Honda CRF450X Owner'S Manual Download Page 86

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Piston/Piston Rings/Piston Pin

Piston Installation

1. Place clean shop towels over the crankcase

opening to keep the piston pin clips from
falling into the crankcase.

2. Apply molybdenum disulfide oil solution (a

mixture of 1/2 engine oil and 1/2
molybdenum disulfide grease containing more
than 3% molybdenum disulfide additive) to
the connecting rod small end.

3. Apply clean engine oil to the piston pin outer

surface and piston pin hole inner surface.

4. Install the piston (1) with the “IN” mark (2)

and/or the large valve recesses (3) facing the
intake side of the engine.
Install the piston pin (4) and new piston pin
clips (5).

Use new piston pin clips. Never reuse old piston
pin clips.
Do not let the piston pin clips fall into the
crankcase.
Do not align the piston pin clip end gap with the
piston cut-out.

NOTICE

(1) piston

(4) piston pin

(2) “IN” mark

(5) piston pin clip

(3) large valve recesses

(6) cut-out

Cylinder Installation

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.

(1)

(3)

(2)

(1)

(5)

(4)

(2)

(6)

(5)

(2)

(1)

Servicing Your Honda

061-085.qxd 06.6.1 11:00 ページ80

Summary of Contents for CRF450X

Page 1: ...ANDBOOK E MANUEL DU CONDUCTEUR ET DE COMPETITION F FAHRER HANDBUCH und WETTBEWERBSANLEITUNG G INSTRUCTIEBOEKJE WEDSTRIJDHANDBOEK D MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES S MANUALE D USO E DEGLI ASSETTI DA COMPETIZIONE I Honda Motor Co Ltd 2006 CRF450X_COVER 6 1 06 11 43 AM 1 ...

Page 2: ...NLY AND IS SOLD AS IS WITH NO WARRANTY IT DOES NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND OPERATION ON PUBLIC STREETS ROADS OR HIGHWAYS IS ILLEGAL STATE LAWS PROHIBIT OPERATION OF THIS MOTORCYCLE EXCEPT IN AN ORGANIZED RACING OR COMPETITIVE EVENT UPON A CLOSED COURSE WHICH IS CONDUCTED UNDER THE AUSPICES OF A RECOGNIZED SANCTIONING BODY OR BY PERMIT ISSUED BY THE LOCAL GOVERNMENTAL ...

Page 3: ...Honda CRF450X OWNER S MANUAL COMPETITION HANDBOOK Contents qxd 06 6 1 10 56 ページ2 ...

Page 4: ...onda Motorcycle Warranties Booklet given to you by your Honda dealer at the line of purchase It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle Your warranty coverage will not be voided if you choose to perform your own maintenan...

Page 5: ...rtant safety information in a variety of forms including Safety Labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instru...

Page 6: ...System 56 Hot Start Lever 60 Spark Plug 61 Exhaust Pipe Muffler 63 Spark Arrester 66 Valve Clearance 67 Piston Piston Rings Piston Pin 76 Chassis Suspension 84 Brakes 88 Wheels 92 Tyres Tubes 93 Side Stand 95 Drive Chain 96 Additional Maintenance Procedures 99 Electrical Battery 101 Headlight Taillight 103 Appearance Care 105 Adjustments for Competition 107 Front Suspension Adjustments 108 Rear Su...

Page 7: ...your CRF safely Please take a few moments to read these pages This section also includes information about the location of the safety labels on your CRF Important Safety Information 2 Important Safety Precautions 2 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 001 030 qxd 06 6 1 10 57 ページ1 ...

Page 8: ...ar clothing that fully covers your legs Keep Your Honda in Safe Condition It s important to keep your CRF properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your CRF before every ride and perform all recommended maintenance 2 Motorcycle Safety Do not wear loose clothing which...

Page 9: ...ortant to your safety If you decide to carry cargo you should be aware of the following information Loading Guidelines As discussed on this page we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects...

Page 10: ...terfere 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 4 Motorcycle Safety Accessories Modifications Modifying your CRF or using non Honda accessories can make your CRF u...

Page 11: ...me labels warn you of potential hazards that could cause serious injury Others provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement DK type only 001 030 qxd 06 6 1 10 57 ページ5 ...

Page 12: ...6 Motorcycle Safety 001 030 qxd 06 6 1 10 57 ページ6 ...

Page 13: ...perating Controls 7 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 8 001 030 qxd 06 6 1 10 57 ページ7 ...

Page 14: ...peration Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip tripmeter start button choke knob fuel valve shift lever kickstarter rear brake pedal 001 030 qxd 06 6 1 10 57 ページ8 ...

Page 15: ...pared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustments see page 107 Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 001 030 qxd 06 6 1 10 57 ページ9 ...

Page 16: ...e page 107 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a helmet increases t...

Page 17: ...e speed for stable and proper RPM 136 Tyres for damage or improper inflation pressure 93 Spokes for looseness 92 Rim locks for looseness 92 Front and rear suspension for proper operation 84 85 Front and rear brakes check operation 88 Drive chain for wear or damage and adequate lubrication 97 Drive chain guide sliders and rollers for damage or wear 98 Exhaust pipe Muffler inspection 63 Every possib...

