Honda CRF450X 2007 Owner'S Manual Download | Manualshive

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Exhaust Pipe/Muffler

Exhaust Pipe/Muffler Inspection

Check the mounting bolts and joint nuts for
tightness.
Check the exhaust pipe and muffler for cracks or
deformation.
A damaged exhaust pipe and muffler may reduce
engine performance.

(1) seat bolt

(3) right side cover

(2) side cover bolt

2. Loosen the muffler clamp bolt (4).
3. Remove the rear muffler mounting

bolt/washer (5), front muffler mounting bolt
(6) and muffler (7).

(4) muffler clamp bolt
(5) rear muffler mounting bolt/washer
(6) front muffler mounting bolt
(7) muffler

4. Remove the muffler gasket.

(1)

(3)

(2)

(5)

(7)

(6)

(4)

Muffler Removal

1. Remove the seat bolt (1), side cover bolt (2)

and right side cover (3).

62

Servicing Your Honda

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Summary of Contents for CRF450X 2007

Page 1: ...ational off road use or competition only and is covered ranty It does not conform to federal motor vehicle safety standards or US EPA On mission regulations and operation on public streets roads or highways is illegal The with a USDA qualified spark arrester If you need to cross a paved or public road get off cycle across mission related items except for competition use Any emission related modifi...

Page 2: ...ons but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway peration on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark ons exhaust emission regulations for off road motorcycles ...

Page 3: ...gh engine load at low vehicle speed the time it takes for the engine to overheat will be shortened especially when the ambient temperature is high Continuing to operate the unit in these conditions will result in engine damage Whenever you ride tread lightly By staying on established trails and riding only in approved areas you help protect the environment and keep off road riding areas open for t...

Page 4: ...ted with operating or maintaining a motorcycle You must use your own good n in a variety of forms including ty alert symbol and one of three signal words DANGER WARNING or CAUTION e KILLED or SERIOUSLY HURT if you don t follow instructions e KILLED or SERIOUSLY HURT if you don t follow instructions e HURT if you don t follow instructions Safety Reminders or Important Safety Precautions Safety ycle...

Page 5: ... Adjustments for Track Conditions 126 Suspension Adjustment Guidelines 127 Carburetor Adjustment Turning Tips 130 Chassis Adjustments 137 Gearing 138 Tire Selection for Track Conditions 139 Personal Fit Adjustments 140 Tips 141 Transporting Your Motorcycle 142 Storing Your Honda 143 You the Environment 145 Troubleshooting 146 Taking Care of the Unexpected 147 If a Fuse Blows 148 If Your Battery Is...

Page 6: ...Motorcycle Safety mportant p you on also f the Important Safety Information 2 Important Safety Precautions 2 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 ...

Page 7: ... be valuable If you need assistance ask your dealer about riding groups in your area Also be sure to read the Tips Practice Guide for the Off Highway Motorcyclist booklet that came with your CRF USA only Be Alert for Off Road Hazards The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always...

Page 8: ... these commonsense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability Place weight as close to the center of the motorcycle as possible Do not attach large or heavy items such as a sleeping bag or tent to the handlebar fork or front fender Check tha...

Page 9: ...nd clearance and lean angle limit suspension travel or steering travel alter your riding position or interfere with operating any controls Modifications We strongly advise you not to remove any original equipment or modify your CRF in any way that would change its design or operation Such changes could seriously impair your CRF s handling stability and braking making it unsafe to ride We also advi...

Page 10: ...afety 5 Safety Labels abels on your CRF Some labels warn you of potential hazards that could cause serious injury Others provide labels carefully and don t remove them read contact your Honda dealer for replacement ...

Page 11: ......

Page 12: ...Operating Controls 7 Operating Controls de It s on your Operation Component Locations 8 ...

Page 13: ...Locations clutch lever hot start lever front brake lever ne stop button throttle grip tripmeter start button choke knob shift lever kickstarter rear brake pedal ...

Page 14: ...Before Riding 9 you and elp get to items etor and Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 ...

Page 15: ...ure etor and n or for n ection ible hance or WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Be sure you always wear a helmet eye protection and other protective apparel when you ride ...

Page 16: ...buretor throttle operation 55 Engine idle speed for stable and proper RPM 136 Tires for damage or improper inflation pressure 92 Spokes for looseness 91 Rim locks for looseness 91 Front and rear suspension for proper operation 83 84 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication 96 Drive chain guide sliders and rollers for damage or wear 97 Exhaust...

Page 17: ......

Page 18: ...uctions ow to k in Safe Riding Precautions 14 Side Stand 14 Tripmeter 14 Starting Stopping the Engine 15 Preparation 15 Fuel Valve 15 Starting Procedure 15 Flooded Engine 16 How to Stop the Engine 16 Shifting Gears 17 Braking 18 Parking 19 Post ride Inspection 20 Break in Guidelines 21 ...

Page 19: ...out OFF and turn it until the meter shows all zeros 0 then push the knob in ON ctions please tion g the ge carbon n an 1 side stand 1 tripmeter 2 tripmeter reset knob 1 OFF ON 1 2 Side Stand The side stand 1 is used to support your CRF while parked page 19 To operate use your foot to lower the side stand until it is fully extended Before riding raise the side stand ...

Page 20: ...cold weather 2 Follow steps 1 4 under Normal Air Temperature 3 Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine NOTICE NOTICE Basic Operating Instructions 15 ol the buretor tempting m the ts the buretor ws fuel...

Page 21: ... the engine starts release the hot start lever Using the kickstarter 1 Do not use the choke 2 Shift the transmission into neutral with the throttle fully opened repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine Close the throttle 3 Pull the hot start lever all the way in and start the engine Do not open the throttle 4 As soon as the engine ...

Page 22: ...too high Downshift to a lower gear before you feel the engine laboring lugging at low rpm Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rpm is too high can cause engine damage To prevent transmission damage do not coast or tow the motorcycle for long distances with the engine off NOTICE NOTICE NOTICE Basic Operating Instructions 17 e down warme...

