 6 onto the cylinder head with the decompressor weight 7 facing up as illustrated below 6 Install the cam chain 8 over the cam sprocket 9 While holding the left ca...

Page 76: ... pattern in two or three steps 11 Remove the tensioner stopper 22 from the cam chain tensioner lifter 12 Make sure that the piston is at TDC on the compression stroke page 66 Check that the timing mark 12 on the cam sprocket aligns with the camshaft holder mating surface 13 of the cylinder head If the timing mark doesn t align with the camshaft holder mating surface insert the tensioner stopper in...

Page 77: ... bolt 28 1 Install the spark plug page 64 2 Coat a new O ring 1 with engine oil and install it onto the crankshaft hole cap 2 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 lbf ft 15 N m 1 5 kgf m 23 T mark 24 primary drive gear bolt 25 index mark 24 25 23 IN 0 005 0 001 in 0 13 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 26 feeler...

Page 78: ... Check that the rubber seals 5 are in good condition replace them if necessary Install the rubber seals onto the cylinder head cover with the UP marks 6 facing up 4 Install the cylinder head cover 2 and tighten the cylinder head cover socket bolts 7 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Connect the spark plug cap 8 and breather tube 9 6 Install the fuel tank and seat pages 33 35 Cyli...

Page 79: ...and shims page 67 11 Disconnect the ignition coil A connector 1 and B connector 2 Remove the ignition coil 3 by removing the ignition coil bolts 4 12 Disconnect the ECT sensor connector 5 13 Loosen the radiator hose clamp screw 6 and disconnect the radiator hose 7 14 Remove the right radiator lower mounting bolt 8 and washer 9 15 Loosen the insulator band screw 10 and pull the throttle body 11 out...

Page 80: ...t the washers and cam chain fall into the crankcase 19 Remove the dowel pins 20 and cylinder head gasket 21 NOTICE Do not let the dowel pins and cam chain fall into the crankcase 20 Remove the cam chain guide 22 from the cylinder 23 13 cylinder head hanger bolts 14 cylinder head hanger plate bolts 15 left cylinder head hanger plate 16 right cylinder head hanger plate 14 13 15 Left side Right side ...

Page 81: ...of needle nose pliers 3 Press the piston pin 3 out of the piston 4 and remove the piston Under racing conditions the piston rings and piston pin should be replaced every 6 races or about every 15 0 hours of running NOTICE Be careful not to damage or shock the piston pin Do not clean the piston pin using a commercially available compound cleaner Spread each piston ring 1 and remove by lifting it up...

Page 82: ...he piston 3 4 Install the top ring 4 to the piston with 1R mark 5 side facing up NOTICE Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation 5 After installing the piston rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees ap...

Page 83: ...sulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 to the piston pin 6 outer surface Apply engine oil to the piston outer surface and piston pin hole inner surface Install the piston pin and new piston pin clips 7 NOTICE Be careful not to damage or shock the piston pin Use new pin clips Never reuse old clip...

Page 84: ... 3 NOTICE Do not let the dowel pins fall into the crankcase 5 Apply engine oil to the cylinder bore 4 piston outer surface and piston rings 5 Route the cam chain 6 through the cylinder Install the cylinder over the piston rings by hand while compressing the piston rings NOTICE Do not damage the piston rings and cylinder bore Do not let the cam chain fall into the crankcase Cylinder Installation 1 ...

Page 85: ...e mating surfaces when installing the cylinder head 5 Apply engine oil to all cylinder head bolt threads and seating surface Install the washers and cylinder head bolts 7 and tighten them to the specified torque in a crisscross pattern in two or three steps 37 lbf ft 50 N m 5 1 kgf m NOTICE Do not let the washers fall into the crankcase 6 Install the cylinder bolt 8 and tighten it to the specified...

Page 86: ...ator and tighten the insulator band screw 15 so the distance between the band ends is 0 43 0 04 in 11 0 1 0 mm 9 Install the right radiator lower mounting bolt 16 and washer 17 10 Connect the radiator hose 18 to the water hose joint 19 of the cylinder head as shown 11 Tighten the radiator hose clamp screw 20 as illustrated below 9 left cylinder head hanger plate 10 right cylinder head hanger plate...

