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This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
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Throughout this manual, the following information is intended to help you avoid damage abbreviations are used to identify the respective When you own a Honda, you’re part of a to your CRF, other property, or the environment. parts or system.
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A Few Words About Safety 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.
Contents MOTORCYCLE SAFETY......1 SERVICING YOUR HONDA ......21 Chassis Important Safety Information ......2 Before You Service Your Honda Suspension ............86 Brakes ............. 90 Important Safety Precautions ......2 The Importance of Maintenance .....22 Accessories & Modifications ......3 Maintenance Safety .........23...
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Tire Selection for Track Conditions ..... 140 CONSUMER INFORMATION....161 Personal Fit Adjustments ......141 Authorized Manuals ........162 Control Positioning ........141 Contacting Honda .........163 Handlebar Position, Width & Shape ..141 Your Honda Dealer ........164 The Honda Rider's Club (USA only) ....165 Contents...
Motorcycle Safety Motorcycle Safety This section presents some of the most important Important Safety Information......2 information and recommendations to help you ride Important Safety Precautions ......2 your CRF safely. Please take a few moments to Accessories & Modifications ......3 read these pages. This section also includes Safety Labels............4 information about the location of safety labels on your CRF.
Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.
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.
Safety Labels Safety Labels Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your dealer for replacement. (For Canada) NEVER OPEN WHEN HOT. Hot coolant w i l l scald you. N ' OUVREZ PAS OUAND CHAUD.
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 &...
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...
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 162) for troubleshooting of the PGM-FI symptom.
Before Riding Before Riding Before each ride, you need to make sure you and Are You Ready to Ride? ........12 your CRF are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? ....13 prepared, this section discusses how to evaluate Pre-ride Inspection ........13 your riding readiness, and what items you should check on your CRF.
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.
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 Check the following before each ride: following items (page numbers are at the right): •...
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 Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precautions begininng 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.
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 Always follow the proper starting procedure Your CRF can be kickstarted with the transmission throttle.) described as follow.
Starting & Stopping the Engine How to Stop the Engine 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.
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: •...
Fuel Tank ............34 consequently, routine ignition timing adjustment is Subframe ............37 Appearance Care..........109 unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual Service Procedures (page 162). Fluids & Filters Fuel System............39 An optional tool kit may be available. Check with Engine Oil ............48...
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...
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...
Procedures for items in this schedule are provided 6. Replace every year. in an official Honda Service Manual available for purchase from your dealer (page 162). Maintenance Procedures: I : inspect and clean, adjust, lubricate or replace if...
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94 – 96 STEERING HEAD BEARINGS WE RECOMMEND 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.
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.
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Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White Lithium...
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Always use new gaskets when reassembling components. Refer to Fuel Line Inspection on page 39. handgrips. Check the fuel line for deterioration, damage, or leakage. Refer to an official Honda Service Manual (page 162) for Cylinder head/Cylinder Replace the fuel line every year. installation instructions.
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A small amount of coolant offers added assurance and security. Remove the nuts, weeping from the bleed hole is normal. See an official Honda clean the threads of both the nuts and bolts, apply Pro Service Manual or consult your dealer for replacing the Honda Hondalock or an equivalent and tighten to the mechanical seal or oil seal.
If you decide to wash your CRF or use cleaners, Remove the drive chain, clean and lubricate it refer to Appearance Care (page 109). (pages 98, 99). Be sure the chain is wiped clean and is dry before lubricating the chain. Servicing Your Honda...
(7) hose clamp (8) breather tube (12) fuel feed hose (13) clamp 8. Pull the breather tube (8) out of steering stem nut. 9. Unhook the fuel tank band (9) and air cleaner rubber (10). Servicing Your Honda...
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4. Hook the air cleaner rubber (5) and the fuel tank band (6). (12) (15) (14) (12) fuel feed hose (15) fuel tank stopper cable (14) fuel tank (3) fuel tank (4) collar and fuel tank bolt (5) air cleaner rubber (6) fuel tank band (cont’d) Servicing Your Honda...
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(14) shroud tabs (15) air cleaner housing cover tabs (10) (16) shroud B bolts (13) (17) collars and shroud A bolts (11) 11. Install the seat (page 33). (12) (10) recesses (11) shroud hooks (12) shrouds (13) frame Servicing Your Honda...
Right side: 4. Remove the air cleaner box (3) from the subframe (4). (1) subframe upper bolts (2) subframe lower bolts (7) subframe lower bolts (8) subframe upper bolts (9) subframe (3) air cleaner box (4) subframe (cont’d) Servicing Your Honda...
