Honda CRF1000 Shop Manual
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Honda CRF1000 Shop Manual

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Table Of Contents
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Table of Contents

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SHOP MANUAL
CRF1000/A/D
CRF1000/A/D
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Summary of Contents for Honda CRF1000

  • Page 1 SHOP MANUAL CRF1000/A/D CRF1000/A/D...

  • Page 2: How To Use This Manual

    Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the motorcycle.
  • Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or equivalent). Example: • Molykote® G-n Paste manufactured by Dow Corning U.S.A. • Honda Moly 60 (U.S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.

  • Page 5: Table Of Contents

    MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVE/CAMSHAFT ALTERNATOR/STARTER CLUTCH CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) CRANKCASE/TRANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D)
  • Page 6 dummyhead dummyhead MEMO...

  • Page 7: General Information

    dummytext 1. GENERAL INFORMATION SERVICE RULES··································· 1-2 SPECIAL TOOL LIST ··························· 1-24 MODEL IDENTIFICATION ······················· 1-3 CABLE & HARNESS ROUTING ············· 1-26 SPECIFICATIONS·································· 1-5 EMISSION CONTROL SYSTEMS ··········· 1-47 TORQUE VALUES ······························· 1-12 TECHNICAL FEATURES ······················ 1-50 LUBRICATION & SEAL POINTS ············ 1-22...

  • Page 8: Service Rules

    SERVICE RULES GENERAL INFORMATION 1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 9: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION CRF1000D: CRF1000/A: SERIAL NUMBERS/LABELS The motorcycle Identification Number (V.I.N) [1] is stamped The engine serial number [1] is stamped on the lower back on the right side of the steering head. side of the crankcase.
  • Page 10 GENERAL INFORMATION TYPES TYPE DESTINATION Manual Dual Clutch Anti-lock HSTC CODE CODE Transmission Transmission Brake System CRF1000 ED, IIED, IIIED – – – – – – CRF1000A ED, IIED, IIIED – RU, IIRU, IIIRU – U, IIU, IIIU –...

  • Page 11: Specifications

    GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,335 mm (91.9 in) Overall width CRF1000 875 mm (34.4 in) CRF1000A/D 930 mm (36.6 in) Overall height 1,475 mm (58.1 in) Wheelbase 1,575 mm (62.0 in) Seat height 870 mm (34.3 in) Footpeg height 351 mm (13.8 in)

  • Page 12: Ignition System Specifications

    dummyhead dummyhead GENERAL INFORMATION ITEM SPECIFICATIONS DRIVE TRAIN Clutch system 2 Multi-plate wet clutches (CRF1000D) Clutch operation system Automatic Transmission Constant mesh, 6-speeds Primary reduction 1.883 (81/43) Final reduction 2.625 (42/16) Gear ratio 2.562 (41/16) 1.761 (37/21) 1.375 (33/24) 1.133 (34/30) 0.972 (36/37) 0.882 (30/34) Gearshift pattern...
  • Page 13 – change After disassembly 5.2 liter (5.5 US qt, 4.6 Imp qt) – Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent motor oil. API classification: SG or higher – JASO T903 standard: MA Viscosity: SAE 10W-30 Oil pressure (at oil filter cartridge) 499 –...
  • Page 14 Starter driven gear boss O.D. 57.749 – 57.768 (2.2736 – 2.2743) – I.D. 44.000 – 44.016 (1.7323 – 1.7329) – CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (CRF1000/A) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 – 20 (0.4 – 0.8) –...
  • Page 15 dummyhead dummyhead GENERAL INFORMATION CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS (CRF1000D) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.D. 35.000 – 35.025 (1.3780 – 1.3789) – 43.000 – 43.025 (1.6929 – 1.6939) – 35.000 – 35.025 (1.3780 – 1.3789) – 25.000 – 25.021 (0.9843 – 0.9851) –...

  • Page 16: Hydraulic Brake Specifications

    – 60 g (2.1 oz) max. Fork Spring free length 433.7 (17.07) 425.0 (16.73) Recommended fork fluid Honda Ultra Cushion Oil 10W (SS-47) – Fluid level 95.0 (3.74) – Fluid capacity 721 ± 2.5 cm (24.4 ± 0.1 US oz, –...
  • Page 17 LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight Brake/taillight Position light Front turn signal/position light (CRF1000) 12 V – 21/5 W x 2 Front turn signal light (CRF1000A/D) Rear turn signal light CRF1000 12 V – 21 W x 2 CRF1000A/D License light 12 V –...

