Honda crf250r 2012 Owner's Manual
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Honda crf250r 2012 Owner's Manual

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Levi stachler
March 11, 2025

Can you tell me what coolant type to put in a 2012 honda crf250r

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1 comments:
Mr. Anderson
March 11, 2025

The recommended coolant type for a 2012 Honda CRF250R is ethylene glycol antifreeze (silicate-free) for aluminum engines in a 50/50 solution with Pro Honda HP Coolant or equivalent distilled water.

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Summary of Contents for Honda crf250r 2012

  • Page 2 2012 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 3 NOTICE symbol. This information is intended to help you abbreviations are used to identify the respective When you own a Honda, you’re part of a avoid damage to your CRF, other property, or the parts or system. worldwide family of satisfied customers – people environment.
  • Page 4 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 5: Table Of Contents

    Contents Chassis MOTORCYCLE SAFETY.......1 SERVICING YOUR HONDA......21 Important Safety Information......2 Before You Service Your Honda Suspension............85 Important Safety Precautions......2 The Importance of Maintenance .......22 Brakes..............90 Wheels...............94 Accessories & Modifications ......3 Maintenance Safety...........23 Tires & Tubes ............95 Safety Labels............4 Important Safety Precautions......23 Maintenance Schedule ........24...
  • Page 6 Wiring Diagram..........158 Gearing ............137 Tire Selection for Track Conditions....138 CONSUMER INFORMATION ....159 Personal Fit Adjustments ........139 Authorized Manuals ........160 Control Positioning ........139 Contacting Honda..........161 Handlebar Position, Width & Shape...139 Your Dealer .............162 The Honda Rider’s Club (USA only) .....163 Contents...

  • Page 8: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Information.......2 information and recommendations to help you Important Safety Precautions......2 ride your CRF safely. Please take a few Accessories & Modifications .......3 moments to read these pages. This section also Safety Labels ............4 includes information about the location of safety labels on your CRF.

  • Page 9: Important Safety Information

    As an experienced rider, you know there is much Keep your Honda in Safe Condition. Maintaining your CRF properly is critical to your you can do to protect yourself when you ride. safety. A loose bolt, for example, can cause a The following are a few precautions we consider to be most important.

  • Page 10: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 11: Safety Labels

    Safety Labels Read these labels carefully and don’t remove them. If the label comes off or becomes hard to read, contact your dealer for replacement. (For Canada) Motorcycle Safety...

  • Page 12: Instruments & Controls

    Instruments & Controls Read this section carefully before you ride. It Operation Component Locations ......6 presents the location of the basic controls on your Indicator ...............7 CRF. MIL Blink Pattern..........7 Current DTC/Freeze DTC .......7 Circuit Inspection..........8 DTC Index ............9 Instruments & Controls...

  • Page 13: Operation Component Locations

    Operation Component Locations clutch lever front brake lever throttle grip engine stop button fast idle knob (engine idle speed) kickstarter rear brake pedal shift lever Instruments & Controls...

  • Page 14: Indicator

    If the MIL comes on at any other time, reduce speed and refer to an official Honda Service Manual available for purchase from your dealer (page 160). If the MIL does not come on when it should, have your dealer check it for problems.

  • Page 15: Circuit Inspection

    Indicator Circuit Inspection Always clean around the ECM and keep debris away from the connectors before disconnecting them. A faulty PGM-FI system is often related to poorly connected or corroded connections. Check the following connections. (1) MAP sensor connector (2) ECT sensor connector (3) TP sensor connector (4) IAT sensor connector (5) Injector connector...

  • Page 16: Dtc Index

    The series of 12, 19, and 69 MIL blinks cannot be checked because the engine cannot be started. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 160) for troubleshooting of the PGM-FI symptom.
  • Page 17 Instruments & Controls...

  • Page 18: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........12 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?....13 you prepared, this section discusses how to Pre-ride Inspection........13...

  • Page 19: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 20: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the Check the following before each ride: right): •...
  • Page 21 Before Riding...

  • Page 22: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions........16 start and stop your engine as well as break-in Starting & Stopping the Engine ......17 guidelines. Fast Idle Knob ..........17 Preparation ............17 Starting Procedure ........17 How to Stop the Engine........18 Break-in Guidelines ...........19 Basic Operating Instructions Basic Operating Instructions...

  • Page 23: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 24: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Warm Engine Starting Starting Procedure described below. 1. Shift the transmission into neutral. 2. Kick-start the engine (Do not open the throttle). Your CRF can be kickstarted with the Always follow the proper starting procedure transmission in gear by pulling in the clutch lever described as follows.