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7. Install the left and right mufflers (page 101). the hole in the rear fender with the hole in the 8. Install the seat (page 33). subframe, and then install the rear fender mounting bolts (5). (5) rear fender mounting bolts Servicing Your Honda...
Never use stale or contaminated gasoline. Avoid getting dirt, dust or water in the fuel tank. (1) fuel quick connect fitting cover (2) fuel line 4. Install the fuel quick connect fitting cover. 5. Install the fuel tank (page 35). Servicing Your Honda...
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(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 (4) bolt (5) clamp and setting rubber Servicing Your Honda...
JASO T 903 standard suggested oil* Pro Honda GN4 4-stroke Oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label.
Improper disposal of drained fluids is harmful to the environment. (1) engine oil fill cap/dipstick (2) upper level mark (3) lower level mark (1) engine oil fill cap/dipstick (2) engine oil drain bolt (3) sealing washer (cont’d) Servicing Your Honda...
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(12) facing out, away from the engine. You should see the “OUT-SIDE” mark (13) on the filter body, near the seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Servicing Your Honda...
Pro Honda GN4 4-stroke Oil (USA & Canada), or Honda 4-stroke oil, 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 performance oils for 4-stroke motorcycle engines.
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(1) transmission oil fill cap (3) sealing washer (2) oil check bolt 5. After inspecting the oil level or adding oil, tighten the oil check bolt with a new sealing washer to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) Servicing Your Honda...
Coolant Recommendation Checking & Adding Coolant Use Pro Honda HP Coolant or an equivalent high Refer to Important Safety Precautions on page 23. quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically 1. Position your CRF on an optional workstand or...
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A small amount of coolant weeping from the 4. Make sure the overflow hose (2) is connected WARNING bleed hole is normal. See an official Honda and not clogged. Service Manual or consult your dealer for Removing the radiator cap while the 5.
Your CRF’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an (1) air cleaner retaining bolt air cleaner of equal quality.
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Install the holder tabs in the holes of the air (1) air cleaner retaining bolt cleaner element. 8. Apply 0.1 – 0.2 oz (3 – 5 g) of Pro Honda NOTICE White Lithium Grease or equivalent to the air cleaner housing contact area of the air cleaner Improper installation of the air cleaner assembly element.
1. Remove the crankcase breather tube plugs (1) from the crankcase breather tubes (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plugs. (1) crankcase breather tube plugs (2) crankcase breather tubes Servicing Your Honda...
Tighten the lock nut (3) to the specified torque: 3.0 lbf·ft (4.0 N·m, 0.4 kgf·m) Install the dust cover and make the adjustment with the lower adjuster. Servicing Your Honda...
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(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...
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...
Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected. (–) (1) lock nut (2) adjuster (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustment (page 62). Servicing Your Honda...
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2. Check the clutch cable for deterioration, kinks, worn, or the clutch discs may be worn. or damage. Inspect the clutch discs and plates (page 64). Servicing Your Honda...
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(4) clutch cover bolts (5) clutch cover (14) clutch discs, clutch plates, judder spring and spring 4. Remove the six clutch spring bolts and springs seat (6). Loosen the bolts in a crisscross pattern in two or three progressive steps. Servicing Your Honda...
10. Connect the spark plug cap. Take care to avoid pinching any cables or wires. (3) sealing gasket (4) spark plug gap 11. Install the fuel tank and seat (pages 33, 35). Servicing Your Honda...
(2) spark plug cap 3. Remove the cylinder head cover socket bolts (3), rubber seals (4) and cylinder head cover (5). (3) cylinder head cover socket bolts (4) cylinder head cover rubber seals (5) cylinder head cover (cont’d) Servicing Your Honda...
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360° and realign the punch mark with the index mark. (1) feeler gauge (2) valve lifters and cam lobes (2) primary drive gear bolt (4) index mark (3) punch mark Servicing Your Honda...
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3. Remove the cam chain tensioner lifter cover clearance need adjustment, see Camshaft Removal bolt (2) and sealing washer (3). (this page) and select the correct shim for each valve. (2) cam chain tensioner lifter cover bolt (3) sealing washer (cont’d) Servicing Your Honda...
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(14) (12) cam chain (9) camshaft holder NOTICE Do not let the set rings fall into the crankcase. If the set rings are remained on the camshaft holder, remove the set rings carefully. (14) (14) valve shims Servicing Your Honda...