  • Page 18: Torque Values

    dummyhead dummyhead GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, N·m (kgf·m, lbf·ft) lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt (Include SH flange bolt) 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
  • Page 19 dummyhead dummyhead GENERAL INFORMATION MAINTENANCE THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft) Throttle cable adjuster lock nut 3.8 (0.4, 2.8) (throttle grip side) Throttle cable A lock nut 8.5 (0.9, 6.3) (throttle body side) Air cleaner element mounting screw 1.1 (0.1, 0.8) Tapping screw Air cleaner cover screw...
  • Page 20 dummyhead dummyhead GENERAL INFORMATION FUEL SYSTEM THREAD TORQUE ITEM Q'TY N·m (kgf·m, REMARKS DIA. (mm) lbf·ft) Fuel filler cap bolt 1.8 (0.2, 1.3) Fuel pump/reserve sensor terminal 1.0 (0.1, 0.7) screw Fuel pump mounting nut 12 (1.2, 9) See page 7-10 Fuel pump mounting cap nut 12 (1.2, 9) See page 7-10...
  • Page 21 137 (14.0, 101) Apply engine oil to the threads and seating surface. Starter clutch torx bolt 29 (3.0, 21) Apply locking agent to the threads. (*2) See page 1-21 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft)
  • Page 22 dummyhead dummyhead GENERAL INFORMATION DUAL CLUTCH TRANSMISSION (CRF1000D) THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft) Feed pipe guide plate bolt 5 (0.5, 3.7) Feed pipe cover bolt 12 (1.2, 9) Right crankcase cover bolt 12 (1.2, 9) Water pipe mounting bolt 12 (1.2, 9) Clutch EOP sensor wire stay bolt...
  • Page 23 dummyhead dummyhead GENERAL INFORMATION CRANKSHAFT/PISTON/CYLINDER THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft) Crankpin bearing cap bolt (new) 22 (2.2, 16) + 120° Apply engine oil to the threads and seating surface. Replace with a new one. Main journal bolt 43 (4.4, 32) Apply molybdenum oil solution to the threads and seating surface.
  • Page 24 dummyhead dummyhead GENERAL INFORMATION REAR WHEEL/SUSPENSION THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft) Rear brake disc bolt 42 (4.3, 31) ALOC bolt: replace with new ones. Driven sprocket nut 100 (10.2, 74) Apply engine oil to the threads and seating surface.
  • Page 25 dummyhead dummyhead GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft) Brake caliper bleed valve 5.4 (0.6, 4.0) Front brake master cylinder reservoir 1.5 (0.2, 1.1) cap screw Rear brake master cylinder reservoir 1.5 (0.2, 1.1) cap screw Rear brake master cylinder reserve 10 (1.0, 7)
  • Page 26 THREAD TORQUE ITEM Q'TY REMARKS N·m (kgf·m, DIA. (mm) lbf·ft) Clutch lever pivot bolt (CRF1000/A) 1.0 (0.1, 0.7) Clutch lever pivot nut (CRF1000/A) 5.9 (0.6, 4.4) U-nut Pillion step bracket mounting bolt 34 (3.5, 25) Throttle cable A/B nut 1.5 (0.2, 1.1) (switch housing side) *1: Apply locking agent to the threads as shown.
  • Page 27 dummyhead dummyhead GENERAL INFORMATION *2: Apply locking agent to the threads as shown. 6.5 ± 1.0 mm (0.26 ± 0.04 in) Apply this area. The bolt shown is typical. 1-21...
  • Page 28 Camshaft journals cam lobes, and thrust surface disulfide grease) Valve stem sliding area and stem end Starter reduction gears shaft outer surfaces Clutch outer guide entire surface (CRF1000/A) Primary driven gear teeth and clutch outer sliding surface (CRF1000/A) Judder spring and judder spring seat entire surface...