  • Page 25: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine (1) throttle (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Lightly open the throttle (1) two or three times, and then close it. 3. Push and hold the engine stop button (2) until the engine stops completely.

  • Page 26: Break-In Guidelines

    Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...
  • Page 27 Basic Operating Instructions...

  • Page 28: Servicing Your Honda

    You’ll also find Drive Chain ............97 important safety precautions, information on oils, Service Preparations Exhaust Pipe/Muffler ........100 and tips for keeping your Honda looking good. Maintenance Component Locations....32 Steering Damper..........103 Seat ..............33 Additional Maintenance Procedures ....105 An ECM system is used on this motorcycle;...

  • Page 29: The Importance Of Maintenance

    Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda...

  • Page 30: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 31: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only Honda...
  • Page 32 94-96 STEERING HEAD BEARINGS WE RECOMMENDED THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1.Clean after every moto for dusty riding condition.

  • Page 33: General Competition Maintenance

    Use Honda Genuine Parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 34 Lithium Grease, or an equivalent, is handy for this because any dirt that penetrates this sealing area will show up clearly (page 56). Use a Honda Genuine air cleaner or an equivalent air cleaner Engine Oil and Filter specified for your model.
  • Page 35 Remove the nuts, clean remove the nuts, clean the threads, and apply Pro Honda the threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent before torquing the nuts. Hondalock or an equivalent and tighten to the specified torque.
  • Page 36 If oil leaks through the bleed hole, the oil seal is the throttle operation is perfect after servicing and damaged. See an official Honda Service Manual or consult inspecting. your dealer for replacing the mechanical seal or oil seal.

  • Page 37: Before & After Competition Maintenance

    (1) are in the same position on (2) pressure release screw each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...
  • Page 38 If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 107). Servicing Your Honda...

  • Page 39: Maintenance Component Locations

    (engine idle speed) rebound damping adjuster drain bolt damping adjuster engine oil filter Servicing Your Honda...

  • Page 40: Seat

    2. Install and tighten the seat mounting bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (1) seat front prong (2) seat bracket (3) seat rear prong (4) ECM bracket Servicing Your Honda...

  • Page 41: Fuel Tank

    Do not support the fuel tank by the fuel feed 5. Pull the breather tube (5) out of steering stem hose (8). nut. 6. Unhook the fuel tank band (6). (12) cushion rubbers Servicing Your Honda...
  • Page 42 (11) (13) (10) (3) fuel tank (5) fuel tank band (4) collar and fuel tank bolt (9) shrouds (10) shroud tabs (11) air cleaner housing cover tabs (12) shroud B bolts (13) collars and shroud A bolts Servicing Your Honda...

  • Page 43: Subframe

    7. Loosen the screw (15) on the air cleaner (2) seat mounting bolts (4) seat connecting tube clamp (16). 3. Loosen the muffler clamp bolt (5). (16) (11) (15) (11) IAT sensor connector (15) screw (16) air cleaner connecting tube clamp (5) muffler clamp bolt Servicing Your Honda...
  • Page 44 Be careful not to damage the ECM and wires. (10) right subframe lower bolt (20) (21) (20) subframe (21) crankcase breather tube (2) ECM (5) air cleaner housing cover tabs (3) bracket (6) air cleaner connecting tube (cont’d) (4) shroud tabs (7) throttle body Servicing Your Honda...
  • Page 45 0.18 ± 0.06 in (4.5 ± 1.5 mm). (23) (18) (21) (13) (17) 0.18 ± 0.06 in (17) IAT sensor connector (22) (4.5 ± 1.5 mm) (18) muffler clamp (22) tab (21) muffler (23) cutout (13) screw Servicing Your Honda...
  • Page 46 15 lbf·ft (21 N·m, 2.1 kgf·m) (30) (32) (27) (26) muffler mounting B bolt (27) muffler mounting A bolt (28) (29) seat (30) side covers (31) seat mounting bolts (32) bolts (28) muffler clamp bolt Servicing Your Honda...