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2.450 Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3.000 (1) valve lifter (2) shim 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda...
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(4) cylinder head (10) cam sprocket If the operation is not smooth, refer to an official (7) camshaft (11) left camshaft bearing Honda Service Manual (page 162) for (9) cam chain decompressor disassembly or see your dealer. Servicing Your Honda...
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(18) camshaft holder (20) camshaft holder bolts (long) (12) timing mark NOTICE (19) “ ” mark (21) camshaft holder bolts (short) (13) camshaft holder mating surface Do not let the set rings fall into the crankcase. (cont’d) Servicing Your Honda...
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15. Install a new sealing washer (24) and tighten the cam chain tensioner lifter cover bolt (25). (1) O-ring (new) (2) crankshaft hole cap (25) (24) (24) sealing washer (new) (25) cam chain tensioner lifter cover bolt Servicing Your Honda...
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4. Install and tighten the cylinder head cover socket bolts (6) to the specified torque: 7 lbf·ft (10 N·m, 1.0 kgf·m) (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (6) cylinder head cover socket bolts Servicing Your Honda...
Remove the ignition coil (2) by removing the connecting tube clamp (11). bolts (3). (11) (5) radiator hose clamp screw (6) radiator hose (10) (1) ignition coil connectors (3) bolts (2) ignition coil (10) screw (11) air cleaner connecting tube clamp Servicing Your Honda...
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(16) throttle body (17) insulator (13) (18) (18) cylinder head hanger bolts (19) cylinder head hanger plate bolts (20) left cylinder head hanger plate (13) rear shock absorber upper nut (21) right cylinder head hanger plate (14) bolt (cont’d) Servicing Your Honda...
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(23) cylinder head bolts and washers Do not let the cam chain fall into the crankcase. (24) cylinder head Do not pry on or strike the cylinder. (28) (27) (27) cam chain guide (28) cylinder (4) cylinder (5) piston Servicing Your Honda...
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6 races or about every 15.0 hours of running. Replace the piston pin every 12 races or about every 30.0 hours of running. (6) dowel pins (7) cylinder gasket (1) piston ring (1) piston pin clips (3) piston (2) piston pin Servicing Your Honda...
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Piston Ring Installation rotate freely, without sticking. Space the ring end gaps 180 degrees apart We recommend you consult an official Honda 1. Remove the carbon deposits from the piston between top ring and upper side rail. Service Manual or your dealer for correct Service head and piston ring grooves.
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Install the piston pin and new piston pin clips (7). NOTICE Use new pin clips. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8). Servicing Your Honda...
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3. Install a new cylinder gasket (1) and dowel pins (2). NOTICE Do not let the dowel pins fall into the crankcase. (6) O-ring (new) (8) bolts (7) water hose joint (3) cylinder (5) cam chain (4) piston rings (1) cylinder gasket (2) dowel pins Servicing Your Honda...
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Install the washers and cylinder head bolts (7) and tighten them to the specified torque in a crisscross pattern in two or three steps: 38 lbf·ft (51 N·m, 5.2 kgf·m) NOTICE Do not let the washers fall into the crankcase. (cont’d) Servicing Your Honda...
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(19) air cleaner connecting tube (20) throttle body (9) left cylinder head hanger plate (21) air cleaner connecting tube band screw (10) right cylinder head hanger plate (11) cylinder head hanger plate bolts (12) cylinder head hanger bolts Servicing Your Honda...
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Check for the following: (25) (28) ECT sensor connector – compression leaks (26) – abnormal engine noise – secondary air leaks (25) radiator hose – exhaust gas leaks (26) water hose joint – coolant leaks – oil leaks Servicing Your Honda...
(4). Remove the Check the dust seals for dust, dirt, and foreign fork leg when replacing the wear ring. materials. Check the oil for any contamination. Install the wear ring with its end gap (5) facing rearward. Servicing Your Honda...
• If you have a problem finding an acceptable worn or loose swingarm bearings. There adjustment, return to the standard position and should be no movement. If there is, have the begin again. bearings replaced by your dealer. Servicing Your Honda...
3. Drain the fork oil from the outer tube (1). Drain the fork oil from the oil holes (6) of the fork damper. (1) outer tube (3) lock nut wrench (2) fork damper (4) slider (1) outer tube (6) oil holes Servicing Your Honda...