Page 87: ...e 72 16 Install the cylinder head cover page 73 17 Install the spark plug page 64 18 Install the exhaust pipe page 115 19 Install the subframe page 37 and left and right mufflers page 113 20 Install the fuel tank and seat pages 33 35 21 Fill and bleed the cooling system page 143 Check for the following compression leaks abnormal engine noise secondary air leaks exhaust gas leaks coolant leaks oil ...

Page 88: ...sioner stopper 1 into a new cam chain tensioner lifter 2 Turn the tensioner stopper clockwise and lock the cam chain tensioner lifter by pushing the handle 3 to the cam chain tensioner lifter Tensioner stopper 07AMG 001A100 2 Install a new gasket 4 and cam chain tensioner lifter 2 Cam Chain Tensioner Lifter Removal 1 cam chain tensioner lifter cover bolt 2 sealing washer 3 tensioner stopper 4 cam ...

Page 89: ...e tensioner stopper 1 from the cam chain tensioner lifter 4 5 Install a new sealing washer 6 and tighten the cam chain tensioner lifter cover bolt 7 5 bolts 1 tensioner stopper 2 cam chain tensioner lifter 5 2 1 6 sealing washer new 7 cam chain tensioner lifter cover bolt 6 7 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 90: ...n 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 132 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 confused abou...

Page 91: ... from entering system 4 Loosen the fork bridge upper pinch bolts 8 5 Loosen the fork bolts assembly 9 but do not remove them yet 6 Loosen the fork damper assembly 10 using a lock nut wrench 11 but do not remove them Lock nut wrench 07WMA KZ30100 NOTICE Do not use an adjustable wrench to loosen the fork damper assembly it may damage them 7 Remove the disc cover 12 by removing disc cover socket bolt...

Page 92: ...11 Remove the fork protector socket bolts 23 and fork protectors 24 12 Loosen the fork bridge lower pinch bolts 25 then pull the fork legs down and out 13 Clean the fork assembly especially the sliding surface 26 of the slider and fork dust seal 27 14 Measure the length 28 between the axle holder and outer tube and record it before disassembling the fork 14 front axle nut 16 front axle shaft 15 ax...

Page 93: ...6 US oz 13 7 cm3 of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 68 F 20 C Pour the drained oil into a suitable container and dispose of it in an approved manner page 144 NOTICE Improper disposal of drained oil is harmful to the environment Recommended Fork Oil suggested oil Pro Honda HP Fork Oil SS 19 Fork Outer Tube Disassembly 1 outer tube 3 lock nut ...

Page 94: ...page 123 2 Install a new O ring 2 on the fork damper assembly 3 Apply the recommended fork oil to the O ring 3 Pull up the fork outer tube 1 slowly and temporarily tighten the fork damper assembly 4 using the a lock nut wrench 5 Lock nut wrench 07WMA KZ30100 1 Insert both fork legs into the fork clamps Tighten the fork bridge lower pinch bolts 1 to the specified torque 15 lbf ft 20 N m 2 0 kgf m F...

Page 95: ...ter the forks are installed loosen the fork bridge lower pinch bolts 1 and position the outer tubes so that the fork air pressure release screws 5 are in front of the compression damping adjuster 6 5 Align the groove 7 in the outer tube with the top surface of the upper fork bridge 8 6 Tighten the fork bridge lower pinch bolts 1 to the specified torque 15 lbf ft 20 N m 2 0 kgf m 7 Tighten the fork...

Page 96: ...ake caliper mounting bolts to the specified torque 22 lbf ft 30 N m 3 1 kgf m 12 Clean the surfaces where the axle and axle clamps contact each other Apply grease to each dust seal lips of the front wheel Install the left side collar 19 and right side collar 20 into the wheel hub 13 Install the front wheel between the fork legs while inserting the disc between the pads being careful not to damage ...

Page 97: ...l times to seat the axle and check front brake operation 18 While keeping the forks parallel alternately tighten the right axle pinch bolts 31 to the specified torque 15 lbf ft 20 N m 2 0 kgf m NOTICE To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 19 Install the disc cover 32 and tighten the disc cover socket bolts 33...