  • Page 47: Fuel System

    91 (or higher) and flame away. • Handle fuel only outdoors. Use only unleaded fuel in your Honda. If you • Wipe up spills immediately. ride your Honda in a country where leaded fuel might be available, take precautions to use only 3.
  • Page 48 Fuel Pump side: (1) fuel quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting 5. Remove the bolt (4), clamp and setting rubber (5). (8) shop towel (cont’d) (4) bolt (5) clamp and setting rubber Servicing Your Honda...
  • Page 49 • Handle fuel only outdoors. • Wipe up spills immediately. Injector side: Fuel Pump side: Align (1) retainer (new) (3) locking pawls (2) connector (4) connector grooves (10) (10) (9) retainer tabs (10) locking pawls Servicing Your Honda...
  • Page 50 (11) with the groove (16) rubber cover (12) of the stay. 7. Install the fuel tank (page 35). (11) 8. Increase the fuel pressure (page 48). (10) (12) (8) rubber (11) clamp tab (9) clamp (12) groove (10) bolt Servicing Your Honda...
  • Page 51 (10) (11) (1) fuel pump mounting bolts (2) stopper cable guide (10) fuel pump wire terminals (3) stopper cable (11) fuel pump base (4) washers (5) collars (6) conical spring washers (7) fuel pump plate Servicing Your Honda...
  • Page 52 13. Remove the fuel pump filter from the fuel pump assembly (20). (12) hooks (14) grooves (13) tabs (17) (19) (18) (20) (17) fuel pump stopper (18) damper rubber (19) fuel pump assembly (20) fuel pump filter Servicing Your Honda...
  • Page 53 (12) O-ring (new) pump filter as shown. (13) fuel pump base Install the fuel pump stopper (11). (14) fuel pump unit holder assembly (15) hooks (16) grooves (17) tabs (11) (10) (10) new damper rubber (11) fuel pump stopper Servicing Your Honda...
  • Page 54 (19) black wire terminal (20) fuel pump base terminals (26) fuel pump plate (27) identification mark (21) O-ring (new) (22) fuel pump unit 15. Connect the fuel line (page 42). 16. Increase the fuel pressure (page 48). Servicing Your Honda...
  • Page 55 (3) between the main and sub-harness as shown. Connect the battery harness positive (+) cable first, then connect the battery harness negative (–) cable to a 12V battery terminals. • Battery harness 070MZ-MEN0100 • Battery harness adapter 070MZ-KRN0100 Servicing Your Honda...

  • Page 56: Engine Oil

    SAE 10W–30 (weight) JASO T 903 standard MA suggested oil* Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil* * Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label.

  • Page 57: Changing Engine Oil & Filter

    Improper disposal of drained fluids is harmful to the environment. (1) engine oil fill cap/dipstick (1) engine oil fill cap/dipstick (2) upper level mark (2) engine oil drain bolt (3) lower level mark (3) sealing washer (new) Servicing Your Honda...
  • Page 58 (9) facing out, away from the engine. You should see the “OUT-SIDE” mark (10) on the filter body, near the rubber seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Servicing Your Honda...

  • Page 59: Transmission Oil

    Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil* JASO T 903 standard The JASO T 903 standard is an index for engine * Suggested 4-stroke engine oils are equal oils for 4-stroke motorcycle engines.
  • Page 60 1– 4. 12 lbf·ft (16 N·m, 1.6 kgf·m) 5. After inspecting the oil level or adding oil, tighten the oil check bolt to the specified torque: Oil Check Bolt: 9 lbf·ft (12 N·m, 1.2 kgf·m). Servicing Your Honda...

  • Page 61: Coolant

    Coolant Recommendation Checking & Adding Coolant 1.09 US qt (1.03R) after draining 3. Install the radiator cap securely. Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 23. quality ethylene glycol antifreeze containing NOTICE corrosion protection inhibitors specifically 1.
  • Page 62 2. Check the water hoses (1) for cracks, through the bleed hole, the oil seal is are mechanically qualified. Refer to the Honda deterioration, and hose clamp for looseness. Service Manual (page 160).

  • Page 63: Air Cleaner

    Your CRF’s air cleaner has very specific performance requirements. Use a new Honda (1) air cleaner retaining bolt Genuine air cleaner specified for your model or (2) air cleaner assembly an air cleaner of equal quality.
  • Page 64 Install the holder tab (5) in the hole (6) of the air cleaner element. NOTICE 8. Apply 0.1 – 0.2 oz (3 – 5 g) of Pro Honda (3) air cleaner element (5) holder tab White Lithium Grease or equivalent to the air...

  • Page 65: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) crankcase breather tube Servicing Your Honda...

  • Page 66: Throttle

    4. Operate the throttle grip to ensure that it functions smoothly and returns completely. If you can’t get the freeplay within the specified range, contact your dealer. (–) (2) dust cover (+) increase (3) lock nut (–) decrease (4) upper adjuster Servicing Your Honda...
  • Page 67 (1) throttle housing (2) paint mark 2. Check for smooth rotation of the throttle (3) from fully open to fully closed in all steering positions. If there is a problem, see your dealer. (3) throttle Servicing Your Honda...