Page 18: ...12 Before Riding 001 030 qxd 06 6 1 10 57 ページ12 ...

Page 19: ...nd stop your engine as well as break in guidelines Safe Riding Precautions 14 Side Stand 14 Tripmeter 14 Starting Stopping the Engine 15 Preparation 15 Fuel Valve 15 Starting Procedure 15 Flooded Engine 16 How to Stop the Engine 16 Shifting Gears 17 Braking 18 Parking 19 Post ride Inspection 20 Break in Guidelines 21 001 030 qxd 06 6 1 10 57 ページ13 ...

Page 20: ... the Important Safety Precautions beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 1 side stand 1 tripmeter 2 tripmeter reset knob 1 OFF 1 2 ON Side Stand The s...

Page 21: ...ming 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 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON Turning the f...

Page 22: ...to 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 starts release the hot start lever 16 Basic Operating Instructions How to Stop the Engine 1 2 1 throttle 2 engine stop ...

Page 23: ...ttern To start riding after the engine has been warmed and the side stand raised 1 Close the throttle and pull the brake lever in 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the brake lever Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engi...

Page 24: ...y reduce your speed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your CRF When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Ra...

Page 25: ...ing Lower the side stand to support your CRF If you re through riding for the day turn the fuel valve OFF Always choose a level surface to park Basic Operating Instructions 19 001 030 qxd 06 6 1 10 57 ページ19 ...

Page 26: ...F and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your CRF for leaks or damage Be sure to lubricate the drive chain page 98 to prevent rusting 20 Basic Operating Instructions 001 030 qxd 06 6 1 10 57 ページ20 ...

Page 27: ... first operating day or 25 km 15 miles 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 Basic Operating Instructions 21 001 030 qxd 06 6 1 10 57 ページ21 ...

Page 28: ...22 Basic Operating Instructions 001 030 qxd 06 6 1 10 57 ページ22 ...

Page 29: ...Service Your Honda The Importance of Maintenance 24 Maintenance Safety 25 Important Safety Precautions 25 Maintenance Schedule 26 General Competition Maintenance 29 Before After Competition Maintenance 33 Between Motos Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Se...

Page 30: ...den over rough off road terrain To help you properly care for your CRF this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your CRF to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to help you avoid a ...

Page 31: ... parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side stand or an optional workstand to provide support To reduce the possibility ...

Page 32: ...verlooking required service we urge you to develop a convenient way to record the number of days and or distance traveled you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for r...

Page 33: ...R I L I I I 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 I I R I I I I I I I I I 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 R I I I I I I I I I I I 41 42 55 51 53 61 67 43 44 136 48 48 46 96 98 98 89 91 88 104 56 95 84 85 66 100 155 157 92 93 99 FREQUENCY ITEMS NOTE km mi Month 150 100 1 1 000 600 6 2 000 1 200 12 I L every 500 km 300 mi or 3 months 3 000 1 800 18 4...

Page 34: ...E MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL NUTS BOLTS FASTENERS WHEELS TYRES STEERING HEAD BEARINGS NOTE 1 NOTE 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 55 60 51 53 61 48 67 43 44 136 78 78 46 48 96 98 98 97 97 89 91 88 56 99 63 84 85 32 87 113 100 155 157 92 93 99 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 FORK TUBE SLIDER DAMPER FREQUENCY NOTE R...

Page 35: ...ivalent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check a...

Page 36: ...netration Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the air cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air clea...

Page 37: ... page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the tank remove and clean the fuel joint and fuel filter Replace the fuel joint O ring if there are any signs of damage or deterioration page 42 Loosen the carburetor drain screw and examine the fuel that flows out of the float bowl If you notice anything in the fu...

Page 38: ... hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged 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 replac...

Page 39: ...ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 kpa 0 kgf cm2 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 2 pressure release screw 1 2 After Competition Maintenance It is impo...

Page 40: ...able from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to ...

Page 41: ...ttery main fuse rear suspension high speed compression 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 clutch lever hot start le...

Page 42: ...all the seat 2 while aligning the seat front 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 26 N m 2 7 kgf m 19 lbf ft 1 seat bolts 2 seat 3 seat front prong 4 seat bracket 5 seat rear prongs 6 tabs 1 2 3 5 2 1 4 6 36 Servicing Your Honda 031 060 qxd 06 6 1 10 58 ページ36 ...

Page 43: ...4 breather tube 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt collar 9 Disconnect the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 10 Remove the bolt 10 and fuel valve 11 Remove the fuel tank 8 fuel line 10 bolt 9 fuel valve WARNING Petrol is highly flammable and explosive You can be burned ...

Page 44: ...he fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 8 Install the shroud 8 by aligning its tab 11 with subframe 12 8 shroud 12 subframe 11 tab 9 Install the shroud B bolts 9 and shroud A bolts collars 10 10 Tighten the shroud B bolts to the specified torque 5 N m 0 5 kgf m 3 7 lbf ft 9 shroud B bolts 10 shroud A bolts collars 11 Install the seat page 36 4 fuel tank bolt collar 6...