Page 23: ...ifting to aking as To h lever support ght foot e pedal and r brake the l of your ontrols rol then e raking or Either lip Any ur CRF or on d stop ld be se loss me rning e engine th lever in lling the the ou re ...

Page 24: ...Parking F the fuel e to Basic Operating Instructions 19 ...

Page 25: ...oughly d brush ed up F for 97 to ...

Page 26: ...Basic Operating Instructions 21 Break in Guidelines and how 15 rts and each ced ...

Page 27: ......

Page 28: ...Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids Filters Fuel System 41 Engine Oil 43 Transmission Oil 46 Coolant 48 Air Cleaner 51 Crankcase Breather 53 Engine Throttle 54 Clutch System 56 Hot Start Lever 60 Spark Plug 61 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Cle...

Page 29: ...ore you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual ntenance l for It will e ride pecially to be this ance hedule ubject lly wet pecially stly crash ajor repairs ...

Page 30: ...quired To help prevent the motorcycle from falling over park it on a firm level surface using the side stand or an optional workstand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a non flammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related pa...

Page 31: ...ical knowledge Certain items particularly those marked and may require more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page 166 In the interest of safety we recommend these items be serviced only by your Honda dealer...

Page 32: ... I I C I I I R R I I I R I I I I I I I C I C I I I R R I I R I I R I I I I I I I I I I I 41 42 55 51 53 61 66 43 44 136 48 48 46 95 97 97 88 90 87 103 56 94 83 84 65 99 154 156 91 92 98 NOTE mi km Month 100 150 1 600 1 000 6 1 200 2 000 12 I L every 300 mi 500 km or 3 months C every 1 000 mi 1 600 km or every 100 operating hours 1 800 3 000 18 2 400 4 000 24 Refer to Page Whichever Comes First Ini...

Page 33: ... 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 55 60 51 53 61 48 66 43 44 136 77 77 46 48 95 97 97 96 96 88 90 87 56 98 62 83 84 32 85 113 99 154 156 91 92 98 I I C I I I I I I I I L I I I I I I I I I L I I I I R L R I R R R R R I R CY NOTE Ref Page About 2 5 hours About 7 5 hours About 15 0 hours About 22 5 hours About 30 0 hours o the Honda shop manual condition Machine subjected to severe ...

Page 34: ...Servicing Your Honda 29 General Competition Maintenance nd using art with d tighten cross ent point n ace Grease d tall new lips tallation ...

Page 35: ...r cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oili...

Page 36: ...its contents page 133 For maximum efficiency drain and replace fuel that has remained in your fuel tank for more than a month Gaskets Always use new gaskets when reassembling components Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Pro Honda Hondalock o...

Page 37: ...lant indicates a worn or damaged mechanical seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced Fork Oil Performance Disassemble clean and inspect the front fork and replace oil regularly Contamination due to the tiny metal particles produced from the normal action of the fork as well as normal oil breakdown will deteriorate the performa...

Page 38: ...s important to the long term performance of your CRF to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rust in...

Page 39: ...ition Maintenance st to stled s brushes d are he many on the lt water t dry it arts leaners ...

Page 40: ...damping adjuster rear suspension low speed compression damping adjuster rear suspension rebound damping adjuster front suspension compression damping adjuster transmission oil filler cap transmission oil check bolt front suspension rebound damping adjuster rear brake pedal rear brake fluid reservoir rear brake caliper h lever hot start lever front brake lever fuel fill cap throttle grip radiator c...

Page 41: ...t prong 3 with the seat bracket 4 and seat rear prongs 5 with the tabs 6 of the frame 2 Install and tighten the seat bolts 1 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat bolts 2 seat 3 seat front prong 4 seat bracket 5 seat rear prongs 6 tabs 1 3 5 2 1 4 6 ...

Page 42: ...ct the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 8 fuel line 10 bolt 9 fuel valve WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 4 7 6 5 ...

Page 43: ...ts tab 11 with subframe 12 8 shroud 12 subframe 11 tab 9 Install the shroud B bolts 9 and shroud A bolts collars 10 9 shroud B bolts 10 shroud A bolts collars nd be 6 11 Install the seat page 36 10 Tighten the shroud B bolts to the specified torque 3 7 lbf ft 5 N m 0 5 kgf m ...

Page 44: ...oot clamp 6 Loosen the subframe upper mounting bolts 9 and remove the subframe lower mounting bolts 10 9 subframe upper mounting bolts 10 subframe lower mounting bolts Servicing Your Honda 39 7 Lift the subframe 11 as shown Tighten the subframe upper mounting bolts to the specified torque 22 lbf ft 30 N m 3 1 kgf m by side 6 5 8 7 10 9 90 11 11 subframe ver bolt ver ...

Page 45: ...ing cover 8 and turn the quick fastener 9 clockwise 6 left side cover 8 air cleaner housing cover 7 left side cover bolt 9 quick fastener 6 Install the right side cover 10 and right side cover bolt 11 bolts ubframe g the air etor bolts 3 bolts gf m gf m 5 4 4 screw 5 air cleaner connecting boot clamp 6 7 9 8 10 11 10 right side cover 11 right side cover bolt 7 Install the seat page 36 ...

Page 46: ...g the tank There should be no fuel in the filler neck 3 Close the fuel fill cap by turning the cap clockwise and insert the breather tube in the steering stem nut 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 Fuel Line 1 fuel line 1...

Page 47: ...left side filter rburetor an nk by oint ondition se order ll the eck for 3 fuel filter 4 O ring 4 3 ...

Page 48: ...denum additives 4 stroke oil or an equivalent viscosity weight SAE 10W 30 JASO T 903 standard MA Your CRF does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication Oil is a major factor affecting the peformance and service life of the engine Other viscos...

Page 49: ...l mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Install the engine oil filler cap dipstick securely 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 dipstick 1 fro...

Page 50: ...d properly it will cause serious engine damage 13 Apply engine oil to the O ring and install it to the oil filter cover 14 Install the oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m 15 Install the left engine guard and bolt then tighten it NOTICE 16 Fill the crankcase with the recommended oil Capacit...