  • Page 68: Engine Idle Speed

    3. Shift the transmission into neutral. Start the engine. 4. Keep the motorcycle in an upright position. 5. Adjust idle speed with the fast idle knob (1). Idle speed: 2,000 ± 100 rpm (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 69: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. Servicing Your Honda...
  • Page 70 If you can’t get proper adjustment, or the clutch 2. Check the clutch cable for deterioration, does not work properly, the cable may be kinked kinks, or damage. or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 65). Servicing Your Honda...
  • Page 71 3. Remove the five clutch spring bolts and clutch clutch lifter if the bearing plate does not turn springs (4). smoothly. Loosen the bolts in a crisscross pattern in two or three progressive steps. (6) clutch lifter (7) clutch lifter rod Servicing Your Honda...
  • Page 72 Service Limit: 0.112 in (2.85 mm) Replace the clutch discs and clutch plates as an assembly. (2) clutch plate If you feel the clutch slippage when replacing the clutch discs and plates, replace the clutch springs. (1) clutch disc Servicing Your Honda...
  • Page 73 (1) spring seat (4) clutch plates 9 lbf·ft (12 N·m, 1.2 kgf·m) (2) judder spring (5) clutch disc A (3) clutch discs (8) clutch pressure plate (9) clutch spring bolts/clutch springs Servicing Your Honda...

  • Page 74: Spark Plug

    10. Connect the direct ignition coil. Take care to avoid pinching any cables or wires. (3) sealing gasket 11. Install the fuel tank and seat (pages 33, 35). (4) spark plug gap Servicing Your Honda...

  • Page 75: Valve Clearance

    (1) breather tube (2) spark plug cap 3. Remove the cylinder head cover bolts/rubber seals (3) and cylinder head cover (4). (3) cylinder head cover bolts/rubber seals (4) cylinder head cover 4. Remove the spark plug hole packing. Servicing Your Honda...
  • Page 76 If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 70) and select the correct shim for each valve. (2) primary drive gear bolt (4) “∆” mark (3) punch mark (5) exhaust rocker arm Servicing Your Honda...
  • Page 77 (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. (1) cam chain tensioner lifter cover bolt (2) sealing washer (3) tensioner stopper Servicing Your Honda...
  • Page 78 Do not let the set rings fall into the crankcase. NOTICE If the set rings are remained on the camshaft holder, remove the set rings carefully. Do not let the valve lifters or shims fall into the crankcase. (10) (10) valve lifters Servicing Your Honda...
  • Page 79 2. Measure the shim thickness with a micrometer and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...
  • Page 80 (3). Install the valve lifters to the proper position. (15) (13) set rings (15) camshaft bearing grooves (12) (7) cam shaft (12) cam chain (8) intake cam lobes (cont’d) (3) valve lifters Servicing Your Honda...
  • Page 81 11 lbf·ft (15 N·m, 1.5 kgf·m) (14) (20) sealing washer (24) (21) cam chain tensioner lifter cover bolt (14) (23) (18) (14) camshaft holders (17) camshaft holder bolts A (23) O-ring (new) (18) camshaft holder bolts B (24) crankshaft hole cap Servicing Your Honda...
  • Page 82 5. Connect the spark plug cap (7) and breather tube (8). (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (7) spark plug cap (8) breather tube 6. Install the fuel tank and the seat (pages 33, 35). Servicing Your Honda...

  • Page 83: Piston/Piston Rings/Piston Pin

    (7) out from the insulator (8). Do not hang the throttle body and support it with a suitable strap. (2) radiator hose clamp screw (3) radiator hose (6) insulator band screw (7) throttle body (8) insulator Servicing Your Honda...
  • Page 84 (14) cylinder bolt (10) (12) (15) cylinder head stud bolts/washers (16) cylinder head (9) cylinder head hanger bolts (10) cylinder head hanger plate bolts (11) left cylinder head hanger plate (12) right cylinder head hanger plate (cont’d) Servicing Your Honda...
  • Page 85 18. Remove the dowel pins (17), cylinder head gasket (18) and cam chain guide (19). NOTICE Do not let the dowel pins and cam chain fall into the crankcase. (19) (17) (18) (17) dowel pins (19) cam chain guide (18) cylinder head gasket Servicing Your Honda...
  • Page 86 2. Remove the dowel pins (3) and cylinder (1) piston ring gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 87 Space the ring end gaps 180 degrees apart between the top ring and the upper side rail. spacer ring Space the ring end gaps 90 degrees apart side rail between the upper side rail, spacer, and the lower side rail. Servicing Your Honda...
  • Page 88 (6). (1) dowel pins (2) cylinder gasket 5. Clean any gasket material off the cylinder. (1) piston (4) piston pin (2) “O” mark (5) piston pin clip (3) large valve recess (6) piston cut-out (cont’d) Servicing Your Honda...
  • Page 89 Do not let the dowel pins fall into the crankcase. Do not damage the piston rings and cylinder walls. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (5) piston rings (4) cylinder Servicing Your Honda...
  • Page 90 Do not let the washers and nuts fall into the crankcase. (10) (10) (3) cylinder head (4) cylinder head stud bolts/washers (7) left cylinder head hanger plate (8) right cylinder head hanger plate (9) cylinder head hanger plate bolts (10) cylinder head hanger bolts (cont’d) Servicing Your Honda...
  • Page 91 – secondary air leaks (16) – coolant leaks 0 – 0.04 in – oil leaks (0 – 1.0 mm) (19) radiator hose clamp screw (15) (14) (14) rear shock absorber (16) nut (15) rear shock absorber upper bolt Servicing Your Honda...