  • Page 29 Rear brake middle arm pivot sliding surface Parking brake stopper stay teeth and lock lever pivot sliding surface (CRF1000D) Parking brake lever pivot sliding surface (CRF1000D) Clutch lever pivot sliding area (CRF1000/A) Molybdenum disulfide grease Sidestand collar outer surface (containing more than 3%...
  • Page 30 Interior cutter, 34 mm (60° IN/EX) ALTERNATOR/STARTER CLUTCH 07725-0040001 Flywheel holder 07733-0020001 Rotor puller CLUTCH/GEARSHIFT LINKAGE 07724-0050002 Clutch center holder P.D. 48 - 135 (CRF1000/A) 07916-9690000 Lock nut wrench 30 x 40 mm 07749-0010000 Driver 07746-0010100 Attachment, 32 x 35 mm 07746-0040400 Pilot, 17 mm...
  • Page 31 dummyhead dummyhead GENERAL INFORMATION TITLE TOOL No TOOL NAME CRANKCASE/TRANSMISSION/BALANCER 07724-0010100 Gear holder, 2.5 07LAE-PX40000 Clutch compressor set 07936-ZV10100 Bearing remover shaft set, 25 mm 07741-0010201 Remover weight 07949-3710001 Driver, 15 x 280L 07746-0010400 Attachment, 52 x 55 mm 07746-0040600 Pilot, 25 mm 07746-0040200 Pilot, 12 mm...
  • Page 32 GENERAL INFORMATION CABLE & HARNESS ROUTING THROTTLE CABLE B CRF1000/A: CLUTCH CABLE THROTTLE CABLE A CRF1000D: PARKING BRAKE CABLE CRF1000/A: CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE CRF1000D: PARKING BRAKE CABLE THROTTLE CABLE B THROTTLE CABLE A RIGHT HANDLEBAR SWITCH WIRE 70 mm (2.8 in)
  • Page 33 MAIN SENSOR 2P (Black) HARNESS 2 WIRE CONNECTOR 12P (Gray) HARNESS CONNECTOR FRONT SUB HARNESS 3 RIGHT FRONT TURN CONNECTOR SIGNAL LIGHT 2P CRF1000/A: 12P (Black) FRONT SUB HARNESS 1 (Light blue) CRF1000D: 8P (Black) 12P (Black) CONNECTOR CONNECTOR 1-27...
  • Page 34 SWITCH WIRE 0 – 3 mm (0.0 – 0.1 in) FRONT WHEEL SPEED SENSOR WIRE (CRF1000A/D) CRF1000: FRONT BRAKE HOSE A CRF1000A/D: FRONT BRAKE HOSE D FRONT WHEEL SPEED SENSOR (CRF1000A/D) CRF1000: FRONT BRAKE HOSE B CRF1000A/D: FRONT BRAKE HOSE E...
  • Page 35 CONNECTOR LEFT (Left grip heater) HANDLEBAR SWITCH WIRE GROUND TERMINALS LEFT HANDLEBAR SWITCH CONNECTOR CRF1000: 4P (Black) CRF1000A: 6P (Black) CRF1000D: 12P (Black) LEFT HANDLEBAR SWITCH CONNECTOR CRF1000: 12P (Gray) CRF1000A/D: 10P (Gray) ECT SENSOR 2P (Black) CONNECTOR MAIN WIRE HARNESS No.1 CYLINDER SUB PLUG CAP...
  • Page 36 GENERAL INFORMATION CRF1000/A (CRF1000 shown) ALTERNATOR ASSEMBLY WIRE SIDESTAND SWITCH WIRE To VS sensor GEAR POSITION SWITCH WIRE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE RADIATOR RESERVE TANK DRAIN HOSE SIDESTAND SWITCH WIRE ALTERNATOR ASSEMBLY WIRE FUEL TANK...
  • Page 37 dummyhead dummyhead GENERAL INFORMATION CRF1000D: VS/OUTER MAINSHAFT SENSOR WIRE SIDESTAND ALTERNATOR SWITCH WIRE ASSEMBLY WIRE SHIFT CONTROL MOTOR 2P (Black) CONNECTOR FUEL TANK ALTERNATOR DRAIN HOSE ASSEMBLY WIRE SIDESTAND SWITCH WIRE FUEL TANK BREATHER HOSE RADIATOR RESERVE TANK DRAIN HOSE EOP SENSOR 3P (Black) SIDESTAND CONNECTOR...
  • Page 38 THROTTLE CABLES FRONT BRAKE HOSE A FRONT BRAKE PIPE A 40 ± 10 mm (1.0 ± 0.4 in) CRF1000: FRONT BRAKE HOSE A CRF1000A/D: FRONT BRAKE HOSE D FRONT BRAKE PIPE C FRONT WHEEL SPEED SENSOR WIRE CRF1000: FRONT BRAKE HOSE B...
  • Page 39 GENERAL INFORMATION CRF1000/A (CRF1000 shown) RIGHT HANDLEBAR SWITCH OPTION 2P (Black) CONNECTOR 8P (Gray) CONNECTOR (Right grip heater) THROTTLE CABLE A THROTTLE CABLE B CLUTCH CABLE WATER RIGHT FAN MOTOR BOTTOM HOSE 2P (Black) CONNECTOR SIPHON AIR CLEANER...