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86°F/30°C to the fork damper. Be sure the oil capacity is the same in both fork legs. Inverted time (minutes) (1) outer tube (2) fork damper (7) O-ring Servicing Your Honda...
(3). recommended limit (page 93), there is probably air in the brake system. Refer to an official Honda Service Manual or see your dealer to have the air bled from the system. (–) (1) lock nut...
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Refer to an official Honda If the pulling distance for the front brake lever Service Manual or see your dealer for brake feels excessive, there is probably air in the brake bleeding.
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• The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 Brake Fluid or an equivalent. DOT 4 Brake Fluid or an equivalent.
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0.04 in (1.0 mm) (1) brake pads (3) brake disc (2) rear brake caliper replace 0.04 in (1.0 mm) wear indicator grooves (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...
Wheel Rims & Spokes Axles & Wheel Bearings Keeping the wheels true (round) and maintaining 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Service Manual for correct spoke tension is critical to safe motorcycle damage. inspection information: operation.
Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...
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• 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...
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...
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Measure the diameter of the drive chain rollers and turn the adjusting bolts (3) counterclockwise to be used in preference to motor oil. Pro Honda HP replace them if below the service limit. decrease slack or clockwise to increase slack.
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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...
5. Remove the mud guard (8) by removing the (1) side covers (3) bolts (2) air cleaner housing covers screws (9). 3. Loosen the right muffler clamp bolt (4). (8) mud guard (9) screws (4) right muffler clamp bolt Servicing Your Honda...
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(11) left muffler mounting A bolt (12) washer A (13) left muffler mounting B bolt (14) washer B (11) (15) left muffler (11) left muffler clamp bolt (2) left muffler clamp (5) tab (4) left muffler (6) cutout (cont’d) Servicing Your Honda...
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(12) mud guard (13) screws (19) air cleaner housing covers (21) bolts 13. Tighten the right muffler clamp bolt (18) to the (20) side covers specified torque: 15 lbf·ft (20 N·m, 2.0 kgf·m) 16. Install the seat (page 33). Servicing Your Honda...
15 lbf·ft (21 N·m, 2.1 kgf·m) 5. Tighten the left muffler clamp bolt, left muffler mounting A bolt and B bolt (page 101). 6. Install the mud guard (page 102). 7. Install the right muffler (page 102). Servicing Your Honda...
• After break-in, test run your CRF with the dealer for further inspection. Your dealer is Refer to an official Honda Service Manual or steering damper at the standard setting before qualified to determine whether or not replacement see your dealer for steering damper making any adjustments.
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If the damper rod does not extend to its maximum length, refer to an official Honda Service Manual for disassembly and inspection instructions or see your dealer. 4. Install the number plate (3) by aligning its holes (7) with the tabs (8) on the steering stem.
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Replace the spherical bearing if it does not move damper rod and its stopper ring (3) facing smoothly and quietly. toward the front side. Refer to an official Honda Service Manual or see 3. Install the collar (4) and steering damper your dealer. mounting bolts (5).
If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to an official Honda Service Manual for replacement or adjustment procedures, or see your dealer.
CRF. under extreme pressure can penetrate the dust Leaving water on the surface to air dry can You may use Pro Honda Hondabrite, a multi- seals of the suspension pivot points and cause dulling and water spots. As you dry,...
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#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...
Adjustments for Competition Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments.......112 for maximum competition performance. Front Suspension Damping......112 Fork Springs..........113 Initial suspension adjustments should be Front Suspension Disassembly ....114 performed after a minimum of 2 hours of easy Damper Oil Change ........118 break-in time.
Front Suspension Adjustments Front Suspension Adjustments The front suspension can be adjusted for the rider’s Both compression and rebound damping can be Front Suspension Damping weight and riding conditions by using one or more increased by turning the adjuster clockwise. of the following methods: Compression Damping Adjustment NOTICE...
Front Suspension Adjustments The correct “cold” PSF air pressures are: Oil capacity Fork Springs standard: 33 psi (230 kPa, 2.3 kgf/cm • Adjust the oil capacity refer to Fork Assembly on page 122. The CRF uses a pneumatic spring in the front fork. soft (minimum) 31 psi (220 kPa, 2.2 kgf/cm The front fork spring rate can be adjusted by...
3 hours of riding. See NOTICE an official Honda Service Manual or your dealer for this service. Keep the master cylinder upright to prevent air • When disassembling the fork, turn the from entering system.