Page 45: ...ame 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 30 N m 3 1 kgf m 22 lbf ft 1 right side cover bolt 2 right side cover 3 Open the air cleaner housing cover 3 by turning the quick fastener...

Page 46: ...ing bolts Installation 1 Loosen the subframe upper mounting bolts 1 2 Loosely attach the lower ends of the subframe 2 to the mainframe while connecting the air cleaner connecting boot to the carburetor Be careful not to bend the subframe Install the subframe lower mounting bolts 3 Tighten the subframe upper mounting bolts first then tighten the subframe lower mounting bolts to the specified torque...

Page 47: ...petrol or an oil petrol mixture Avoid getting dirt dust or water in the fuel tank Type Unleaded Research Octane Number 95 or higher Refueling Procedure Fuel Tank Capacity 8 6R 2 27 US gal 1 89 Imp gal 1 fuel fill cap 3 steering stem nut 2 breather tube 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 and turn the fuel fill cap counterclockwise 2 Add fuel until ...

Page 48: ...el tank page 37 3 Remove the fuel joint 1 from fuel tank by removing the bolts 2 4 Wash the fuel filter 3 in high flash point cleaning solvent 5 Check that the O ring 4 is in good condition and install it onto the fuel joint Reassemble the fuel joint in the reverse order of removal 6 Install the fuel tank page 38 and refill the fuel Turn the fuel valve to ON or RES check for leaks 3 fuel filter 4 ...

Page 49: ...energy conserving on the circular API service label suggested oil Honda 4 STROKE MOTORCYCLE OIL or 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 affe...

Page 50: ...p dipstick If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Install the engine oil filler cap dipstick securely 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine for 3 minutes ...

Page 51: ...the O ring then tighten the oil filter cover bolts to the specified torque 10 N m 1 0 kgf m 7 lbf ft 15 Install the left engine guard and bolt then tighten it NOTICE 16 Fill the crankcase with the recommended oil Capacity 0 70R 0 74 US gt 0 62 Imp gt at oil and filter change 0 67R 0 71 US gt 0 59 Imp gt at oil change 17 Install the engine oil filler cap dipstick 18 Check the engine oil level by fo...

Page 52: ...use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Transmission Oil Oil is a major factor affecting the performance and service life of the transmission and clutch Other viscosities shown in the following chart may be used when the average temperature in your riding area is within t...

Page 53: ...ole until oil start to flow out of the oil check bolt hole Install the oil check bolt with a new sealing washer and transmission oil filler cap Repeat step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 10 N m 1 0 kgf m 7 lbf ft 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine for 3 ...

Page 54: ... and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection NOTICE Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system...

Page 55: ... for looseness 3 Check the radiator mount for looseness 4 Make sure the siphon hose 2 is connected and not clogged 5 Check the radiator fins for clogging 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the mechanical seal is damaged If oil leaks through the check hole the transmission oil seal is ...

Page 56: ...the system as follows Shift the transmission into neutral Start the engine and let it idle 2 3 minutes Snap the throttle 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 cau...

Page 57: ...e engine wear NOTICE Cleaning 1 Open the air cleaner housing cover 1 by turning the quick fastener 2 counterclockwise 4 Remove the air cleaner element 5 out from the air cleaner holder 6 1 air cleaner housing cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 3 Remove the air cleaner assembly 4 while turning the cleaner assembly clockwise 5 air cleaner element 8 hole 6 air cleaner ho...

Page 58: ... element and holder Install the tab 7 of the holder in the hole 8 of the air cleaner element tab 9 10 Install the air cleaner assembly into the air cleaner housing 11 Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner element holder with the mark 11 of the air cleaner housing by rotating the air cleaner assembly counterclockwis...

Page 59: ...the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube 1 2 031 060 qxd 06 6 1 10 58 ページ53 ...

Page 60: ...grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 38 If you can t get the freeplay within the specified range 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...

Page 61: ...ositions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 Servicing Your Honda 55 03...

Page 62: ...urn 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 Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the...

Page 63: ...erioration kinks or damage Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 47 2 Remove the brake pedal 1 by removing the pin 2 pivot bolt 3 washer 4 and dust seals 5 Servicing Your Honda 57 1 brake pedal 4 washer 2 pin 5 dust seals 3 pivot bolt 6 clutch cover bolts 7 clutch cover 4 Loosen the clutch spring bolts in a crisscross pattern in 2 or 3 progressive steps Remove the six c...

Page 64: ... length of each spring Service Limit 43 7 mm 1 72 in Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch plates have been burnt heat discoloured 1 58 Servicing Your Honda 6 Remove the washer 11 needle bearing 12 clutch lifter 13 and clutch lifter rod 14 7 Remove the eight clutch discs and seven clutch plates 15 Assemble the clutch lifter needle beari...