Page 98: ... and install the piston base 4 or mechanic s stopper tool between the axle holder 1 and fork center bolt lock nut Piston base 07958 2500001 6 Make the mechanic s stopper tool out of a thin piece of steel 0 08 in 2 0 mm thick as shown if you do not have a special tool 7 Hold the fork center bolt lock nut and remove the fork center bolt from the fork damper NOTICE Do not remove the lock nut from the...

Page 99: ...om the outer tube which can damage the guide bushings 12 To avoid damage hold both the outer tube and slider 1 Check the fork center bolt lock nut 1 is installed on the fork damper piston rod 2 properly NOTICE If the lock nut was removed the piston rod will fall into the fork damper and you will not be able to reassemble the fork damper 2 Loosen the fork bolt assembly 3 while holding the fork damp...

Page 100: ... fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper assembly 4 Recommended Oil Pro Honda HP Fork Oil SS 19 Recommended Amount 8 4 US oz 248 cm3 8 Pump the fork damper piston rod 2 slowly several times to bleed the air from the fork damper assembly 4 9 Apply fork oil to the fork bolt bushings 6 new O rings 7 and new piston ring 8 on the fork bolt assembly 3 ...

Page 101: ... assembly 4 12 Completely screw in the fork center bolt lock nut 1 to the fork damper piston rod 2 13 Check the fork damper piston rod sliding surface for damage 14 Hold the fork damper 4 in an upright position and pump the fork piston rod 2 3 9 in 100 mm slowly several times NOTICE Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked 2 fork damper piston rod ...

Page 102: ...an approved manner page 144 NOTICE Improper disposal of drained fluids is harmful to the environment 17 Blow out any oil from the oil hole 12 of the fork damper assembly 4 using compressed air Wipe off the oil completely from the fork damper If your cannot use compressed air remove the fork air pressure release screws 13 from the fork bolt assembly Hold the fork damper upside down for 20 minutes a...

Page 103: ...sure the thread length A as shown Standard 0 35 0 43 in 9 11 mm Wipe the oil completely off the fork damper 3 Apply recommended fork oil to the slider bushing 3 Install the seat stopper 4 back up ring 5 and spring seat collar 6 to the fork damper 7 Make sure the black side of the back up ring is seated on the seat stopper side 2 fork damper piston rod 4 fork damper assembly 4 2 Fork Dumper install...

Page 104: ...er tool between the axle holder 12 and fork center bolt lock nut Measure the thread length again Standard 0 35 0 43 in 9 11 mm Piston base 07958 2500001 8 Install the push rod 14 into the piston rod 15 until it stops 9 Apply fork oil to new O ring 16 and install it to the fork center bolt 17 Install the fork center bolt to the fork damper piston rod 15 by aligning the each flat side of the fork ce...

Page 105: ...ile pushing the fork damper Install the fork center bolt 17 to the axle holder and tighten it to the specified torque 51 lbf ft 69 N m 7 0 kgf m 13 Remove the fork from the vice 14 Measure the length between the axle holder and outer tube Standard 12 2 0 1 in 311 2 mm 15 Compare the length 18 at assembly and at disassembly They should be the same length If the length at assembly is longer than at ...

Page 106: ...nts Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 134 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and reb...

Page 107: ...ion the front brake lever farther away from the handgrip turn the adjuster 3 clockwise To position the front brake lever closer to the handgrip turn the adjuster counterclockwise 4 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m 5 Apply silicone grease to the contacting areas of the adjuster and knocker arm 4 6 Install the front brake lever cove...

Page 108: ... are no fluid leaks Check for deterioration or cracks in the hoses and fittings Rear Brake Fluid Level Check With the motorcycle in an upright position check the fluid level It should be above the LOWER mark 1 If the level is at or below the LOWER mark check the brake pads for wear page 105 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If th...

Page 109: ...ing Rear Brake Fluid NOTICE Spilled brake fluid will severely damage painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended brake fluid is Hon...

Page 110: ...ar side of the caliper to determine the brake pad wear If either brake pad is worn anywhere to a thickness of 0 04 in 1 0 mm both brake pads must be replaced Check that the front brake lever and rear brake pedal assemblies are positioned properly page 102 and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Brake Pad Wear 1...