Page 51: ...utch 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 SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 30 MA without friction modifiers such as molybdenum additives Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke eng...

Page 52: ...n oil filler cap Repeat step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil filler cap 1...

Page 53: ...Precautions on page 25 1 With the engine at normal operating temperature check the coolant level in the reserve tank It should be between the UPPER 1 and LOWER 2 level marks If the reserve tank 3 is empty or if coolant loss is excessive check for leaks and see your Honda dealer for repair 1 UPPER level mark 3 reserve tank 2 LOWER level mark 2 Remove the reserve tank cap 4 Always add coolant to the...

Page 54: ... can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap Servicing Your Honda 49 ee the oting of seness s ected 3 below Make eaks al seal is ck hole See the r Honda al or the replaced 1 water hoses 2 siphon hose 3 water leakage check hole 4 water pump cover To properly dispose of drained coolant refer to You the Enviro...

Page 55: ...e 3 4 times to bleed air from the system Stop the engine and if necessary add coolant up to the proper level Reinstall the radiator cap Check the level of coolant in the reserve tank and fill to the UPPER level if it is low If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage 5 Install the radiator reserve tank cap NOTIC...

Page 56: ...element tab 7 tab 5 Wash the air cleaner element in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner element is made in two pieces inner and outer which cannot be separated 6 Clean the inside of the air cleaner housing 7 Allow the air cleaner element to dry thoroughly After drying soak the air cleaner element in clean Pro Hond...

Page 57: ...nter the engine and cause rapid wear of the piston rings and cylinder NOTICE e ealing nt and holder hole 8 3 he air of the eaner 1 of the cleaner d 3 1 air cleaner housing cover 2 quick fastener 2 1 12 Close the air cleaner housing cover 1 and turn the quick fastener 2 clockwise ...

Page 58: ...Crankcase Breather Servicing Your Honda 53 dden in its in the lug 1 ts into a plug ...

Page 59: ... Install the fuel tank page 38 If you can t get the freeplay within the specified range see your Honda dealer 5 6 1 Pull the dust cover 2 back 2 Loosen the upper lock nut 3 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten the lock nut to the specified torque 3 0 lbf ft 4 N m 0 4 kgf m Install the dust ...

Page 60: ...Throttle sitioned ht tle 1 teering our bles buretor it in all ally emature Servicing Your Honda 55 ...

Page 61: ... near its limit or the correct freeplay cannot be obtained 3 lock nut increase 4 integral cable adjuster decrease 1 Turn the cable end adjuster in direction seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engine pull the clutch lever in and shift into gear ...

Page 62: ...2 pin 5 dust seals 3 pivot bolt 6 clutch cover bolts 7 clutch cover 8 O ring 4 Loosen the clutch spring bolts in a crisscross pattern in 2 or 3 progressive steps Remove the six clutch spring bolts and clutch springs 9 5 Remove the clutch pressure plate 10 3 Remove the six clutch cover bolts 6 clutch cover 7 and O ring 8 Check that the O ring is in good condition and replace it if necessary 9 clutc...

Page 63: ... plate warpage on a surface plate using a feeler gauge Measure the thickness of each clutch plate Service Limit 0 006 in 0 15 mm Replace the clutch discs and plates as a set 1 Clutch Spring Inspection 1 clutch spring Measure the free length of each spring Service Limit 1 72 in 43 7 mm Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch plates have be...

Page 64: ... 14 pivot bolt 17 pin 15 Fill the crankcase with transmission oil page 47 Servicing Your Honda 59 15 17 16 14 13 12 7 Install the clutch pressure plate 8 8 Install the six clutch springs and bolts 9 9 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 9 lbf ft 12 N m 1 2 kgf m 8 clutch pressure plate 9 clutch spring bolts springs 10 O ring 11 clutch cover 9 8 10 11 1...

Page 65: ...le adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster clockwise will increase freeplay and turning it counterclockwise will decrease freeplay After adjustment tighten the lock nut 3 lock nut increase 4 adjuster decrease 2 4 3 ...

Page 66: ... then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If you re using a new plug ride for at least ten minutes before taking a plug reading a brand new plug will not color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a pro...

Page 67: ...emove the rear muffler mounting bolt washer 5 front muffler mounting bolt 6 and muffler 7 4 muffler clamp bolt 5 rear muffler mounting bolt washer 6 front muffler mounting bolt 7 muffler 4 Remove the muffler gasket 1 3 2 5 7 6 4 Muffler Removal 1 Remove the seat bolt 1 side cover bolt 2 and right side cover 3 ...

Page 68: ... 19 lbf ft 26 N m 2 7 kgf m 5 Tighten the muffler clamp bolt 8 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 6 front muffler mounting bolt 7 rear muffler mounting bolt washer 8 muffler clamp bolt 9 right side cover 11 seat bolt 10 side cover bolt 6 Install the right side cover 9 and side cover bolt 10 7 Install the seat bolt 11 and tighten it to the specified torque 19 lbf ft 26 N m 2 7 kgf m...

Page 69: ... pipe gasket 1 2 Install the exhaust pipe 2 and exhaust pipe joint nuts 3 3 Tighten the nuts 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 4 Install the muffler page 63 ket 3 3 1 2 3 ...

Page 70: ...n deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary 4 Install a new gasket and the spark arrester in the muffler and tighten the four bolts 1 to the specified torque 9 lbf ft 12 N m 1 2 kgf m 1 bolts 1 ...

Page 71: ...g hole packing and cylinder head cover packing Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 1 breather tube 2 spark plug cap 4 Remove the cylinder head cover A bolt 3 cylinder head cover B bolts 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 1 5 3 4 1 se and rance au...

Page 72: ...ment see Camshaft Holder Assembly Removal page 68 and select the correct shim for each valve 5 3 2 1 1 5 4 1 feeler gauge 2 valve lifters 3 intake cam lobes Valve Clearance IN 0 006 0 001 in 0 16 0 03 mm rimary punch gns with ase either ke mark kwise h the e piston when closed moving it is an nd that e If it is e gn the 5 exhaust rocker arm Valve Clearance And Decompressor Arm Clearance Inspection...