Page 65: ...N m 1 2 kgf m 9 lbf ft 10 Install the O ring 10 in the groove of the clutch cover 11 11 Install the clutch cover by tightening the six cover bolts to the specified torque 10 N m 1 0 kgf m 7 lbf ft 8 clutch pressure plate 9 clutch spring bolts springs 10 O ring 11 clutch cover 8 9 11 10 Clutch Disc Plate Installation 1 Coat the clutch disc A 1 B 2 and plates 3 with clean transmission oil 2 Starting...

Page 66: ...just to the specified range Adjustment Adjustments can be made with the cable 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 60 Servicing Your Honda 1 2 4 3 031 060 qxd 06 6 1 10 58 ページ60 ...

Page 67: ...asket 3 for damage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 1 0 1 1 mm 0 039 0 043 in 3 sealing gasket 4 spark plug gap 3 4 Servicing Your Honda 61 Standard IFR8H11 NGK or VK24PRZ11 DENSO Optional IFR9H11 NGK or VK27PRZ11 D...

Page 68: ...lug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 10 Connect the spark plug cap Take care to avoid pinching any cables or wires 11 Install the fuel tank and seat pages 36 38 NOTICE 62 Servicing Your Honda 061 085 qxd 06 6 1 10 59 ページ62 ...

Page 69: ...olt 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 Servicing Y...

Page 70: ...Tighten the front muffler mounting bolt and rear muffler mounting bolt to the specified torque 26 N m 2 7 kgf m 19 lbf ft 5 Tighten the muffler clamp bolt 8 to the specified torque 21 N m 2 1 kgf m 15 lbf ft 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 1...

Page 71: ...rque 21 N m 2 1 kgf m 15 lbf ft 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 4 Install the muffler page 64 Exhaust Pipe Removal 1 Remove the muffler page 63 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 1 2 3 1 3 2 Servicing Your Honda 65 061 085 qxd 06 6 1 10 59 ページ65 ...

Page 72: ...rom the muffler 1 bolts 3 gasket 2 spark arrester 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of 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 12 N m 1 2 kgf m 9 lbf ft 1 bolts 1 2...

Page 73: ... 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 4 5 3 1 Refer to Safety Precautions on page 25 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance when the engine ...

Page 74: ...r be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the index mark The inspection must 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 the exhaust rocker arm 5 If it is free it is...

Page 75: ...eds adjustment see Decompressor Arm Clearance Adjustment page 74 Camshaft Holder Assembly Removal 1 Record the intake valve clearance exhaust valve clearance and decompressor arm clearance 2 Remove the cam chain tensioner lifter 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 tensio...

Page 76: ...the piston is at TDC Top Dead Centre on the compression storoke Loosen the camshaft holder bolts 7 in a crisscross pattern in 2 or 3 steps 7 Remove the camshaft holder bolts and 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 loc...

Page 77: ... using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with the micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over...

Page 78: ...ocations in the camshaft holder 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 14 N m 1 4 kgf m 10 lbf ft Tighten the camshaft holder assembly bolts in a crisscross patt...

Page 79: ...12 cam chain 7 Clean and apply a locking agent to the cam sprocket bolt threads coating width 6 5 1 mm 0 26 0 04 in 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 20 N m 2 0 kgf m 15 lbf ft Turn the primar...

Page 80: ...ght Exhaust Valve Clearance 0 28 0 03 mm 0 011 0 001 in 1 feeler gauge 3 shim 2 right side rocker arm 2 Pull out the feeler gauge 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 RIGH...

Page 81: ...spark plug hole packing 2 spark plug hole 2 Inspect the cylinder head cover packing 3 for damage or deterioration replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 4 3 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 s...

Page 82: ...e exhaust pipe page 65 8 Remove the spark plug page 61 9 Remove the camshaft holder assembly lifters and shims page 69 10 Remove the left radiator grill 1 and left radiator lower mounting bolt washer 2 3 primary wire connector 4 bolts clamp 5 ignition coil 12 Loosen the radiator hose clamp 6 and disconnect the radiator hose 7 1 left radiator grill 2 left radiator lower mounting bolt washer 4 3 5 6...

Page 83: ...cable stay 13 left engine hanger plate 14 right engine hanger plate 17 cylinder head nuts washers 18 cylinder head 15 cylinder head bolts 16 cylinder bolt 16 Loosen the cylinder head nuts 17 in a crisscross pattern in 2 or 3 steps Remove the cylinder head nuts washers and cylinder head 18 Do not let the cylinder head nuts and washers fall into the crankcase NOTICE 21 20 19 19 dowel pins 21 cam cha...

Page 84: ... by lifting it up at a point just opposite the gap Do not damage the piston ring by spreading the ends too far NOTICE 2 3 1 5 4 Piston Removal 1 Place clean shop towels in the crankcase to keep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Unde...

Page 85: ...n the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail NOTICE top ring oil ring top ring mark side rail oil ring side rail spacer Piston Piston Pin Piston Ring Inspect...

Page 86: ...4 and new piston pin clips 5 Use new piston pin clips Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt fro...