  • Page 92: Suspension

    Replace the wear ring if it is 0.06 in (1.5 mm) materials. Check the oil for any or flat with the outer tube (4). contamination. When replacing the wear ring, remove the fork leg (page 112). Install the wear ring with its end gap (5) facing rearward. Servicing Your Honda...

  • Page 93: Rear Suspension Inspection

    If there is, have the adjustment.) bearings replaced by your dealer. • If you have a problem finding an acceptable adjustment, return to the standard position and begin again. Servicing Your Honda...

  • Page 94: Recommended Fork Oil

    10/50 18.9 16.5 14.8 13.7 12.5 11.4 0/32 18.4 15.9 14.5 13.7 11.7 10°C/50°F (1) outer tube (3) lock nut wrench 0°C/32°F 20°C/68°F (2) fork damper (4) axle holder 30°C/86°F (1) outer tube (7) oil hole (cont’d) Servicing Your Honda...
  • Page 95 Standard oil 12.8 US oz capacity (377 cm Maximum oil 13.0 US oz Slightly stiffer as capacity (385 cm it nears full compression. Minimum oil 10.2 US oz Slightly softer as capacity (301 cm it nears full compression. Servicing Your Honda...
  • Page 96 When using the lock nut wrench, use a 20 in (500 mm) long deflecting beam 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. Servicing Your Honda...

  • Page 97: Brakes

    (page 93), (1) lock nut there is probably air in the brake system. (2) adjuster Refer to an official Honda Service Manual or see your dealer to have the air 1. Loosen the lock nut (1). (–) 2.
  • Page 98 Honda recommends using Honda DOT 4 system and it must be bled. brake fluid from a scaled container, or an Refer to an official Honda Service Manual or see equivalent. your dealer for brake bleeding. Honda recommends using Honda DOT 4...
  • Page 99 Do not mix different types of fluid as they may not be compatible. may not be compatible. • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent.
  • Page 100 0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) front brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 101: Wheels

    3. Check wheel rim runout. If runout is possible loss of control. It’s also important that noticeable, see the Honda Service Manual for the rim locks are secure to prevent tire slippage. inspection instructions.

  • Page 102: Tires & Tubes

    Underinflated tires can also cause wheel damage on hard terrain. Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...
  • Page 103 • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 104: Drive Chain

    Lubricate the drive chain (page 98) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed (page 98). (2) chain guide slider (3) wear limit Servicing Your Honda...
  • Page 105 2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda HP Chain Lube or an equivalent is rollers and replace them if below the service Align the index marks (4) of the axle plates recommended.
  • Page 106 17 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 107: Exhaust Pipe/Muffler

    B bolt (6), washe A (7), washer B (8) and muffler (9). (1) seat mounting bolt (3) right side cover (2) side cover bolt (5) muffler mounting A bolt (8) washer B (6) muffler mounting B bolt (9) muffler (7) washer A Servicing Your Honda...
  • Page 108 4. Install the muffler clamp (2) by aligning the tab (5) of the muffler clamp with the cutout (6) of the muffler. (11) (11) muffler clamp bolt (2) muffler clamp (5) tab (4) muffler (6) cutout (cont’d) Servicing Your Honda...
  • Page 109 4. Tighten the exhaust pipe joint nuts to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) 5. Tighten the muffler clamp bolt, muffler mounting A bolt and B bolt (page 101). 6. Installation can be done in the reverse order of removal. Servicing Your Honda...