Page 111: ...tant that the rim locks are secure to prevent tire slippage 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Spokes 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Locks 9 lbf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see an official Honda Service Manual for inspection instructions See an official Honda Service Manual...

Page 112: ...m tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding condition make changes a little at a time Take time to inspect your tires and wheels before you ride Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Loo...

Page 113: ... load range as the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Tire Replacement WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual ...

Page 114: ...e chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear Replace the drive chain page 111 if it has damage...

Page 115: ...x marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm 3 Tighten the rear axle nut to the specified torque 94 lbf ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 Turn the adjusting bolt counterclockwise until it touches the axle plates lightly Then tighten the chain adjuster lock nuts to the specified torque while holding the adjusting bo...

Page 116: ... any kinked joints straightened measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service 8 Lubricate the drive chain page 110 9 Pass the chain over the sprockets and join the ends of the chain with the...

Page 117: ...ve the side covers 1 and air cleaner housing covers 2 by removing the bolts 3 The procedure is the same for the both right and left side 3 Loosen the right muffler clamp bolt 4 and washer 5 4 Remove the right muffler mounting A bolt 6 B bolt 7 washer 8 and right muffler 9 Exhaust Pipe Muffler Inspection Muffler Removal 1 side covers 3 bolts 2 air cleaner housing covers 4 right muffler clamp bolt 5...

Page 118: ... torque 15 lbf ft 20 N m 2 0 kgf m 7 Remove the gasket 1 8 Install a new gasket onto the exhaust pipe 2 9 Align the cutout 3 of the right muffler 12 with the tab 5 of the right muffler clamp 13 10 Install the right muffler 12 10 left muffler clamp bolt 11 washer 12 left muffler mounting A bolt 13 left muffler mounting B bolt 14 washer 15 left muffler 11 10 13 14 12 15 Muffler Installation 1 gasket...

Page 119: ...cified torque 19 lbf ft 26 N m 2 7 kgf m 15 Install the air cleaner housing covers 19 and side covers 20 and then tighten the bolts 21 to the specified torque 7 lbf ft 10 N m 1 0 kgf m The procedure is the same for the both right and left side 16 Install the seat page 33 14 washer 15 right muffler mounting B bolt 16 right muffler mounting A bolt 17 right muffler clamp bolt 18 washer 15 14 16 17 18...

Page 120: ...fflers page 113 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 5 Tighten the left muffler clamp bolt left muffler mounting A bolt and B bolt page 113 6 Tighten the right muffler clamp bolt right muffler mounting A bolt and B bolt page 113 Exhaust Pipe Removal 1 exhaust pipe joint nuts 2 exhaust pipe 3 gasket 2 3 1 Exhaust P...

Page 121: ...adjustment procedures or see your dealer 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its original position where the end of the right handlebar holders 2 is aligned with the paint mark 3 3 Check the torque of the handlebar upper holder bolts 4 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first Periodically disconnect the clutch cables at their up...

Page 122: ...ilter cover bolts 7 10 1 0 6 Cylinder head bolts 37 50 5 1 7 Exhaust pipe joint nuts 15 21 2 1 8 Drive sprocket bolt 23 31 3 2 9 Engine oil drain bolt 13 18 1 8 10 Coolant drain bolt 7 10 1 0 1 cylinder head cover socket bolts 2 clutch cover bolts 3 water pump cover bolts 4 crankshaft hole cap 6 cylinder head bolts 7 exhaust pipe joint nuts 10 coolant drain bolt 3 4 10 7 6 1 2 1 cylinder head cove...

Page 123: ...reaser 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 Pro Honda Hondabrite and rinse with a low pressure garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Allow the engine muffler brakes and other high temperature parts to cool before washing 1 Rinse your CRF thorou...

Page 124: ... rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame NOTICE Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminum frame only The fuel tank is made of titanium material To remove mud or dust use ...

Page 125: ...120 Servicing Your Honda 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ BLANK PAGE ...