Page 73: ...ifter cover bolt 1 and sealing washer 2 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool Tensioner stopper 070MG 0010100 3 Turn the tensioner shaft clockwise with the tensioner stopper 3 until it stops in order to retract the tensioner fully Then insert the tensioner stopper fully to hold the stopper in the fully retracted position 3 tensioner stopper 2 1 3 ...

Page 74: ...nd camshaft holder assembly 8 The intake valve lifter and intake valve shim may be sticking in the camshaft holder assembly Keep the intake valve lifters and shims so as to allow identification of the originally installed location such as intake or exhaust right or left 7 camshaft holder bolts 8 camshaft holder assembly 8 Remove the intake valve lifters 9 and shims 10 Do not let the valve lifters ...

Page 75: ...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 valve seat if carbon deposits result in a calculated dimension of over 3 000 mm 1...

Page 76: ...lder assembly 3 4 Install the camshaft holder assembly 3 onto the cylinder head with the intake cam lobes 4 facing up as illustrated below Apply oil to the camshaft holder assembly bolt threads and seating surface Tighten the camshaft holder assembly bolts 5 to the specified torque 10 lbf ft 14 N m 1 4 kgf m Tighten the camshaft holder assembly bolts in a crisscross pattern in 2 or 3 steps 3 camsh...

Page 77: ...g width 0 26 0 04 in 6 5 1 mm from tip Temporarily install the cam sprocket bolt 13 by aligning the bolt holes of the cam sprocket and camshaft Rotate the primary drive gear bolt crankshaft clockwise one turn and tighten the other sprocket bolt 13 to the specified torque 15 lbf ft 20 N m 2 0 kgf m Turn the primary drive gear bolt crankshaft clockwise one turn and tighten the other sprocket bolt to...

Page 78: ...uge 5 6 4 1 1 feeler gauge 5 adjusting screw 4 lock nut 6 right side rocker arm Recheck the decompressor arm clearance 3 Loosen the lock nut 4 and adjusting screw 5 Insert the feeler gauge 1 between the adjusting screw and right side rocker arm 7 DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0 011 in 0 28 mm decompressor ...

Page 79: ... replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 3 4 3 cylinder head cover packing 4 cylinder head cover 3 Install the cylinder head cover 4 4 Tighten the cylinder head cover A bolt 5 and cylinder head cover B bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 4 5 6 4 cylinder head cover 5 cylinder head cover A bolt 6 cylinder hea...

Page 80: ...nnect the radiator hose 12 6 left radiator grill 7 left radiator lower mounting bolt washer Servicing Your Honda 75 cont d 10 Remove the bolts 3 O ring 4 and PAIR control valve 5 11 Remove the camshaft holder assembly lifters and shims page 68 12 Remove the left radiator grill 6 and left radiator lower mounting bolt washer 7 1 2 4 3 5 3 9 8 10 11 12 6 7 13 Disconnet the primary wire connector 8 Re...

Page 81: ...the cylinder head nuts 22 in a crisscross pattern in 2 or 3 steps Remove the cylinder head nuts washers and cylinder head 23 Do not let the cylinder head nuts and washers fall into the crankcase NOTICE 26 25 24 24 dowel pins 26 cam chain guide 25 cylinder head gasket 19 Remove the dowel pins 24 cylinder head gasket 25 and cam chain guide 26 Do not let the dowel pins and cam chain fall into the cra...

Page 82: ...s 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 1 piston pin clip 3 piston 2...

Page 83: ...oil ring install 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 top...

Page 84: ...nstallation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt from entering the engine 2 Clean off any gasket material from the gasket surface of the crankcase 3 Remove the shop towel 4 Install the dowel pins 1 and new cylinder gasket 2 Do not let the dowel pins fall into the crankcase NOTICE 1 dowel pins 2 cylinder gasket 5 Clean the any gasket material off the cylinder...

Page 85: ...bs 9 in the cylinder cut outs 10 Push the cam chain guide until it bottoms in the crankcase guide hole 8 cam chain guide 9 cam chain guide tabs 10 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder head gasket 2 Do not let the dowel pins fall into the crankcase NOTICE 1 dowel pins 2 cylinder head gasket 3 8 10 9 6 cylinder bolt 7 breather tube 6 7 2 1 ...

Page 86: ...ylinder head bolts 5 Install the left engine hanger plate 7 right engine hanger plate 8 clutch cable stay 9 and engine hanger plate bolts 10 and tighten the engine hanger plate bolts until the engine hanger plates lightly contact the frame 6 Install the engine hanger bolt 11 fuel hose guide 12 and engine hanger nut 13 and tighten the engine hanger nut until it lightly contacts the engine hanger pl...

Page 87: ...vacuum hose 23 O ring 26 air suction hose 24 bolts 20 cylinder mp 15 wire 17 bolts 19 connector 21 11 Install the camshaft holder assembly page 71 12 Install the crankshaft hole cap page 74 13 Install the cylinder head cover page 74 14 Install the spark plug and plug cap page 61 24 22 24 23 25 26 17 Install the exhaust pipe page 64 18 Install the carburetor page 135 19 Install the subframe and muf...

Page 88: ...amping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems 1 Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt 2 Check for signs of oil leakage Damaged or leaking fork seals should be replaced before your CRF is ridden 1 fork protector 2 dust seal 3 Inspect the wear rings...

Page 89: ...torcycle up and down and check for smooth suspension action 2 Lift the subframe to the upright position page 39 3 Check for a broken or collapsed spring 4 Check the shock absorber 1 for a bent shaft or oil leaks 1 shock absorber 5 Push the rear wheel sideways to check for worn or loose swingarm bearings There should be no movement If there is have the bearings replaced by your Honda dealer 1 ...

Page 90: ...the outer tube 1 Drain the fork oil from the oil hole 8 of the fork damper 1 outer tube 8 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of 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 ...