Page 87: ...r bolt 6 and connect the breather tube 7 to the cylinder 8 Install the cam chain guide 8 and fit the cam chain guide tabs 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 ...

Page 88: ...ger plate 8 right engine hanger plate 9 clutch cable stay 10 engine hanger plate bolts 11 engine hanger bolt 12 fuel hose guide 13 engine hanger nut 5 cylinder bolt 6 cylinder 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 th...

Page 89: ...e 14 to the cylinder head and tighten the radiator hose clamp 15 14 radiator hose 15 radiator hose clamp 9 Install the ignition coil 16 ground wire 17 and clamp bolts 18 then tighten the bolts Connect the primary wire connector 19 16 ignition coil 18 clamp bolts 17 ground wire 19 primary wire connector 15 14 19 16 18 17 21 15 Install the exhaust pipe page 65 16 Install the carburetor page 135 17 I...

Page 90: ...ion 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 information page 108 for 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 confus...

Page 91: ...ing two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 123 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and rebound d...

Page 92: ...emoved To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 4 dust seal 6 slider 5 guide bushing 7 outer tube 3 Drain the fork oil from 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 le...

Page 93: ...ofter as it nears full compression Minimum oil capacity 1 scribe mark aftermarket parts No mark factory products Optional Stiffer 0 49 kgf mm Fork Spring Standard oil capacity 335 cm3 11 3 US oz 11 8 Imp oz Maximum oil capacity 405 cm3 13 7 US oz 14 3 Imp oz Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 309 cm3 10 5 US oz 10 9 Imp o...

Page 94: ...lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 While holding the adjuster tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake ...

Page 95: ...he brake system and it must be bled Refer to the Honda Shop Manual or see your Honda dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 91 Worn brake pads should be replaced If the pads ...

Page 96: ...r Brake Fluid Spilled brake fluid will severely damage instrument lenses and painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first Always use fresh DOT 4 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 flu...

Page 97: ...t brake caliper Rear Brake Pads Inspect the brake pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 1 mm 0 04 in both pads must be replaced 4 brake pads 6 brake disc 5 rear brake caliper minimum thickness indicator wear indicator grooves replace replace 1 mm 0 04 in 1 mm 0 04 in 2 3 1 1 replace minimum thickness indicator 4 4 6 5 1 ...

Page 98: ...the recommended service in the Regular Off road Use Maintenance Schedule page 27 Wheel Rims Spokes 1 rim lock nut 3 spokes 2 wheel rim 4 spoke nut 1 Inspect the wheel rims 2 and spokes 3 for damage 2 Tighten any loose spoke nut 4 and rim lock nut 1 to the specified torque Front Spoke Nut 3 68 N m 0 4 kgf m 2 7 lbf ft Rear Spoke Nut 3 7 N m 0 4 kgf m 2 7 lbf ft Rim Lock Nut 12 N m 1 2 kgf m 9 lbf f...

Page 99: ...ways check air pressure when your tyres are cold If you check air pressure when your tyres are warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air out of warm tyres to match the recommended cold pressures the tyres will be underinflated The correct cold tyre pressures are If you decide to adjust tyre pressures for a particular riding condition make...

Page 100: ...obably be stretched and if installed in a new tyre could fail U DK type WARNING Installing improper tyres 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 tyres recommended in this owner s manual Front 80 100 21 51M DUNLOP D742F Rear 110 100 18 64M DUNLOP D756 Tyre type bias ply tube ED type Fro...

Page 101: ...5 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with grease 1 086 106 qxd 06 6 1 11 28 ページ95 ...

Page 102: ...on into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 25 35 mm 1 0 1 4 in Excessive chain slack may allow the drive chain to damage the engine cases 1 drive chain slack 3 driven sprocket 2 drive sprocket If the chain is found to be slack in one segment of its length and taut in another th...

Page 103: ...aged O rings or otherwise appears unserviceable 3 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 13 4 mm 0 53 in the drive chain must be replaced Replacement Chain DID520MXV 1 drive chain plate inner 4 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sproc...

Page 104: ...slider 3 wear limit groove Drive Chain Rollers 1 Measure the diameter of the drive chain rollers Replace them if below the service limit Service Limit UPPER ROLLER 39 mm 1 5 in LOWER ROLLER 35 mm 1 4 in 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 side facing out ...

Page 105: ...acement or adjustment procedures or see your Honda dealer Handlebar Inspection 1 Remove the handlebar pad 2 Check the handlebar 1 for bends or cracks 3 Check that the handlebar has not moved from its proper position by inspecting the paint mark 4 Check the torque of the handlebar upper holder bolts 2 22 N m 2 2 kgf m 16 lbf ft Tighten the front bolts first 1 handlebar 2 handlebar upper holder bolt...

Page 106: ...procket bolt Engine oil drain bolt Transmission oil drain bolt Torque lbf ft 7 15 7 11 7 7 7 7 7 23 12 16 N m 10 21 10 15 10 10 10 10 10 31 16 22 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 ENGINE 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts 1 3 4 5 6 2 8 9 10 7 12 11 RIGHT SIDE LEF...