  • Page 40 dummyhead dummyhead GENERAL INFORMATION CRF1000D: LINEAR SOLENOID VALVE 4P (Black) CONNECTOR OPTION 2P (Black) RIGHT HANDLEBAR CONNECTOR SWITCH 6P (Black) (Right grip heater) CONNECTOR LINEAR SOLENOID RIGHT HANDLEBAR VALVE WIRE SWITCH 8P (Gray) CONNECTOR SIPHON HOSE SIPHON HOSE THROTTLE CABLES FRONT BRAKE PARKING PIPE A...
  • Page 41 dummyhead dummyhead GENERAL INFORMATION CRF1000D shown: FRONT WHEEL SPEED SENSOR 2P (Black) CONNECTOR RADIATOR IAT SENSOR HOSE A 2P (Blue) MAIN WIRE PAIR CONTROL CONNECTOR HARNESS SOLENOID VALVE 2P SIPHON (Black) CONNECTOR RADIATOR HOSE AIR SUPPLY HOSE HOSE A BRAKE PIPES MAIN WIRE CRANKCASE...
  • Page 42 GENERAL INFORMATION CRF1000: MAP SENSOR 3P (Black) CONNECTOR IACV 4P (Black) CONNECTOR CLUTCH CABLE MAIN WIRE FUEL TANK HARNESS DRAIN HOSE FUEL TANK SIPHON HOSE BREATHER HOSE FUEL LEVEL SENSOR 2P (Black) CONNECTOR FUEL FEED HOSE FUEL TANK BREATHER...
  • Page 43 dummyhead dummyhead GENERAL INFORMATION CRF1000A/D: MAP SENSOR 3P (Black) CONNECTOR IACV 4P (Black) CONNECTOR MAIN WIRE HARNESS FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE FUEL LEVEL FUEL FEED SENSOR 2P (Black) HOSE CONNECTOR SIPHON HOSE FRONT BRAKE PIPE A FRONT BRAKE PIPE C FUEL TANK BREATHER...
  • Page 44 GENERAL INFORMATION CRF1000: MAIN WIRE HARNESS SEAT LOCK CABLE FUEL PUMP 3P (Black) CONNECTOR TURN SIGNAL LIGHT RELAY REGULATOR/RECTIFIER 3P (Black) CONNECTOR FUEL PUMP 3P (Black) CONNECTOR MAIN WIRE HARNESS HISS 2P (Red) CONNECTOR SEAT LOCK CABLE MAIN WIRE HARNESS...
  • Page 45 dummyhead dummyhead GENERAL INFORMATION CRF1000A/D: REAR WHEEL SPEED SENSOR REAR WIRE BRAKE HOSE B FRONT BRAKE HOSE C REAR FENDER FRONT BRAKE HOSE B REAR FUEL PUMP UNIT BRAKE 3P (Black) HOSE A CONNECTOR REAR WHEEL SPEED SENSOR 2P (Black) SEAT CONNECTOR LOCK...
  • Page 46 GENERAL INFORMATION CRF1000: MAIN WIRE HARNESS FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE C ALTERNATOR (OPEN AIR) ASSEMBLY WIRE FUEL TANK BREATHER HOSE BATTERY ALTERNATOR 3P (Gray) CONNECTOR BATTERY NEGATIVE (-) REAR BRAKE HOSE B CABLE BATTERY...
  • Page 47 GENERAL INFORMATION CRF1000/A: JUNCTION 1 JUNCTION 2 MAIN WIRE HARNESS ALTERNATOR SIDESTAND ASSEMBLY WIRE SWITCH 2P (Black) ALTERNATOR CONNECTOR ASSEMBLY 6P (Black) CONNECTOR REAR BRAKE LIGHT SWITCH 2P (Gray) FUEL TANK CONNECTOR BREATHE HOSE REAR BRAKE LIGHT SWITCH...
  • Page 48 REAR OPTION 6P CONNECTOR FAN CONTROL RELAY MAIN WIRE HARNESS BRAKE/TAILLIGHT 3P (Black) CONNECTOR OPTION 10P (Black) CONNECTOR (Grip heater controller) TURN SIGNAL LIGHT DIODE (CRF1000) LEFT TURN SIGNAL LIGHT WIRE LICENSE LIGHT WIRE RIGHT TURN SIGNAL LIGHT WIRE LEFT REAR TURN...
  • Page 49 GENERAL INFORMATION CRF1000: SIPHON HOSE REAR BRAKE LIGHT SWITCH REAR BRAKE RESERVE TANK REAR BRAKE HOSE A REAR BRAKE HOSE A 1-43...
  • Page 50 dummyhead dummyhead GENERAL INFORMATION CRF1000A/D: REAR BRAKE CRF1000D shown: HOSE B SIPHON REAR REAR BRAKE PARKING HOSE BRAKE REAR WHEEL SPEED HOSE A BRAKE CABLE LIGHT SENSOR WIRE (CRF1000D) SWITCH REAR BRAKE REAR BRAKE HOSE B RESERVE TANK PARKING PARKING BRAKE CABLE BRAKE CABLE (CRF1000D)
  • Page 51 HOSE B White paint Left White paint Left Lower Lower Prevent the water hose band from interfering with the 45° 45° radiator stay. 45° Front 40° Right Yellow paint RADIATOR HOSE B CRF1000/A: Rear Right 45° RADIATOR LOWER HOSE 1-45...
  • Page 52 White paint Rear 45° Lower WATER BOTTOM Insert the hose until the index mark. HOSE Rear Lower CRF1000/A: Yellow paint 45° Insert the hose until the index mark. WATER BOTTOM Front HOSE 45° Insert the hose until the punch mark.