Page 91: ...ity 11 3 US oz 335 cm3 Maximum oil capacity 13 7 US oz 405 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 5 US oz 309 cm3 3 scribe marks Be sure the oil capacity is the same in both fork legs 6 Check that the O ring 9 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring Temporarily install the...

Page 92: ...y Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay 3 8 13 16 in 10 20 mm 6 Apply silicone grease to the contacting faces of the adjuster and piston 3 Rear Brake Pedal Height The brake pedal height should be approximately level with the right footpeg 1 Loosen the lock nut 1 and turn the adjusting bolt 2 in d...

Page 93: ... level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 90 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake pedal freeplay exceeds 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding 2 ...

Page 94: ...es of fluid they may not be compatible The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent NOTICE 5 bolts 8 diaphragm 6 reservoir cap 9 upper level mark 7 set plate 1 Remove the bolts 5 reservoir cap 6 set plate 7 and diaphragm 8 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 9 Do not overfill 3 Reinstall the diaphragm set plate and reservoir cap Do not...

Page 95: ... mm both pads must be replaced 4 brake pads 6 brake disc 5 rear brake caliper Other Inspections Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings m thickness icator eplace ace 0 04 in 1 mm 0 04 in 1 mm 1 replace 0 04 in 1 mm minimum thickness indicat...

Page 96: ...t Spoke Nut 2 7 lbf ft 3 68 N m 0 4 kgf m Rear Spoke Nut 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Lock Nut 9 lbf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see the Honda Service Manual for inspection instructions Axles Wheel Bearings See the Honda Service Manual for inspection information 1 Check the axle shaft for runout 2 Check the condition of the wheel bearings 4 3 ...

Page 97: ...heels 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 Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3...

Page 98: ...Servicing Your Honda 93 Tires Tubes signed ng broad he a tire d and if which es ual ...

Page 99: ...mage edom of the h ...

Page 100: ...nother this indicates that some of the links are either worn kinked or binding Kinking and binding can frequently be eliminated by thorough cleaning and lubrication If the drive chain requires adjustment procedure is as follows NOTICE Adjustment 1 Loosen the rear axle nut 1 2 Loosen the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decreace slack or clockwise to increase slack Ali...

Page 101: ... or use new sprockets with a badly worn drive chain Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Use of a new chain with worn sprockets will cause rapid chain wear NOTICE 5 Lubricate the drive chain 6 Recheck chai...

Page 102: ... if below the service limit Service Limit UPPER ROLLER 1 5 in 39 mm LOWER ROLLER 1 4 in 35 mm 2 Replace the roller if necessary as follows Install the upper drive chain roller Green 1 with the mark 2 facing toward the frame and lower drive chain roller Black 3 with the mark 2 side facing out Tighten the drive chain roller bolt and nut to the specified torque Upper roller bolt 9 lbf ft 12 N m 1 2 k...

Page 103: ...er holder bolts 2 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first 1 handlebar 2 handlebar upper holder bolts Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant If the clutch lever hot start lever and throttle operation is not smooth replace the cable B...

Page 104: ...e Procedures ers ue m kgf m 1 0 2 1 1 0 1 5 1 0 1 0 1 0 1 0 1 0 3 2 1 6 2 2 2 3 8 9 10 7 12 11 LEFT SIDE 7 cylinder bolt 8 oil filter cover bolts 9 cylinder head bolts 10 drive sprocket bolt 11 engine oil drain bolt 12 transmission oil drain bolt ...

Page 105: ...ated under the seat Removal 1 Remove the seat page 36 2 Remove the battery band 1 3 Remove the positive terminal cover 2 4 Disconnect the negative terminal 3 first then the positive terminal 4 and remove the battery 5 1 battery band 4 positive terminal 2 positive terminal cover 5 battery 3 negative terminal 1 battery band 5 Unless you have been riding regulary charge the battery see page 101 6 Sto...

Page 106: ...Battery Servicing Your Honda 101 e with uctions mage er 1 ft g longer harger otorcycle ...

Page 107: ...ight bulb out push and turn the headlight bulb socket 6 counterclockwise 6 headlight bulb socket 4 Install a new headlight bulb 7 into the headlight unit while aligning the tab 8 with the groove 9 of the headlight unit If you touch the bulb with your bare hands clean it with a cloth moistened with denatured alcohol to prevent early bulb failure 5 While pushing the headlight bulb socket 6 turn it c...

Page 108: ...attery for easy engine starting There is a possibility of damage to the lighting system if the battery is carelessly removed Never kick start the engine without the battery connected If it becomes necessary to kick start the engine with the battery removed remove the relays to the battery to prevent damage to the lighting ...

Page 109: ...ly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CRF with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damag...

Page 110: ...otch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame Do not use steel wool to clean the frame as it could damage or discolor the frame surface...

Page 111: ......

Page 112: ...108 Rear Suspension Adjustments 122 Suspension Adjustments for Track Conditions 126 Suspension Adjustment Guidelines 127 Carburetor Adjustment Tuning Tips 130 Chassis Adjustments 137 Gearing 138 Tire Selection for Track Conditions 139 Personal Fit Adjustments 140 Adjustments for Competition 107 Adjustments for Competition ...

Page 113: ...heck that the O ring 2 is in good condition 4 Install the pressure release screw to the specified torque 0 9 lbf ft 1 2 N m 0 1 kgf m 1 pressure release screw 2 O ring 1 2 Front Suspension Damping Rebound Damping Adjustment The fork rebound damping adjuster 1 has 16 positions or more Turning the adjuster screw one full turn clockwise advances the adjuster four positions To adjust the rebound dampi...

Page 114: ...hing 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 turn and lower the oil level in increments of 0 2 ...

Page 115: ...pinch bolts 17 then pull the fork legs down and out 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 difficulty in fitting the brake disc between the brake pads 7 tripmeter cable 9 axle pinch bolts 8 front axle nut 10 front axle shaft 9 Remove the fork protector bolts 11 tripmeter cable clamp screws 12 brake hose...

Page 116: ... guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE nch end 21 outer tube 25 oil hole the fork the outer lider 22 21 24 21 25 cont d 16 Temporarily install the fork damper to the outer tube 17 Set the axle holder 26 of the slider in a vise with a piece of wood or soft jaws to avoid damage Over tightening the vise c...