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Front Suspension Adjustments 6. Remove the brake hose clamp bolts (10), stay 8. Remove the fork protector socket bolts (15) 11. Release the PSF air pressure. and fork protectors (16). A (11) and stay B (12). 7. Remove the brake caliper mounting bolts (13) (15) and brake caliper (14).
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Front Suspension Adjustments 13. Loosen the fork cap (21) using an adjustable 15. Loosen the fork bridge lower pinch bolts (25), 16. Hold the outer tube, then remove the fork wrench (22) and a lock nut wrench (23) but do then pull the fork legs down and out.
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Front Suspension Adjustments 17. Drain the fork oil from the outer tube/slider 20. Hold the fork center bolt lock nut (32) and 22. Remove the fork damper assembly (34) from (29) and oil holes (30) of the fork damper. remove the fork center bolt (31) from the fork the fork assembly (35).
Front Suspension Adjustments 2. Remove the fork cap assembly (1) from the 5. Clean the fork cap and fork damper threads (8). Damper Oil Change fork damper threads and then pop it out by pumping the fork damper piston rod (5) 1.
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Front Suspension Adjustments 7. Pump the fork damper piston rod (5) slowly 9. Extend the fork damper piston rod (5) to 10. Temporarily install the fork cap assembly (1) several times to bleed the air from the fork maximum length, holding it, install the fork to the fork damper (2) using an adjustable damper (2).
Front Suspension Adjustments 12. Check the fork damper piston rod sliding 14. Drain the extra oil from the oil holes (6) of the Fork Assembly surface for damage. fork damper oil/air chamber (7). 13. Cover the fork damper piston rod end with 1.
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Front Suspension Adjustments 3. Install the fork damper assembly (3) to the fork 6. Measure the length of the fork center bolt lock Amount of fork oil left in the fork unit: US oz assembly (1). nut (2) and fork center bolt (7) clearance. (without damper) Standard: 0.04 –...
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Front Suspension Adjustments 7. Tighten the fork center bolt lock nut (2) to the 9. Apply locking agent to the fork center bolt Fork Oil Capacity: fork center bolt (7) closely by hand. Tighten threads. the fork center bolt lock nut to the specified Install the fork center bolt (7) to the axle holder Standard oil 8.3 US oz...
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Front Suspension Adjustments 13. Insert both fork legs into the fork clamps. 14. Tighten the fork damper (11) to the specified 15. Tighten the fork cap (13) to the specified Tighten the fork bridge lower pinch bolts (10) torque using the lock nut wrench (12). torque using the open end wrench (14) and the to the specified torque: Actual:...
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Front Suspension Adjustments 18. Compare the length (15) at assembly and at 20. Tighten the fork bride lower pinch bolts (10) to 22. Clean the threads of the fork protector socket disassembly. They should be the same length. the specified torque: bolts (19) and axle holder thoroughly.
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Front Suspension Adjustments 23. Align the brake caliper (21) and hose (22) with 26. Clean the surfaces where the axle and axle the left fork leg, making sure that the brake clamps contact each other. (30) hose is not twisted. An improperly routed Apply grease to each dust seal lips of the front brake hose may rupture and cause a loss of wheel.
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Front Suspension Adjustments 30. Install the number plate (page 104). 33. Install the disc cover (34) and tighten the disc 31. With the front brake applied, pump the fork up cover socket bolts (35) to the specified torque: 10 lbf·ft (13 N·m, 1.3 kgf·m) and down several times to seat the axle and check front brake operation.
9.39 in (238.5 mm) loosening the shock spring lock nut (1) and Honda Service Manual. turning the adjusting nut (2). To decrease spring pre-load If your CRF is new, put enough part-throttle break-...
Rear Suspension Adjustments High Speed Damping: Rebound Damping Rear Suspension Damping The high speed damping can be adjusted by The rebound damping adjuster (3) is located at the lower end of the rear shock absorber. turning the hexagonal portion of the compression Compression Damping adjuster.
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 SEAT MOUNTING BOLT Setting the proper race sag (ride height) is very rider.
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Rear Suspension Adjustments Spring Rates A spring that is too stiff for your weight will not If you are lighter or heavier than the average rider allow the rear tire to hook up under acceleration and cannot set the proper ride height without and will pass more bumps on to you.
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.
Suspension Adjustment Guidelines Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 112 – 130. 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...
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Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
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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: –...