  • Page 53: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel evaporation also releases hydrocarbons to the atmosphere. Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide, hydrocarbons, and oxides of nitrogen. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
  • Page 54 dummyhead dummyhead GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a secondary air injection system, a three-way catalytic converter and PGM-FI system. SECONDARY AIR SUPPLY SYSTEM The secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control solenoid valve.

  • Page 55: Noise Emission Control System

    dummyhead dummyhead GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local low may prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new motorcycle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...

  • Page 56: Technical Features

    dummyhead dummyhead GENERAL INFORMATION TECHNICAL FEATURES ABS WITH MODE-SELECTION MECHANISM (REAR ABS OFF MODE) (CRF1000A/D) SYSTEM OVERVIEW The CRF1000A/D (ABS type) is equipped with an ABS with selectable modes. In the ABS with mode-selection mechanism, the front ABS functions as a regular ABS, but the rear ABS can be cancelled; this mechanism gives greater freedom of off-road riding while ensuring the safety.
  • Page 57 dummyhead dummyhead GENERAL INFORMATION COMBINATION METER REAR ABS SWITCH Switch signal Rear wheel speed Front wheel speed ABS MODULATOR Indicator signal output Indicator signal output Rear ABS OFF Indicator diagnosis ABS DIAGNOSIS Rear ABS OFF mode SYSTEM switching judgement System fail signal Rear ABS OFF mode switching signal output ABS CONTROL:...
  • Page 58 dummyhead dummyhead GENERAL INFORMATION G RIDE (CRF1000D) SYSTEM OVERVIEW The CRF1000D (DCT type) is equipped with the G ride designed for off-road riding. To switch to the G ride, press the G switch with the throttle fully closed when the motorcycle is stopped. The G indicator displays to confirm that the mode is successfully switched to the G ride.
  • Page 59 dummyhead dummyhead GENERAL INFORMATION DUAL CLUTCH TRANSMISSION CONTROL CIRCUIT (G RIDE) COMBINATION METER RIGHT HANDLEBAR G SWITCH SWITCHES ABS MODULATOR LEFT HANDLEBAR SWITCHES [21] [22] PGM-FI THROTTLE CONTROL BODY ALTERNATOR [10] CONTROL [11] NO.1 LINEAR SOLENOID VALVE NO.2 LINEAR SOLENOID VALVE [12] SHIFT...
  • Page 60 dummyhead dummyhead GENERAL INFORMATION S MODE (CRF1000D) SYSTEM OVERVIEW The CRF1000D (DCT type) is equipped with the S mode designed for sport riding. To switch to the S mode, press the N-D switch when the motorcycle is stopped for safety. The S indicator displays to confirm that the mode is successfully switched to the S mode.
  • Page 61 dummyhead dummyhead GENERAL INFORMATION D AND S MODE SHIFT TIMING D MODE S MODE Engine speed high Sports Level 3 Level 2 Level 1 D MODE Comfort Engine speed 1-55...
  • Page 62 dummyhead dummyhead MEMO...

  • Page 63: Frame/Body Panels/Exhaust System

    dummytext 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION························ 2-2 TANK SIDE COVER ······························· 2-9 TROUBLESHOOTING ···························· 2-2 TANK REAR COVER···························· 2-10 BODY PANEL LOCATIONS····················· 2-3 SKID PLATE (CRF1000A/D) ·················· 2-10 MAIN SEAT ·········································· 2-4 LEFT REAR COVER ···························· 2-10 WINDSCREEN ······································ 2-5 PILLION SEAT ····································...
  • Page 64 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM GENERAL • This section covers removal and installation of the body panels, exhaust system and sidestand. • Always replace the exhaust pipe gaskets after removing the exhaust pipes from the engine. •...
  • Page 65 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS [20] [19] [18] [17] [16] [15] [21] [14] [10] [11] [12] [13] Front cover (page 2-7) [12] Left rear cover (page 2-10) Windscreen (page 2-5) [13] Rear fender B (page 2-13) Tank front cover (page 2-9) [14] Side cover (page 2-11) Knuckle guard (CRF1000A/D) (page 2-5)
  • Page 66 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM MAIN SEAT MAIN SEAT REMOVAL/INSTALLATION Unlock the main seat [1] using the ignition key [2]. Remove the seat while pulling it forward and upward. Install the seat while aligning its hook [3] with the retainer on the rear carrier. Push the seat downward, and lock it.
  • Page 67 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN REMOVAL/INSTALLATION Remove the socket bolts [1], plastic washers [2], rubber washers [3], and windscreen [4]. Remove the well nuts [5] and cowl stay covers [6] if necessary. Installation is in the reverse order of removal. •...
  • Page 68 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM MIDDLE COWL REMOVAL/INSTALLATION Remove the tank side cover (page 2-9). Remove the socket bolts [1] and trim clips [2]. Release the bosses [3]. Remove the middle cowl [4] by releasing the tabs [5]. Installation is in the reverse order of removal. DISASSEMBLY/ASSEMBLY Remove the middle cowl (page 2-6).
  • Page 69 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SPOILER REMOVAL/INSTALLATION Remove the middle cowl (page 2-6). Remove the trim clips [1]. Remove the front spoiler [2] by releasing the tabs [3] from the front cover and inner cover. Installation is in the reverse order of removal. FRONT COVER REMOVAL/INSTALLATION Remove the front spoiler (page 2-7).
  • Page 70 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM INNER PANEL COVER REMOVAL/INSTALLATION Remove the front cover (page 2-7). Right side shown: Disconnect the following: Left side: – Front turn signal light 2P (Orange) connector Right side: – Front turn signal light 2P (Light blue) connector [1] –...