Page 117: ...d lock nut 29 while pushing the fork damper Be careful not to damage the lock nut and fork center bolt hole NOTICE 24 Remove the fork damper assembly 31 from the fork assembly 32 Remove the fork from the vise Remove the fork spring 33 from the fork assembly 26 axle holder 30 push rod 29 lock nut 31 fork damper assembly 33 fork spring 32 fork assembly 26 28 29 27 26 30 29 31 33 32 m the ng the olt ...

Page 118: ...owly several times to bleed the air from the fork damper 1 1 fork damper 5 fork damper piston rod 3 2 2 1 1 1 4 1 5 7 Extend the fork damper piston rod to maximum length Pour the recommended fork oil 4 into the fork damper 1 Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 5 US oz 192 cm3 6 8 Imp oz 4 Remove the fork cap assembly 2 from the fork damper 1 Be careful not ...

Page 119: ...damper 3 lock nut wrench 2 fork cap assembly 13 Hold the fork damper 1 in an upright position and pump the fork damper piston rod 5 to 3 9 in 100 mm slowly several times 1 3 2 11 Place the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage 12 Tighten the fork cap assembly 2 to the specified torque by holding the fork damper 1 using the lock nut wrench 3 The fork cap assembly...

Page 120: ...g chamber through the oil hole and cause 5 9 US oz 175 cm3 of fork fluid to be left in the chamber ft jaws per 1 ork k stroked 17 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 18 If you can not use compressed air remove the pressure release screw 10 on the fork cap Hold the fork damper upside down for 10 minute...

Page 121: ... off the fork spring 3 Install the fork spring into the fork assembly Temporarily install the fork damper assembly 4 to the fork assembly 1 1 fork assembly 4 fork damper assembly 3 fork spring Amount of fork oil left in the fork without damper and spring unit cc minute C F 30 86 20 68 10 50 0 32 5 7 1 10 6 11 8 12 9 10 5 9 8 2 8 3 10 6 20 4 7 7 1 7 2 9 4 35 4 2 5 9 6 2 8 2 55 3 5 5 6 5 8 7 9 85 3 ...

Page 122: ... to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 2 lock nut 8 fork center bolt 10 Apply fork oil to the fork center bolt O ring 9 Remove the piston base or mechanic s stopper tool while pushing to the fork damper Install the fork center bolt to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 9 fork center bolt O ring 11 Measure the length 10 between the axle ho...

Page 123: ...Maximum oil capacity 13 8 US oz 407 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 5 US oz 311 cm3 No mark factory products 2 scribe marks 1 scribe mark aftermarket parts or Optional Stiffer 0 49 kgf mm Fork Spring Standard oil capacity 11 3 US oz 335 cm3 Maximum oil capacity 13 7 US oz 405 cm3 Slightly stiffer as it nears ful...

Page 124: ...tually applied to the fork damper 18 For ease of releasing air pressure after the forks are installed loosen the bottom bridge pinch bolts and position the outer tubes so that the pressure release screws are in front of the compression damping adjusters Align 15 the top surface of the top bridge 16 with the outer tube 1 upper surface as shown 19 Tighten the bottom bridge pinch bolts 13 to the spec...

Page 125: ... fork legs while inserting the disc between the pads and align 29 the tab of the tripmeter gear box as shown Check that the tripmeter gear box O ring 30 is in good condition replace it if necessary Apply a thin layer of grease to the axle 31 and insert the axle from the right side 26 Install and tighten the axle nut 32 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m Tighten the left axle pinch ...

Page 126: ... pinch bolts be sure the axle is seated firmly onto the right fork leg clamp inner surface 31 Connect the tripmeter cable 38 and tighten the lock nut securely NOTICE 32 Install the disc cover 39 and tighten the bolts 40 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m 37 right axle pinch bolts 38 tripmeter cable 39 disc cover 40 bolts 33 Return the rebound damping adjuster and compression dampin...

Page 127: ...ngth Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 1 16 in 1 5 mm 1 lock nut 3 pin spanners 2 adjusting nut 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanners 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 9 8 in ...

Page 128: ...ightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 3 4 1 1 4 turns and the punch marks are aligned Low Speed Compression Damping The low speed compression damping can be adjusted by turning the center screw of the compression adjuster The low speed compression damping adjuster has 13 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4...

Page 129: ...RF set at the standard race sag s very eel travel with you he race of the oad blishes on ight should parel ecessary rom the the ustrated rear with nd kstand he 3 Measure the loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both ...

Page 130: ...too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that is too stiff for your weight will not allow the rear tire to hook up under acceleration and ...

Page 131: ...s for Track Conditions d g front amping d bumps between ver pension up and ngs are may be of the y ffect you mal but on and ing the mall p better l returns nd sult is a ...

Page 132: ... 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 the problem install the optional stiff spring If initial and middle travel aren t st...

Page 133: ...btained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments If initial and middle travel aren t stiff Test stiffer compression ...

Page 134: ... speed compression adjustments simultaneously 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 If it still feels stiff replace the spring with a softer spring optional and begin with the standard sett...

Page 135: ...ture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mixture must be delivered to the cylinder when a hot engine is being started When the hot start lever is pulled back the hot start valve 1 opens allowing air to be supplied to the main bore 2 through the hot start air passage ...

Page 136: ...4 pilot outlet 2 slow air jet 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters the venturi past the needle jet Baffle Plate The baffle plate 5 prevents foaming of fuel or abnormal fuel level around the main jet Float Bowl The float 6 and float valve 7 operate to maintain a constant lev...

Page 137: ...ng nut 3 shock absorber upper mounting bolt 8 Disconnect the throttle position sensor connector 4 4 throttle position sensor connector 9 Loosen the insulator band screw 5 and remove the carburetor 6 from the insulator 7 5 insulator band screw 7 insulator 6 carburetor 10 Loosen the hot start cable nut 8 and remove the hot start valve 9 from the carburetor 8 hot start cable nut 9 hot start valve 2 3...