Page 107: ... best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging on page 102 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to k...

Page 108: ...ckle charger 1 for home charging These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage 1 trickle charger 1 0...

Page 109: ...stall the front visor by aligning its grommets 11 with the tabs 12 on the steering stem Install and tighten the front visor bolts 3 To pull the headlight 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 ...

Page 110: ...s LED illumination If the taillight does not function properly see your Honda dealer for service This model is equipped with an electric starter and battery for easy engine starting There is a possibility of damage to the lighting system if the battery is carelessly removed Never kick start the engine without the battery connected If it becomes necessary to kick start the engine with the battery r...

Page 111: ... suspension pivot points High pressure water or air can damage certain parts of your CRF You may use a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the multi surface cleaner degreaser and rinse with a garden hose at full pressure Stubborn deposits may require a quick ...

Page 112: ...lel 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 discolour the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated alum...

Page 113: ... your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 108 Rear Suspension Adjustments 122 Suspension Adjus...

Page 114: ...e screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place your CRF on an optional workstand or equivalent support with the front wheel off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pressure releas...

Page 115: ...Springs The fork springs in CRF s are about right for riders weighing between 68 and 73 kg 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 ...

Page 116: ...or bolts 12 tripmeter cable clamp screws 13 brake hose clamp bolts 14 fork protectors 15 caliper mounting bolts 16 brake caliper 10 Loosen the bottom bridge 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 p...

Page 117: ...seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 21 outer tube 23 lock nut wrench 22 fork damper 24 slider lower end 21 outer tube 25 oil hole 18 slider 20 length 19 dust seal 14 Hold the outer tube 21 then remove the fork damper 22 from the outer tube using the lock nut wrench 23 Gently slide the outer ...

Page 118: ... not to damage the lock nut and fork centre 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 19 Push out the fork centre bolt 27 from the axle holder 26 of the slid...

Page 119: ... Clean the fork cap and fork damper threads 1 fork damper 4 fork oil 8 Pump the fork damper piston rod 5 slowly several times to bleed the air from the fork damper 1 1 fork damper 5 fork damper piston rod 1 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 Honda ULTRA CUSHION OIL SPECIAL 5W or equivalent R...

Page 120: ...rk cap assembly 2 to the specified torque by holding the fork damper 1 using the lock nut wrench 3 The fork cap assembly torque 30 N m 3 1 kgf m 22 lbf ft 1 fork damper 4 fork oil 10 Apply fork oil to the bushing 6 and new O rings 7 on the fork cap assembly 2 Extend the fork damper piston rod to maximum length holding it install the fork cap assembly to the fork damper 1 Be careful not to damage t...

Page 121: ...n rod end with soft jaws to prevent fork damage Blow the extra oil off to the fork damper 1 spring chamber 9 by pumping the fork damper piston rod to full stroke Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked NOTICE 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 ...

Page 122: ...pe the oil completely off the fork damper 2 lock nut A thread length 3 Using compressed air blow all oil off the fork spring 3 Install the fork spring 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 1 Amount of fork oil left in the fork without damper and spring unit cc minute C F 30 86 20 68 10 50 0 ...

Page 123: ...re bolt 6 push rod 9 centre bolt adjusting rod 8 Measure the length of the lock nut 2 and fork centre bolt 8 clearance Standard 1 5 2 0 mm 0 06 0 08 in If the clearance is out of specification check the lock nut and centre bolt installation 2 lock nut 8 fork centre bolt 9 Tighten the lock nut 2 to the fork centre bolt 8 closely by hand Tighten the lock nut to the specified torque 22 N m 2 2 kgf m ...

Page 124: ...5 kgf mm Fork Spring Standard oil capacity 338 cm3 11 4 US oz 11 9 Imp oz Maximum oil capacity 407 cm3 13 8 US oz 14 3 Imp oz Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 311 cm3 10 5 US oz 10 9 Imp oz No mark factory products 2 scribe marks 1 scribe mark aftermarket parts or Optional Stiffer 0 49 kgf mm Fork Spring Standard oil ca...

Page 125: ...h long deflecting been type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 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 dam...

Page 126: ...ar 24 and tripmeter gear box 25 for wear or damage Install the left side collar to the left wheel hub Install the trip meter gear box while aligning its tabs 26 of the tripmeter gear box with the grooves 27 on the right wheel hub 25 Clean the clamping surface of the axle and axle holders Install the front wheel 28 between the fork legs while inserting the disc between the pads and align 29 the tab...

Page 127: ...ile keeping the forks parallel alternately tighten the right axle pinch bolts 37 to the specified torque 20 N m 2 0 kgf m 15 lbf ft To avoid damage when torquing the axle 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 spe...

Page 128: ...d the Honda Shop Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Optional pin spanners are available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place your CRF on an optional workstand or equivalent support with the rear wheel off the ground 2 Lift the subfra...