  • Page 110: Steering Damper

    (9) as shown. steering damper at the standard setting before Refer to the Honda Service Manual or see making any adjustments. your Honda dealer for steering damper • Check the spherical bearings and dust seal for disassembly.
  • Page 111 (1), collar (2) and steering damper (3). Replace the spherical bearing if it does not move smoothly and quietly. Refer to the Honda Service Manual or see your dealer. (1) steering damper (2) “UP” mark (3) stopper ring...

  • Page 112: Additional Maintenance Procedures

    (1) handlebar (2) handlebar holders the fork bushings may be worn. Refer to the (3) paint mark Honda Service Manual for replacement or (4) handlebar upper holder bolts adjustment procedures, or see your dealer. Control Cables Periodically, disconnect the throttle, clutch and hot start cables at their upper ends.
  • Page 113 (12) drive sprocket bolt Transmission oil drain bolt (6) clutch cover bolts (13) transmission oil drain bolt Cylinder head stud bolts (7) coolant drain bolt (14) cylinder head stud bolts (8) engine oil drainbolt Servicing Your Honda Servicing Your Honda...

  • Page 114: Appearance Care

    Wet any heavy deposits with water first. Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge. Servicing Your Honda...
  • Page 115 #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda Servicing Your Honda...

  • Page 116: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments ......110 for maximum competition performance. Rear Suspension Adjustments ......125 Suspension Adjustments for Track Initial suspension adjustments should be Conditions...........129 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....130 break-in time.

  • Page 117: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Compression Damping Adjustment as it is worked (such as in a fork).

  • Page 118: Fork Springs

    Front Suspension Adjustments Both compression and rebound damping can be Fork Springs increased by turning the adjuster clockwise. The fork springs in CRF’s are about right for NOTICE riders weighing between 170 lb (77 kg) and 200 Always start with full hard when adjusting lb (91 kg) (less riding gear).

  • Page 119: Front Suspension Disassembly

    NOTICE disassembled and cleaned after the first 3 hours of riding. See an official Honda Keep the master cylinder upright to prevent air Service Manual or your dealer for this service. from entering system.
  • Page 120 Front Suspension Adjustments 7. Remove the front axle nut (9) and loosen the 11. Loosen the fork bridge lower pinch bolts (19), then pull the fork legs down and out. axle pinch bolts (10) on both forks. (15) (14) Pull the front axle shaft (11) out of the wheel hub and remove the front wheel with disc cover/collar.
  • Page 121 Front Suspension Adjustments 14. Hold the outer tube, then remove the fork 15. Drain the fork oil from the outer tube/slider 18. Make the mechanic's stopper tool out of a thin damper (6) from the outer tube using a lock (26) and oil holes (27) of the fork damper.

  • Page 122: Damper Oil Change

    Front Suspension Adjustments 23. Remove the fork damper assembly (32) from Damper Oil Change (23) the fork assembly (33). (30) Remove the fork from the vise. Remove the fork spring (34), spring retainer 1. Place the fork damper (1) in a vise with a (29) (35) and collar/washer (36) from the fork piece of wood or soft jaws to avoid damage.
  • Page 123 Front Suspension Adjustments 3. Remove the fork cap assembly (2) from the 6. Clean the fork cap and fork damper threads 8. Pump the fork damper piston rod (4) slowly several times to bleed the air from the fork fork damper threads and then pop it out by (6).
  • Page 124 Front Suspension Adjustments 10. Extend the fork damper piston rod (4) to 11. Place the fork damper (1) in a vise with a 13. Check the fork damper piston rod sliding maximum length, holding it, install the fork surface for damage. piece of wood or soft jaws to avoid damage.