Page 138: ... the jet needle holder 4 and jet needle 5 from the throttle valve 6 4 jet needle holder 5 jet needle 6 throttle valve 3 Remove the link arm torx screw 7 When installing the link arm torx screw apply a locking agent to the link arm torx screw threads 4 Remove the throttle valve 8 throttle valve roller 9 and floating valve 10 7 link arm torx screw 9 throttle valve roller 8 throttle valve 10 floating...

Page 139: ...elerator pump cover 16 spring 14 D ring 17 diaphragm 15 O ring 18 float bowl 7 Remove the holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 22 and float bowl 18 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws 22 tube guides 8 Remove the pump rod 23 while pushing the link lever 25 Clean the pump rod and rod passage 24 Install the pump ro...

Page 140: ... cover screws 1 5 lbf ft 2 1 N m 0 2 kgf m top cover bolts 1 5 lbf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 lbf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 lbf ft 2 1 N m 0 2 kgf m shock absorber upper mounting nut 32 lbf ft 44 N m 4 5 kgf m After installing the carburetor adjust the throttle cable 1 freeplay and hot start cable 2 freeplay After installing the carburetor check the thrott...

Page 141: ...t it and warm it up 3 minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift into neutral Start the engine 4 Keep the motorcycle in an upright position 5 Adjust idle speed with the throttle stop screw 1 Idle speed 1 700 100 rpm 1 throttle stop screw 1 ...

Page 142: ... sure to recheck the race sag and adjust it if necessary In the past a general rule was lengthen the wheelbase to add straight line stability shorten the wheelbase to improve turning However we suggest you do not lengthen the wheelbase of your CRF unless you are racing on a track with more fast sections than normal As a general recommendation keep the wheelbase as short as possible This positions ...

Page 143: ...n sections or perhaps you can just rev it out a bit longer For tight tracks consider lower gearing to avoid having to slip the clutch frequently Repeated fanning or pulling of the clutch lever in a turn to raise engine rpm may eventually damage the clutch system A gearing change may help for riding in sand where you want to keep the front end light so it can float from the peak of one sand whoop t...

Page 144: ...ns for specific terrain follow Hard Slick Soil Use tires with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface The rubber compound needs to be softer for hard ground in order to hook up but not so soft that the knobs roll over easily and affect holding a straight line These tires tend to wear more quickly than standard tires b...

Page 145: ...es Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide further adjustment to riding position and may better suit your partic...

Page 146: ...Tips Tips 141 t and 142 143 145 146 ...

Page 147: ... the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that you do not transport your CRF on its sid...

Page 148: ...k cap 9 reserve tank 8 siphone tube 8 Reinstall the reserve tank and reserve tank cap and connect the siphone tube 1 2 4 3 7 8 9 6 5 riod pect ore t be CRF n occur F If or salt and wipe 44 o an g the into an buretor 1 bolt 2 right engine guard 3 center engine guard mounting bolts collars 4 center engine guard 6 Remove the radiator cap and coolant drain bolt sealing washer 5 at the water pump 6 to ...

Page 149: ...ar nonbreathing coated materials that restrict air flow and allow heat and moisture to accumulate Removal from Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the start of storage pages 44 47 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with recommended fuel page 41 4 Charge the ...

Page 150: ...protect nd preserve owner sh your t which zone way see sposal htless to a drain and can hurt rinking you have er toxic nd take ocal or nmental your area e of Improper disposal of drained fluids is harmful to the environment NOTICE ...

Page 151: ...plug P 61 rk plug P 61 on control shorted spark er coil shorted ignition ne stop button sconnected tem wires on pulse open der and piston maged ad gasket alve timing ecompressor P 73 ve hoke operation incorrectly aking gnition timing tion coil or se generator minated ot start P 60 flooded ed ve open dirty P 51 POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Disconnect fuel line at carbureto...

Page 152: ...Taking Care of the Unexpected Taking Care of the Unexpected 147 p you If a Fuse Blows 148 If Your Battery Is Low or Dead 149 ...

Page 153: ...ou do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace the spare fuse that was i...

Page 154: ...If Your Battery Is Low or Dead cially if attery ge your ars dealer Taking Care of the Unexpected 149 ...

Page 155: ......

Page 156: ... Information ties and Vehicle Identification 152 Specifications 153 Torque Specifications 154 Emission Control Systems 157 Oxygenated Fuels 159 Competition Logbook 160 Optional Parts List 162 Spare Parts Equipment 163 Wiring Diagram 164 ...

Page 157: ...equired also be s You eference of the The engine number 2 is stamped on the left crankcase LEFT SIDE 2 engine number 2 1 ...

Page 158: ... 0 1 Valve clearance cold Intake 0 006 0 001 in 0 16 0 03 mm Exhaust 0 011 0 001 in 0 28 0 03 mm Clutch type Transmission Primary reduction Gear ratio I Gear ratio II Gear ratio III Gear ratio IV Gear ratio V Final reduction Item English Metric Drive train Electrical Wet multi plate type 5 speed constant mesh 2 739 2 230 1 625 1 235 1 000 0 826 3 923 NGK DENSO NGK DENSO Gear shift pattern Ignition...

Page 159: ...rankshaft hole cap Oil filter cover bolts Cylinder bolt Cylinder head bolts Exhaust pipe joint nut Drive sprocket bolt Engine oil drain bolt Transmission oil drain bolt Torque Remarks lbf ft N m kgf m 7 7 7 7 11 7 7 7 15 23 12 16 10 10 10 10 15 10 10 10 21 31 16 22 1 0 1 0 1 0 1 0 1 5 1 0 1 0 1 0 2 1 3 2 1 6 2 2 1 UBS bolt NOTE NOTE 1 1 9 5 4 2 3 8 10 7 12 11 ...