  • Page 71: Front Fender

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the socket bolts [1] and collars [2]. Remove the fender cover [3]. CRF1000A/D: Release the front speed sensor wire [4] from the fender clamp [5]. Remove the bolt [6] and brake hose clamp [7]. Remove the socket bolts [8] and collars [9].
  • Page 72 TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft) LEFT REAR COVER REMOVAL/INSTALLATION CRF1000/A: Remove the gearshift arm (page 12-21). Release the sidestand wire clip [1] from the left rear cover [2]. Release the sidestand wire from the left rear cover wire guide.

  • Page 73: Pillion Seat

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM PILLION SEAT REMOVAL/INSTALLATION Remove the main seat (page 2-4). Remove the bolts [1] and collars [2]. Release the tab [3] and remove the pillion seat [4] by pulling forward. Installation is in the reverse order of removal. ETC TRAY REMOVAL/INSTALLATION Remove the seat catch stay (page 2-4).

  • Page 74: Rear Carrier

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the side cover (page 2-11). Remove the screws [1]. Remove the side inner cover [2] by releasing the tab [3]. Installation is in the reverse order of removal. REAR CARRIER REMOVAL/INSTALLATION Remove the side covers (page 2-11). [4] [3] Remove the socket bolts [1].

  • Page 75: Rear Fender B

    CRF1000A/D: Drain the brake fluid from the hydraulic system (page 19-6). Remove the following: – Regulator/rectifier (page 21-8) – Fuel tank (page 7-6) Remove the wire band [1]. Disconnect the turn signal light relay 18P (Black) connector [1]. Release the turn signal light relay [1]. CRF1000: 2-13...
  • Page 76 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the following: – Grip heater control (Option) 10P (Black) connector – Brake/taillight 3P (Black) connector [2] Release the following: – Fan control relay [3] – Dummy connector/DLC [4] Remove the rear fender A (page 2-12) Release the rear speed sensor wire clip [1].
  • Page 77 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Remove the screw [1]. Remove the mud guard [2] downward by releasing its tab [3] from the slit [4] of the rear fender B. CRF1000A/D: Loosen the brake pipe joint nuts [5] and disconnect the brake pipes [6]. Remove the joint bolt [7].
  • Page 78 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER/EXHAUST PIPE MUFFLER REMOVAL/INSTALLATION RUBBER WASHER MUFFLER MOUNTING BOLT WASHER MUFFLER STAY MUFFLER ASSEMBLY EXHAUST PIPE OUTER COVER GASKET MUFFLER BAND BOLTS PAN SCREWS 17 N·m (1.7 kgf·m, 13 lbf·ft) 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) COLLAR EXHAUST OUTER COVER SCREW 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
  • Page 79 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER DISASSEMBLY/ASSEMBLY Remove the muffler (page 2-16). TAIL CAP COVER BOLT MUFFLER 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) COLLARS TAIL CAP COVER RUBBER WASHERS GROMMETS PAN SCREWS 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) MUFFLER COVER •...
  • Page 80 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Remove the pan screw [1] and exhaust pipe cover A [2]. Loosen the band screw and remove the band [3] and exhaust pipe cover B [4]. Remove the mounting bolt [5], collar [6], and mounting nut [7]. Remove the exhaust pipe joint nuts [8], gaskets [9], and exhaust pipe [10].
  • Page 81 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SIDESTAND REMOVAL/INSTALLATION Remove the sidestand switch (page 22-27) (not necessary to disconnect the connector). Support the motorcycle securely using a hoist or equivalent. Remove the sidestand return springs [1]. Remove the sidestand pivot nut [2] and bolt [3], then remove the sidestand [4] and collar [5].
  • Page 82 dummyhead dummyhead MEMO...