Page 126: ...petition 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 Engine Mode Select Button 122 Current Mode 122 Mode Selection 122 Front Suspension Adjustments 123 Front Suspension Air Pressure 123 Front Suspension Damping 124 Fork Springs 124 Fork Oil Adjustment 125 Rear Suspensio...

Page 127: ... 2 With your CRF stopped and the throttle closed push and hold the engine mode select button for 1 or more second Make sure that the fast idle knob is pushed in page 17 If the fast idle knob is pulled out the engine mode will not change 3 Release the engine mode select button The mode indicator will indicate a selected mode by the number of times the indicator blue blinks 4 Repeat steps 2 3 until ...

Page 128: ...a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race For this reason release built up air pressure in the fork legs between motos Be sure the fork is fully extended with the front tire off the ground when you release the pressure The standard air pressure is 0 psi 0 kPa 0 kgf cm2 You may r...

Page 129: ...n adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the compression and rebound adjusters are firmly located in a detent and not between positions Both compression and rebound damping can be increased by turning the adjuster clockwise The fork springs in CRF s are about right for riders weighing between 170 lb 77 kg and 200 l...

Page 130: ...1 US oz 387 cm3 Slightly stiffer as it nears full compression Minimum oil capacity 10 2 US oz 302 cm3 Slightly softer as it nears full compression No mark factory products Force N Stroke mm Oil capacity 13 1 US oz 387 cm3 MAX Oil capacity 11 9 US oz 352 cm3 STANDARD Oil capacity 10 2 US oz 302 cm3 MIN Standard oil capacity 12 1 US oz 357 cm3 Maximum oil capacity 13 3 US oz 392 cm3 Slightly stiffer...

Page 131: ...ring 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 Remove the subframe page 36 3 Check that the spring pre load is adjusted to the standard length Adjust as necessary by loosening the shock spring lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjusting nut changes the ...

Page 132: ...he compression damping adjusters make sure to use the proper size tool to avoid damage Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise Adjust the high speed compression damping adjuster in 1 4 turn increments Be sure the high speed compression adjuster is firmly located in a detent and not between positions High Speed Damping The high ...

Page 133: ...djuster 6 is located at the lower end of the rear shock absorber It has 17 clicks or more Turning the adjuster one full turn advances the adjuster 8 clicks When adjusting the rebound damping adjuster make sure to use the proper size tool to avoid damage Rebound damping can be increased by turning the adjuster clockwise Be sure that the rebound adjuster is firmly located in a detent and not between...

Page 134: ...ider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to measure the lo...

Page 135: ... even top out when you dismount your CRF Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the f...

Page 136: ...vent stiffer optional springs front and rear may help especially if you are heavier than the average rider Your CRF may be under sprung because of the added weight of the clinging mud 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 c...

Page 137: ...ping in one click increments Middle travel too soft Front end dives when cornering 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 adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments If that doesn t solve...

Page 138: ... 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 compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on large bumps especiall...

Page 139: ... further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large bumps 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 If it stil...

Page 140: ...ound the center electrode where it exits the porcelain Light gray or white color streaks the porcelain insulator and center electrode indicate lean air fuel mixture Wet or black sooty streaks on the porcelain indicate rich air fuel mixture NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose the piston may be damaged If a plug is too tight the threads may be damag...

Page 141: ... adjustment page 129 in the 3 7 4 5 in 95 115 mm range The position of the fork in the clamp is not adjustable Standard Position The groove 1 in the outer tube is aligned with the top surface of the upper fork bridge 2 Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be su...

Page 142: ...t 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 change in sp...

Page 143: ...they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual dema...

Page 144: ...e handlebar so that both gripping the bar and operating the controls are comfortable while both seated and standing while riding straight ahead and turning Tighten the forward handlebar upper holder bolts first The handlebar position may be moved backward either 0 1 in 3 mm using optional handlebar lower holders or 0 2 in 6 mm by rotating the standard holders 180 degrees Refer to an official Honda...

Page 145: ... 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ BLANK PAGE ...

Page 146: ...ansport and store your CRF as well as three troubleshooting flow charts Transporting Your Motorcycle 142 Storing Your Honda 143 Preparation for Storage 143 Removal from Storage 143 You the Environment 144 Troubleshooting 145 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 147: ...he front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on truck bed or trailer rail Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about hal...