Page 160: ... arm nuts swingarm side shock link side Rear shock link nuts Shock spring lock nut Kickstarter arm bolt Shroud mounting bolts upper Spark arrester mounting bolts Brake pedal adjuster lock nut Torque Remarks lbf ft N m kgf m 80 16 15 16 32 65 15 94 20 40 19 40 40 32 32 65 25 22 39 39 39 32 28 3 7 9 4 4 108 22 20 22 44 88 20 128 27 54 26 54 54 44 44 88 34 30 53 53 53 44 38 5 12 5 9 11 0 2 2 2 0 2 2 ...

Page 161: ...iven sprocket nuts Seat bolts Front brake reservoir cap screws Rear brake reservoir cap bolts Fork air pressure release screw Left step bracket mounting bolts upper lower Torque Remarks lbf ft N m kgf m 7 3 25 22 12 12 27 2 7 2 7 9 22 36 9 9 51 16 10 5 2 0 5 3 8 19 19 15 24 19 0 7 0 7 0 9 41 22 9 9 34 30 16 16 36 3 68 3 7 12 30 49 12 12 69 22 13 7 0 7 5 2 26 26 21 32 26 1 1 1 2 55 30 1 0 3 5 3 1 1...

Page 162: ...oval of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer Problems that May Affect Motorcycle Emissions If you are awar...

Page 163: ...ms x and trogen ical but it ystems rogen ngs No n idle rew eparate em sists of uces xhaust helps made onents is nkcase n ...

Page 164: ...service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated the fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately Oxygenated fuels can d...

Page 165: ... hour each six minutes represents one tenth of an hour Racing Records Information worth recording for this section of your logbook may include Your placing in each moto and overall finishing position Thoughts on what you could do to improve your performance next time Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may ...

Page 166: ...Technical Information 161 ent Comments Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc ture use Competition Logbook ...

Page 167: ... from other optional springs 308 0 lbf in 5 50 kgf mm No mark factory products Red paint aftermarket parts or 296 8 lbf in 5 30 kgf mm 26 32 lbf in 0 47 kgf mm 25 20 lbf in 0 45 kgf mm 27 44 lbf in 0 49 kgf mm Red Blue 319 2 lbf in 5 70 kgf mm 330 4 lbf in 5 90 kgf mm Pink Silver rom your TOOLS Remarks For checking tire air pressure Pin spanner A Workstand To adjust spring pre load two spanners re...

Page 168: ...WMA KZ30100 Tensioner Stopper 070MG 0010100 Spoke Wrench 07JMA MR60100 Piston Base 07958 2500001 Chemical Products Pro Honda GN4 HP4 without molybdenum additives 4 stroke Oil Engine Oil Pro Honda HP Trans Oil or Pro Honda GN4 or HP4 without molybdenum additives 4 stroke Oil Transmission Oil Urea based multi purpose grease with extreme pressure Pro Honda Hondalock Pro Honda HP Fork Oil 5W Pro Honda...

Page 169: ......

Page 170: ...Consumer Information 165 Consumer Information cial Authorized Manuals 166 Warranty Coverage 167 Warranty Service 168 Contacting Honda 169 Your Honda Dealer 170 The Honda Rider s Club USA only 171 ...

Page 171: ...tion and ow S H I P T O NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation Customer Name Attention Street Address No P O Box Number Apt City State Zip Code Daytime Telephone Number P A Y M E N T Check or money order enclose...

Page 172: ...Warranty Coverage ranties y d es nties ler at the onda anties ty for or erage ration ed if you e ls and to ance are n be lan our Consumer Information 167 ...

Page 173: ...ntenance rranty ms such our ur an he ed to l give oblem ill erage or o the of all r If you g of the oblem rship s eady Parts e Owner entative ...

Page 174: ...Consumer Information 169 er most r he r Honda ht away your ship is s why erences nces with end your A only Motor 0509 at was in your respond directly Contacting Honda ...

Page 175: ...ou about competition events in your area You ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda ...

Page 176: ...ent rough r TV or aler eds of s the ery for your nce for as long or street e with Service and ssful cialty asers of gazine e istance otocross elected ATV or ide Contact your Honda dealer for more information or call 1 800 847 4722 or log on to www hrca honda com ...

Page 177: ...61 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 75 Chassis Suspension 83 Brakes 87 Wheels 91 Tires Tubes 92 Side Stand 94 Drive Chain 95 Additional Maintenance Procedures 98 Electrical Battery 100 Headlight Taillight 102 Appearance Care 104 Adjustments for Competition 107 Front Suspension Adjustments 108 Rear Suspension Adjustments 122 Suspension Adju...

Page 178: ...Table of Contents 151 152 153 154 157 159 160 162 163 164 165 166 167 168 169 170 171 172 174 Table of Contents 173 ...

Page 179: ...cting Honda 169 controls operating 7 coolant 48 customer service 170 cylinder system 77 damping adjustments front 108 rear 123 dealer your Honda 170 diagram wiring 164 drive chain 95 engine flooded 16 idle speed 136 number 152 pinging 41 starting 15 stop button 16 stopping 16 won t start 146 environment protecting 145 filter air 51 oil 44 flooded engine starting 16 fork front suspension adjustment...

Page 180: ...e load rear suspension 122 pre ride inspection 11 protective apparel 2 rear suspension maintenance 84 Rider s Club Honda 171 riding apparel 2 basic operation 13 before 9 important safety information 2 safety precautions 2 safety a few words about Safety Messages important information 2 important precautions 2 labels 5 maintenance 25 riding precautions 14 schedule maintenance 27 28 serial numbers 1...

Page 181: ... 83 84 108 122 126 127 46 130 54 55 92 92 93 163 154 156 142 14 146 92 15 152 167 167 168 104 3 91 164 ...

Page 182: ...Memo 177 ...

Page 183: ......

Page 184: ...Memo 179 ...

Page 185: ...gine oil or an equivalent Front 80 100 21 51M Rear 110 100 18 64M DUNLOP D742F DUNLOP D756 Type bias ply tube type Front 15 psi 100 kPa 1 0 kgf cm2 Rear 15 psi 100 kPa 1 0 kgf cm2 standard IFR8H11 NGK or VK24PRZ11 DENSO optional IFR9H11 NGK or VK27PRZ11 DENSO ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or an equivalent distilled water m...

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