  • Page 83: Maintenance

    BRAKE LOCK OPERATION (CRF1000D)········································ 3-21 VALVE CLEARANCE ····························· 3-8 HEADLIGHT AIM ································· 3-22 ENGINE OIL ······································· 3-11 CLUTCH SYSTEM (CRF1000/A)············· 3-22 ENGINE OIL FILTER ···························· 3-12 SIDESTAND ······································· 3-23 CLUTCH OIL FILTER (CRF1000D) ········· 3-13 SUSPENSION ····································· 3-23 ENGINE IDLE SPEED··························· 3-14 NUTS, BOLTS, FASTENERS ·················...

  • Page 84: Maintenance Schedule

    * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1.

  • Page 85: Fuel Line

    dummyhead dummyhead MAINTENANCE FUEL LINE Remove the middle cowl (page 2-6). Remove the ETC tray (page 2-11). Remove the bolt [1] and washer [2]. Lift the fuel tank [3] by releasing its grooves [4] from the mounting rubbers [5]. Put the grooves onto the mounting rubbers and install the fuel tank grommet [6] into the frame boss [7].

  • Page 86: Air Cleaner

    dummyhead dummyhead MAINTENANCE Throttle grip freeplay can be adjusted at either end of the throttle cable. Minor adjustments is made with the upper adjuster. Release the dust cover [1]. Adjust the freeplay by loosening the lock nut [2] and turning the adjuster [3]. Tighten the lock nut while holding the adjuster to the specified torque.

  • Page 87: Crankcase Breather

    dummyhead dummyhead MAINTENANCE CRANKCASE BREATHER Check the air cleaner housing drain hoses [1]. Service if the Left side: deposits level can If necessary, remove the drain plugs [2] from the drain be seen in the hoses and drain the deposits into a suitable container. transparent section Reinstall the plugs securely.
  • Page 88 dummyhead dummyhead MAINTENANCE Remove the bolts [1] and washers [2]. [1]/[2] Release the siphon hose [1]. Release the connector clip [2] from the radiator shroud. Release the linear solenoid [3] and main wire harness [4] from the clamp [5]. Release the air cleaner housing drain hose [6] from the clamp [7].
  • Page 89 dummyhead dummyhead MAINTENANCE Pull the right radiator to outside (page 3-5). Remove the spark plug cap [1]. Remove the No.2 cylinder sub plug [2] using the equipped spark plug wrench. Remove the spark plug cap [1]. Remove the No.2 cylinder main plug using the equipped spark plug wrench [2].

  • Page 90: Valve Clearance

    dummyhead dummyhead MAINTENANCE VALVE CLEARANCE • Inspect and adjust the valve clearance while the engine is cold (below 35°/95°F). Remove the cylinder head cover (page 10-4). Remove the crankshaft hole cap [1] and the timing hole cap [2]. Rotate the crankshaft counterclockwise and align the "T1"...
  • Page 91 dummyhead dummyhead MAINTENANCE Check the No.2 cylinder intake valve clearances by inserting a feeler gauge [1] between the valve lifter and cam lobe. No.2 cylinder intake valve clearance: 0.16 ± 0.03 mm (0.006 ± 0.001 in) Adjust the valve clearance by changing the valve lifter shim (page 3-10).
  • Page 92 dummyhead dummyhead MAINTENANCE Check the No.1 cylinder exhaust valve clearances by inserting a feeler gauge [1] between the locker arm roller and cam lobe. No.1 cylinder exhaust valve clearance: 0.23 ± 0.02 mm (0.009 ± 0.001 in) Adjust the No.1 cylinder exhaust valve clearance by loosening the lock nut [1] and turning the adjusting screw [2] until there is a slight drag on the feeler gauge [3].

  • Page 93: Engine Oil

    [3] and fill the crankcase with the recommended oil up to the upper level line [4] (page 3- 12). RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent motor oil. API service classification: SG or higher JASO T903 standard: MA...

  • Page 94: Engine Oil Change

    Fill the engine with the recommended engine oil (page 3-11). ENGINE OIL CAPACITY: CRF1000/A: 3.9 liter (4.1 US qt, 3.4 Imp qt) at draining 4.1 liter (4.3 US qt, 3.6 Imp qt) at oil filter change 4.9 liter (5.2 US qt, 4.3 Imp qt) at disassembly CRF1000D: 4.0 liter (4.2 US qt, 3.5 Imp qt) at draining...
  • Page 95 dummyhead dummyhead MAINTENANCE Check the oil filter boss [1] protrusion from the 6.5 ± 1.0 mm Apply this area. crankcase is within the specified length as shown. (0.26 ± 0.04 in) SPECIFIED LENGTH: 15.5 – 16.5 mm (0.61 – 0.65 in) •...