Page 148: ...their recommended pressures 9 Place your CRF on an optional workstand or equivalent to raise both tires off the ground 10 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 11 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 12 Cover your CRF with a porous mater...

Page 149: ...nts away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline coolant and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and ot...

Page 150: ...ight 2 Check the tire pressure P 107 Faulty valve core Punctured tire 3 Check the engine speed change accordingly when clutch is engaged Clutch slipping Improperly adjusted clutch lever freeplay P 59 Worn clutch discs plates P 62 Warped clutch discs plates P 62 Weak clutch springs Sticking clutch lifter Additive in engine oil 4 Check the engine speed increase Dirty air cleaner element Clogged muff...

Page 151: ...Loose or disconnected ignition system wires Faulty engine stop button Faulty regulator rectifier Faulty condenser CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT WEAK OR INTERMITTENT SPARK POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Check the ignition timing Faulty ECM Faulty CKP sensor 2 Remove the air cleaner P 53 Not cleaned...

Page 152: ...dentification 148 Serial Numbers 148 Specifications 149 Torque Specifications 150 Nuts Bolts Fasteners 150 Oxygenated Fuels 153 Competition Logbook 154 Optional Parts List 156 Spare Parts Equipment 157 Spare Parts 157 General Tools 157 Honda Special Tools 157 Chemical Products 157 Other Products 157 Wiring Diagram 158 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 153: ...ay also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head The engine number 2 is stamped on the left crankcase Serial Numbers 1 VIN 1 2 engine number 2 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 154: ...damper 8 2 US oz 243 cm3 Item English Metric Engine Type Liquid cooled 4 stroke Cylinder arrangement Single 10 inclined from vertical Bore and stroke 3 7795 x 2 4464 in 96 000 x 62 138 mm Displacement 27 436 cu in 449 77 cm3 Compression ratio 13 5 1 Valve clearance cold Intake 0 005 0 001 in 0 13 0 03 mm Exhaust 0 011 0 001 in 0 28 0 03 mm Engine oil capacity 1 06 US qt 1 00 ℓ after draining after...

Page 155: ...over socket bolts 7 10 1 0 2 Clutch cover bolts 7 10 1 0 3 Water pump cover bolts 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 NOTE 1 5 Oil filter cover bolts 7 10 1 0 6 Cylinder head bolts 37 50 5 1 NOTE 2 7 Exhaust pipe joint nuts 15 21 2 1 8 Drive sprocket bolt 23 31 3 2 9 Engine oil drain bolt 13 18 1 8 NOTE 2 10 Coolant drain bolt 7 10 1 0 NOTES 1 Apply grease to the threads 2 Apply engine oil to...

Page 156: ...r plate nuts 19 26 2 7 11 Lower engine hanger nut 40 54 5 5 12 Cylinder head hanger bolts 40 54 5 5 13 Cylinder head hanger plate bolts 24 32 3 3 14 Rear suspension upper 32 44 4 5 NOTE 1 lower 32 44 4 5 NOTE 1 15 Swingarm pivot nut 65 88 9 0 NOTE 1 16 Fork fork dumper assembly 56 76 7 7 fork bolt assembly 22 30 3 0 17 Rear shock arm nuts swingarm side 38 52 5 3 NOTE 1 5 shock link side 38 52 5 3 ...

Page 157: ...tor socket bolts 5 2 7 0 0 7 NOTE 4 37 Left right muffler clamp bolt 15 20 2 0 38 Driven sprocket nuts 24 32 3 3 NOTE 1 39 Seat mounting bolts 19 26 2 7 40 Front brake reservoir cap screws 0 7 1 0 0 1 41 Rear brake reservoir cap bolts 0 7 1 0 0 1 42 Fork air pressure release screw 1 0 1 3 0 1 43 Right left muffler mounting bolt A 19 26 2 7 Right left muffler mounting bolt B 19 26 2 7 44 Throttle c...

Page 158: ...olume Gasoline containing ethanol may be marketed under the name Gasohol METHANOL methyl or wood alcohol up to 5 by Volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubb...

Page 159: ...engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guesstimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft...