  • Page 125: Fork Assembly

    Front Suspension Adjustments 15. Drain the extra oil from the oil holes (12) of NOTICE Fork Assembly the fork damper oil chamber (5). Improper disposal of drained fluids is harmful to By doing this procedure, about 0.2 US oz (5 cm 1.
  • Page 126 Front Suspension Adjustments 3. Install the collar (3) to the C-ring (4) of the 4. Blow out the oil completely off the fork 5. Place the lower end (axle holder) of the slider fork damper assembly (5) as shown. in a vise with a piece of wood or soft jaws to spring (8) using compressed air.
  • Page 127 Front Suspension Adjustments 9. Measure the length of the fork center bolt lock 11. Remove the piston base or mechanic's stopper 14. Remove the fork damper from the fork. nut (2) and fork center bolt (12) clearance. tool while pushing the fork damper. 15.
  • Page 128 Front Suspension Adjustments 16. Install a new O-ring (15) on the fork damper Fork Oil Capacity: Optional Stiffer 26.20 lbf/in (4.59 N/mm) Fork Spring assembly (4). Apply the recommended fork Standard 25.12 lbf/in (4.4 N/mm) Fork Spring oil to the O-ring. 17.
  • Page 129 Front Suspension Adjustments 19. Tighten the fork damper (17) to the specified 23. Clean the threads of the fork protector socket torque using the lock nut wrench (18). bolts (22) and axle holder thoroughly. Actual: Apply locking agent to the bolt threads. 25 lbf·ft (34 N·m, 3.5 kgf·m) Install the fork protectors (23), fork protector Torque wrench scale reading:...
  • Page 130 Front Suspension Adjustments 26. Clean the threads of the brake caliper 30. Install the handlebar (34), mounting rubbers, mounting bolts (29) and brake caliper washers and handlebar lower holder nuts (35) (30) (31) thoroughly. and tighten the handlebar holder nuts to the Apply locking agent to the bolt threads.
  • Page 131 Front Suspension Adjustments 32. With the front brake applied, pump the fork 34. Install and tighten the disc cover socket bolt up and down several times to seat the axle and (37) to the specified torque: check front brake operation. 10 Ibf·ft (13 N·m, 1.3 kgf·m) (37) (37) disc cover socket bolt...

  • Page 132: Rear Suspension Adjustments

    Service or disposal should only be done by your dealer or a qualified mechanic, equipped with the proper tools, safety equipment and the Honda Service 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.

  • Page 133: Rear Suspension Damping

    Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression Compression Damping adjuster. Compression damping may be adjusted in two The high speed damping adjuster has 3 1/2 turn or more.

  • Page 134: Rear Suspension Race Sag

    Rear Suspension Adjustments unloaded: motorcycle on an optional workstand Ask the other helper to measure the loaded Rear Suspension Race Sag with rear suspension fully extended, no rider. with rider dimension. loaded with rider: motorcycle on ground, with REAR FENDER MOUNTING BOLT Setting the proper race sag (ride height) is very rider.
  • Page 135 Rear Suspension Adjustments 5. Measure the loaded without rider dimension. Spring Rates A spring that is too stiff for your weight will not Do this with your CRF set at the standard race If you are lighter or heavier than the average allow the rear tire to hook up under acceleration rider and cannot set the proper ride height and will pass more bumps on to you.

  • Page 136: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 137: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 110 – 129. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 138 Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 139 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: –...

  • Page 140: Tuning Tips

    Tuning Tips An optional PGM-FI setting tool can change the NOTICE NOTICE ignition timing and amount of the fuel injection (page 157). Using spark plugs with an improper heat range An improperly tightened spark plug can damage Be sure to observe the PGM-FI setting by or incorrect reach can cause engine damage.

  • Page 141: Steering Damper Adjustment

    Steering Damper Adjustment The steering damper can be adjusted for riding Steering Damper Adjustment conditions by using following method: • Damping – Turning the steering damper adjuster adjusts how quickly the steering The steering damper adjuster (1) has 13 positions damper extends and retracts.

  • Page 142: Steering Damper Adjustment Guidelines

    Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods decribed on this page. Symptoms and Adjustment • Always begin with the standard settings. • Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment. Test ride after each adjustment.

  • Page 143: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle not adjustable. Align the groove in the outer tube changes in overall handling.

  • Page 144: Gearing

    Unless you have the required mechanical • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate knowhow, tools, and Honda Service Manual, higher gear (less teeth) to keep engine rpm appraisal of the gearing change. “Seat-of-the- sprocket changing should be done by your dealer.

  • Page 145: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 146: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to Handlebar Position, Width & Shape the threads of these bolts prior to adjustment to help ensure the correct torque is retained.
  • Page 147 Adjustments for Competition...

  • Page 148: Tips

    Tips Here’s helpful 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 ........144 Troubleshooting..........145 Tips...

  • Page 149: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 150: Storing Your Honda

    If you won’t be riding for an extended period, Removal from Storage such as during the winter, thoroughly inspect your Honda and correct any problem before storing it. That way, needed repairs won’t be 1. Uncover and clean your CRF.

  • Page 151: You & The Environment

    You & the Environment Owning and riding a motorcycle can be NOTICE enjoyable, but you must do your part to protect nature. When you show respect for the land, Improper disposal of drained fluids is harmful to wildlife, and other people, you also help preserve the environment.

  • Page 152: Troubleshooting

    The items that require use of an CORRECT • Worn cylinder and • Brake dragging 1. Check the wheel INCORRECT official Honda Service Manual are followed by piston ring • Worn or damaged spin smoothly • Damaged cylinder head wheel bearings an asterisk (*).
  • Page 153 Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy • Faulty ECM • Incorrect spark plug 1. Check the ignition INCORRECT 1. Check the spark INCORRECT •...