Page 129: ... speed compression damping can be increased by turning the appropriate adjuster clockwise Adjust the high speed compression damping adjuster in 1 12 turn increments 1 high speed compression damping adjuster 2 low speed compression damping adjuster High Speed Compression Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed compre...

Page 130: ...ar spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the centre of the rear fender mounting bolt to the centre of the chain adjuster lock nut as ...

Page 131: ...step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF With the spring pre load set to obtain the proper race sag the rear suspension should sag 10 to 25 mm 0 4 to 1 0 in If the rear of your CRF sags less than 10 mm 0 4 in from its own weight the spring is too stiff for your weight It is not compressed enough even though you have th...

Page 132: ...t springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and reboun...

Page 133: ...pecially downhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adj...

Page 134: ...sion too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer ...

Page 135: ...ire travel too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment 2 If it s...

Page 136: ...gine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mixture must be delivered to t...

Page 137: ...tered by the slow jet 1 and mixed with air from the slow air jet 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 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 pas...

Page 138: ... and bolt 3 2 shock absorber upper mounting 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 ...

Page 139: ... 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 valve 1 3 2 6 5 4 8 7 9 10 8 11 Remove the throttle drum cover bolt 10 and throttle drum cover 11 10 throttle drum cover bolt 11 throttle drum cover 12...

Page 140: ...rator pump cover 13 make sure the D ring s flat side faces down away from the float bowl 18 13 accelerator 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 pum...

Page 141: ...mbly procedures To install the carburetor reverse the removal procedures Tighten the following parts to the specified torque float bowl screws 2 1 N m 0 2 kgf m 1 5 lbf ft accelerator pump cover screws 2 1 N m 0 2 kgf m 1 5 lbf ft top cover bolts 2 1 N m 0 2 kgf m 1 5 lbf ft throttle drum cover bolt 3 4 N m 0 3 kgf m 2 5 lbf ft hot start cable nut 2 1 N m 0 2 kgf m 1 5 lbf ft shock absorber upper ...

Page 142: ...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 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 min 1 rpm 1 throttle stop screw 1 132 141 qxd 06 6 1 11 07 ページ136 ...

Page 143: ...3 5 4 3 in range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of outer tube 1 with the top of upper fork clamp 2 STANDARD POSITON Wheelbase Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to rech...

Page 144: ...ibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use ...

Page 145: ...cceptable in other circumstances For example an aggressive mud tyre will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tyre with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands on the transmis...

Page 146: ...hen sitting or standing comfortably on your CRF Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved rearward either 3 mm using optional handlebar lower holders or 6 mm by rotating the sta...

Page 147: ...ul advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 142 Storing Your Honda 143 You the Environment 145 Troubleshooting 146 132 141 qxd 06 6 1 11 07 ページ141 ...

Page 148: ...ttach the lower ends of two straps to the tie down hooks on your CRF Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damage the ...

Page 149: ...g it That way needed repairs won t be forgotten and it will be easier to get your CRF running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the engine oil and filter p...

Page 150: ... 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 battery page 102 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capacity 1 45R 1 53 US qt 1 28 Imp qt at d...

Page 151: ...way 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 petrol and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic waste...

Page 152: ...n control module Broken or shorted spark plug wire Faulty exciter coil Broken or shorted ignition coil Faulty engine stop button Loose or disconnected ignition system wires Faulty ignition pulse generator 3 Test cylinder compression NORMAL Valve stuck open Worn cylinder and piston ring Leaking damaged cylinder head gasket Improper valve timing Improper decompressor clearance P 74 Seized valve 4 St...

Page 153: ... Care of the Unexpected Taking Care of the Unexpected 147 This section gives practical advice to help you solve problems If a Fuse Blows 148 If Your Battery Is Low or Dead 149 142 168 qxd 06 6 1 11 08 ページ147 ...

Page 154: ...3 Remove the starter magnetic switch 5 with the rubber case 4 Disconnect the wire connector 6 of the starter magnetic switch 5 Pull out the main fuse 7 If it is blown 8 install the spare main fuse 9 5 starter magnetic switch 6 wire connector 7 main fuse 8 blown fuse 9 spare main fuse 6 Reconnect the wire connector and install the starter magnetic switch If you do not have a replacement fuse with t...

Page 155: ...he greater amperage of an automobile battery when the car engine is running can damage your CRF s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge see your Honda dealer Taking Care of the Unexpected 149 142 168 qxd 06 6 1 11 08 ページ149 ...

Page 156: ...150 Taking Care of Unexpected 142 168 qxd 06 6 1 11 08 ページ150 ...

Page 157: ...imensions capacities and other technical data Vehicle Identification 152 Specifications 153 Torque Specifications 155 Petrol Containing Alcohol 158 Competition Logbook 159 Optional Parts List 161 Spare Parts Equipment 162 Wiring Diagram 163 142 168 qxd 06 6 1 11 08 ページ151 ...

Page 158: ...equired when you register your CRF They may also be required when ordering replacement parts The VIN number 1 is stamped on the right side of the steering head VIN RIGHT SIDE The engine number 2 is stamped on the left crankcase ENGINE No LEFT SIDE 1 VIN 2 engine number 1 2 142 168 qxd 06 6 1 11 08 ページ152 ...