Tuning Tips Tuning Tips An optional PGM-FI setting tool can change the NOTICE NOTICE ignition timing and amount of the fuel injection (page 159). Using spark plugs with an improper heat range or An improperly tightened spark plug can damage Be sure to observe the PGM-FI setting by checking incorrect reach can cause engine damage.
Steering Damper Adjustment Steering Damper Adjustment The steering damper can be adjusted for riding Steering Damper Damping conditions by using following method: • Damping – Turning the steering damper The steering damper adjuster (1) has 13 positions adjuster adjusts how quickly the steering or more.
Steering Damper Adjustment Guidelines Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described 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.
Chassis Adjustments Chassis Adjustments The following suggestions may improve a specific Fork Height/Angle Wheelbase concern. Subtle changes in overall handling may also be noted. The position of the fork tube in the clamp is not Adjusting your CRF’s wheelbase can offer subtle adjustable.
• Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate higher gear (less teeth) to keep engine rpm how, tools, and an official Honda Service Manual, appraisal of the change. “Seat-of-the-pants” sprocket changing should be done by your dealer.
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”...
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.
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Personal Fit Adjustments Adjustments for Competition...
Here’s helpful advice on how to transport and store your CRF, as well as three troubleshooting flow charts. Transporting Your Motorcycle...... 144 Storing Your Honda ........145 Preparation for Storage......145 Removal from Storage ......145 You & the Environment ........ 146 Troubleshooting..........
Transporting Your Motorcycle Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport To secure your CRF, brace the front wheel against your CRF, we recommend that you follow these the front of the truck bed or trailer rail. guidelines: Attach the lower ends of two straps to the tie-down •...
Storing Your Honda Storing Your Honda If you won’t be riding for an extended period, such Removal from Storage as during the winter, thoroughly inspect your CRF and correct any problem before storing it. That 1. Uncover and clean your CRF.
You & the Environment You & the Environment Owning and riding a motorcycle can be enjoyable, NOTICE but you must do your part to protect nature. When you show respect for the land, wildlife, and other Improper disposal of drained fluids is harmful to people, you also help preserve the sport of off road the environment.
(Faulty ECM or CKP • Worn cylinder and piston parenthesis. The items that require use of an CORRECT sensor)* ring* official Honda Service Manual are followed by an • Fast idle knob stuck open • Damaged cylinder head asterisk (*). or damaged gasket •...
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Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy 1. Check the spark INCORRECT • Incorrect spark plug heat 1. Check the ignition INCORRECT • Faulty ECM* •...
Vehicle Identification Vehicle Identification The engine number (2) is stamped on the left Serial Numbers crankcase. 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.
Specifications Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 86.3 in 2,191 mm Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type Overall width 32.6 in 827 mm Single 6°30’ inclined Transmission 5-speed, constant mesh Cylinder arrangement from vertical...
Oxygenated Fuels Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating symptoms, with alcohol or an ether compound. These try another service station or switch to another gasolines are collectively referred to as oxygenated brand of gasoline. fuels.
Competition Logbook Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of racing events. The best way to organize the many worked best at a particular location.
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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...
Optional Parts List Optional Parts List These parts and tools may be ordered from your FRAME Remarks authorized dealer. Shock spring 308.3 lbf/in (54 N/mm) Standard FRAME Remarks Pink paint (Medium) Driven sprocket < >: Drive chain links 48 Teeth, Aluminum. Standard 296.9 lbf/in (52 N/mm) Optional...
& Phillips No. 1, 2, 3 (Engine and Transmission Oil) wrench, large adjustable KHL15-11 (KYB) Spare Parts wrenches: open end & box Pro Honda DOT 4 Brake Fluid wrenches: hex (Allen) Pro Honda HP Chain Lube spark plugs wrench, spoke Pro Honda Foam Filter Oil air cleaner (clean &...
Consumer Information Consumer Information This section contains information about contacting Authorized Manuals ........162 Honda and how to get an official Honda Service Contacting Honda ..........163 Manual. Your Honda Dealer ........164 The Honda Rider's Club (USA only) .....165 Consumer Information...
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...
If you wish to comment on your experiences with your CRF or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O. Box 2200, Torrance CA 90509- 2200, Mailstop: 100-4C-7B, Telephone: (866) 784-1870.
Once you purchase your new Honda, get familiar Your Honda dealer can inform you about with the organization of your Honda dealer so you competition events in your area. You’ll also find can utilize the full range of services available.
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...
91 or higher tank: 1.66 US gal (6.3 ℓ) Engine oil Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil. Transmission oil Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil. Tires Front 80/100 –...
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