  • Page 154: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........148 other technical data. Specifications ...........149 Torque Specifications........150 Oxygenated Fuels..........153 Competition Logbook ........154 Optional Parts List ...........156 Spare Parts & Equipment.........157 Wiring Diagram..........158 Technical Information...

  • Page 155: Vehicle Identification

    Vehicle Identification The VIN (vehicle identification number) (1) is Serial Numbers stamped on the right side of the steering head. RIGHT SIDE The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of this manual.

  • Page 156: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85.9 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,181 mm Overall width Single 5˚ inclined from Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement vertical...

  • Page 157: Torque Specifications

    Torque Specifications Torque Nuts, Bolts, Fasteners Remarks Item lbf•ft N•m kgf•m ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts (14) RIGHT SIDE Water pump cover bolts Crankshaft hole cap NOTE 1 Transmission oil check bolt...
  • Page 158 Torque Specifications Frame Torque Item Remarks lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch (14) bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1...
  • Page 159 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (40) FRAME Caliper mounting bolts NOTE 4 (44) (41) (29) (37) Front brake disc nuts NOTE 1 (48) Rear brake disc nuts NOTE 1 Brake pedal pivot bolt NOTE 5 (33) Spoke (front) (rear)

  • Page 160: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions.

  • Page 161: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.
  • Page 162 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Steering Damper Settings, Gearing, Chassis Adjustments, Time Maintenance Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 163: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks authorized dealer. Shock spring 296.9 lbf/in (52.0 N/mm) Standard FRAME Remarks No mark Driven sprocket < >: Drive chain links (factory products) Standard 49 Teeth, Aluminum. Blue <116>...

  • Page 164: Spare Parts & Equipment

    In addition to the usual nuts and bolts, radiator hoses Chemical Products consider the following: radiator shrouds (L & R) brake hoses (front & rear) Pro Honda GN4 4-stroke Oil Spare Parts (Engine and Transmission Oil) General Tools SAE80 or 90 gear oil spark plugs HP Fork Oil, SS-19 air cleaner (clean &...

  • Page 165: Wiring Diagram

    Wiring Diagram Technical Information...

  • Page 166: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........160 contacting Honda and how to get an official Contacting Honda..........161 Honda Service Manual. Your Dealer ............162 The Honda Rider’s Club (USA only) ....163 Consumer Information...

  • Page 167: Authorized Manuals

    Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized manuals) Also available but not necessary to service your model is the Honda Common...

  • Page 168: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 169: Your Dealer

    Parts, Pro Honda products and Honda Genuine Accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department.

  • Page 170: The Honda Rider's Club (Usa Only)

    The Honda Rider’s Club (USA only) The Honda Rider’s Club of America (HRCA) sponsors local riding chapters at Authorized Honda Dealerships across the country. You can log on to the HRCA Clubhouse website for more information at www.hrca.honda.com. Consumer Information...

  • Page 171: Index

    ..........134 competition logbook........154 stop button............18 suspension, front ........110 consumer information ........159 stopping ............18 suspension, rear..........125 contacting Honda ..........161 won’t start ..........145 suspension, track conditions ......129 controls ..............5 environment, protecting ........144 tire selection ..........138 coolant ...............54 after competition maintenance ......30 customer service..........162...
  • Page 172 Index gap, spark plug ..........67 maintenance, rear suspension maintenance......125 gasohol ............153 after competition ..........30 Rider’s Club Honda (USA only).....163 gasoline..............40 before & after competition......30 riding, gearing.............137 between motos & practice......30 apparel ............2 guidelines, component locations ........32 basic operation ..........15 steering damper ..........135 general competition........26...
  • Page 173 Index stopping engine ..........18 storage .............143 subframe ............36 suspension, front ..............85 rear..............86 suspension adjustment, front ............110 rear..............125 for track conditions ........129 guidelines ...........130 transmission oil ..........52 tuning tips............133 throttle, freeplay............59 inspection .............60 tires, air pressure ...........95 flat ..............95 selection............138 tools ...............157 torque specifications engine ............150 frame ...........151-152...
  • Page 174 MEMO...
  • Page 175 MEMO...
  • Page 176 MEMO...

  • Page 177: Quick Reference

    Engine No. important notes. Owner’s: Name How To Avoid Costly Repairs Address City/State The engine of your Honda can be the most Phone expensive component to repair. Proper Dealer’s: maintenance, especially the use of the Name recommended fluids and filters, prevents Address premature wear and damage.

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