Page 160: ...chnical Information 155 Date Running Time Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 161: ...Teeth Aluminum 50 Teeth Aluminum Drive chain size link RK520TXZ 120RJ Handlebar lower holder Standard 0 1 in 3 mm offset Optional no offset TOOLS Remarks Pin spanner A To adjust spring preload two spanners required Workstand For maintenance Air gauge For checking tire air pressure FRAME Remarks Fork spring 27 4 lbf in 4 8 N mm Standard Medium Optional Soft 26 3 lbf in 4 6 N mm Stiff 28 6 lbf in 5 ...

Page 162: ...andard needle nose channel lock set hammer plastic head syringe with adjustable stop air pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment Any special tools for your CRF purchased from your dealer Tensioner stopper 07AMG 001A100 Lock Nut Wrench 07WMA KZ30100 Spoke Wrench 07JMA MR60100 Spoke Wrench 070MA KZ30100 Piston Base 079...

Page 163: ...u Blue G Green R Red White W COLOR COMB GROUND MARKING Br Brown O Orange Lg Light Green P Pink Gr Gray O Bu Bl G Lg Bl W O O G G G G W Y Bu G G R P G R R Y Y G G R R Y G Y Y Y Y G G Bl G R Gr Bu Y Y Y Bu Y W Y Y Y Y Bu Y W Y Bl Bu Bl G W Bu Lg G Bu Bl G Lg Bl W Bl W G Bl O Bl G W Bl W Lg Br G P W O G Bu Bl G Y G R G R G R G R G R G R R Y R Y R Y Y G Y Bu Bl Bu R Y O Bl W Y Bu Y Gr Bu Br R G Bl G B...

Page 164: ...mer Information This section contains information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 160 Contacting Honda 161 Your Honda Dealer 162 The Honda Rider s Club USA only 163 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 165: ... the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Order On Line www helminc com Order Toll Free 1 888 CYCLE9...

Page 166: ...hip level If you wish to comment on your experiences with your CRF or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 Mailstop 100 4C 7B Telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 939 090...

Page 167: ...Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your Honda dealer can inform you about competition events in your area You ll also find that your dealer is a source of information on th...

Page 168: ...lub USA only Consumer Information 163 The Honda Rider s Club USA only The Honda Rider s Club of America HRCA sponsors local riding chapters at Authorized Honda Dealerships across the country 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 169: ...er air 53 cleaning appearance care 118 clutch system adjustment 59 competition logbook 154 consumer information 159 contacting Honda 161 controls 5 coolant 51 customer service 162 cylinder system 76 damping adjustments front 124 rear 127 dealer your Honda 162 diagram wiring 158 drive chain 109 engine does not start 145 flooded 17 idle speed 58 lacks power 145 mode select button 122 number 148 oil ...

Page 170: ...component locations 6 optional parts list 156 sprockets 137 oxygenated fuels 153 pads brake 105 parts optional 156 personal fit adjustments 139 pinging engine 38 plug spark 64 pre load rear suspension 126 pre ride inspection 13 protective apparel 2 rear suspension adjustment 126 Rider s Club Honda USA only 163 riding apparel 2 basic operation 15 before 11 important safety information 2 safety prec...

Page 171: ...spection 57 lubrication 57 tires air pressure 107 flat 107 selection 108 tools 157 torque specifications engine 150 frame 151 152 transporting 142 troubleshooting 145 tubes replacing 107 tuning tips 135 valve clearance 65 vehicle identification no VIN 148 washing your motorcycle 118 wheels 106 wiring diagram 158 T V W 0 ERRN ࢪ 㸰㸮㸯㸴ᖺ㸷 㸯 ࠉᮌ᭙ ࠉ ᚋ㸰 㸳㸴ศ ...

Page 172: ...schedule page 25 lists service frequencies for each race or about 2 5 hours every 3 races or about 7 5 hours every 6 races or about 15 0 hours every 9 races or about 22 5 hours and every 12 races or about 30 0 hours Pre ride Inspection Check the items listed on the Pre ride Inspection checklist each time before you ride page 13 Fuel Tank Capacity unleaded gasoline pump octane number of 91 or highe...

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