Page 159: ...t 0 66 Imp qt 1 28 US qt 1 06 Imp qt 1 53 US qt 1 28 Imp qt After disassembly Cooling system capacity After draining Single 6 inclined from vertical Metric 96 0 x 62 1 mm 8 0 mm 449 cm3 0 65R 0 75R 1 21R 1 45R 0 70R 0 87R 0 67R Item Type Frame Fork oil capacity except fork damper per leg F suspension R suspension Tyre size front U DK type F brake swept area R brake swept area Fuel recommendation F...

Page 160: ...ry 12V 6 Ah Light Headlight 12V 35 W Clutch type Transmission Primary reduction Gear ratio I Gear ratio II Gear ratio III Gear ratio IV Gear ratio V Final reduction Item Gear shift pattern Ignition Starting system Spark plug Standard Optional Spark plug gap 1 0 1 1 mm 0 039 0 043 in Fuse Main fuse 15 A Left foot operated return system 1 N 2 3 4 5 IFR8H11 VK24PRZ11 IFR9H11 VK27PRZ11 142 168 qxd 06 ...

Page 161: ...cover bolts Transmission oil check bolt Crankshaft 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 3 5 4 2 9 6 11 8 10 ...

Page 162: ...de 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 N m kgf m lbf ft 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 4 5 9 0 2 0 13 1 2 8 5 5 2 7 5 5 5 5 4 5 4 5 9 0 3 5 3 1 5 4 5 4 5 4 4 5 3 9 0 5 1 2 0 6 80 16 15 16...

Page 163: ... 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 N m kgf m lbf ft 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 1 0 3 5 3 1 1 6 1 6 3 7 0 4 0 4 1 2 3 1 5 0 1 2 1 2 7 0 2 2 1 3 0 7 0 1 0 5 2 7 2 7 2 1 3 3 2 7 0 1 0 1 0 1 5 6 3 1 9 9 34...

Page 164: ...l even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is not yet complete Before buying fuel from an unfamiliar station try to find out if the fuel contains alcohol If it does confirm the typ...

Page 165: ...e on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many hours of running The most effective way to schedule maintenance is by the hours you have run your CRF An official guesstimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft operators do but without the benefit of an electrica...

Page 166: ...ion Date Running Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Competition Logbook 142 168 qxd 06 6 1 11 08 ページ160 ...

Page 167: ...gf mm 296 8 lbf in 0 47 kgf mm 26 32 lbf in 0 45 kgf mm 25 20 lbf in 0 49 kgf mm 27 44 lbf in FRAME Remarks Driven sprocket Standard Drive chain links 51 Teeth Aluminum 114 Optional 50 Teeth Aluminum 114 Optional no offset 52 Teeth Aluminum 116 Handlebar lower holder Standard 3 mm offset Red Blue 5 70 kgf mm 319 2 lbf in 5 90 kgf mm 330 4 lbf in Pink Silver These parts and tools may be ordered fro...

Page 168: ...1 2 3 wrench large adjustable wrenches open end box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tyre pressure gauge tyre irons tyre pump or air tank feeler gauge set vernier caliper metric Honda Special Tools Any special tools for your CRF purchased from your Honda dealer L...

Page 169: ...Technical Information 163 Wiring Diagram 142 168 qxd 06 6 1 11 08 ページ163 ...

Page 170: ...frame 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 63 Spark Arrester 66 Valve Clearance 67 Piston Piston Rings Piston Pin 76 Chassis Suspension 84 Brakes 88 Wheels 92 Tyres Tubes 93 Side Stand 95 Drive Ch...

Page 171: ... 151 Vehicle Identification 152 Specifications 153 Torque Specifications 155 Petrol Containing Alcohol 158 Competition Logbook 159 Optional Parts List 161 Spare Parts Equipment 162 Wiring Diagram 163 Table of Contents 164 Index 166 142 168 qxd 06 6 1 11 09 ページ165 ...

Page 172: ...ents 130 disassembly assembly 133 idle speed 136 care appearance 105 chain drive 96 chassis adjustments 137 choke knob 15 cleaner air 51 cleaning appearance care 105 clutch system adjustment 56 competition logbook 159 controls operating 7 coolant 48 cylinder system 78 damping adjustments front 108 rear 123 diagram wiring 163 drive chain 96 engine flooded 16 idle speed 136 number 152 pinging 41 sta...

Page 173: ... 158 pinging engine 41 plug spark 61 pre load rear suspension 122 pre ride inspection 11 protective apparel 2 rear suspension maintenance 85 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 ...

Page 174: ...pressure 93 flat 93 selection 94 tools 162 torque specifications 155 157 transporting 142 tripmeter 14 troubleshooting 146 tubes replacing 93 valve fuel 15 vehicle identification no VIN 152 washing your motorcycle 105 weight limit 3 wheels 92 wiring diagram 163 W V T 142 168 qxd 06 6 1 11 09 ページ168 ...

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