  • Page 96: Engine Idle Speed

    dummyhead dummyhead MAINTENANCE ENGINE IDLE SPEED IDLE SPEED INSPECTION • Inspect the idle speed after all other engine maintenance items have been performed and are within specifications. • Before inspecting the idle speed, check that the following items: – No DTC and MIL blinking –...
  • Page 97 dummyhead dummyhead MAINTENANCE COOLING SYSTEM Check the radiator air passages for clogging or damage. Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

  • Page 98: Drive Chain

    dummyhead dummyhead MAINTENANCE DRIVE CHAIN Amputation hazard. Never inspect or adjust the drive chain while the engine is running. DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, support the motorcycle on its sidestand, and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets.

  • Page 99: Cleaning And Lubrication

    dummyhead dummyhead MAINTENANCE CLEANING AND LUBRICATION Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains. Use a soft brush if the drive chain is dirty. Do not use a steam cleaner, high pressure cleaner, wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner or a chain cleaner NOT designed specifically for O-ring chains to clean the drive chain.
  • Page 100 dummyhead dummyhead MAINTENANCE REPLACEMENT This motorcycle uses a drive chain with a staked master link. Fully slacken the drive chain (page 3-16). Remove the drive chain using the special tool. 1 LINK • When using special tool, follow manufacturer's instruction. TOOL: Drive chain tool set 07HMH-MR10103...

  • Page 101: Drive Chain Slider

    dummyhead dummyhead MAINTENANCE DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage. The drive chain slider must be replaced if it is worn to the wear limit indicator [1]. Refer to the swingarm DISASSEMBLY/ASSEMBLY for drive chain slider replacing (page 18-14). BRAKE FLUID •...

  • Page 102: Brake System

    dummyhead dummyhead MAINTENANCE BRAKE PADS WEAR INSPECTION Check the brake pads for wear. Replace the brake pads if either pad is worn to the Front: Rear: bottom of wear limit groove [1]. Refer to front brake pad replacement (page 19-8). Refer to rear brake pad replacement (page 19-9).
  • Page 103 dummyhead dummyhead MAINTENANCE BRAKE LIGHT SWITCH Adjust the brake light switch [1] so that the brake light The front brake light comes on just prior to the brake actually being switch does not engaged. require adjustment. If the light fails to come on, adjust the switch so that the light comes on at the proper time.

  • Page 104: Headlight Aim

    Adjust the headlight vertical beam adjuster [1]. beam as specified by local laws and regulations. CLUTCH SYSTEM (CRF1000/A) Measure the clutch lever freeplay at the end of the clutch lever. FREEPLAY:10 – 20 mm (0.4 – 0.8 in) 10 – 20 mm (0.4 –...

  • Page 105: Front Suspension Adjustment

    TURN COUNTERCLOCKWISE: Decreases the spring pre-load PRE-LOAD ADJUSTER ADJUSTABLE RANGE: 15 turns PRE-LOAD ADJUSTER STANDARD POSITION (from the full soft position): CRF1000/A: 5 turns CRF1000D: 8.5 turns REBOUND DAMPING ADJUSTER Turn the rebound adjuster [1] clockwise until it stops (maximum...

  • Page 106: Rear Suspension Adjustment

    dummyhead dummyhead MAINTENANCE COMPRESSION DAMPING ADJUSTER Turn the compression adjuster [1] clockwise until it stops (maximum position), then turn the adjuster counterclockwise. COMPRESSION ADJUSTER ADJUSTABLE RANGE: 12 clicks or more COMPRESSION ADJUSTER STANDARD POSITION (from maximum position): 8 clicks REAR SUSPENSION INSPECTION Check the action of the shock absorber by compressing it several times.
  • Page 107 dummyhead dummyhead MAINTENANCE REBOUND DAMPING ADJUSTER • Always start on fully hard when adjusting the damping. • Do not turn the adjuster screws more than the given positions or the adjusters may be damaged. The rebound damping can be adjusted by turning the adjuster [1].

  • Page 108: Steering Head Bearings

    dummyhead dummyhead MAINTENANCE WHEELS/TIRES Support the motorcycle securely and raise the front wheel off the ground. Hold the front fork leg and move the front wheel sideways forcefully to see if the wheel bearings are worn. For front wheel service (page 17-10). Support the motorcycle securely and raise the rear wheel off the ground.

  • Page 109: Pgm-Fi System

    4. PGM-FI SYSTEM SERVICE INFORMATION························ 4-2 ECM (CRF1000/A)/PCM (CRF1000D) ······ 4-39 SYSTEM LOCATION ······························ 4-2 MAP SENSOR····································· 4-41 SYSTEM DIAGRAM ······························· 4-3 ECT SENSOR ····································· 4-41 PGM-FI TROUBLESHOOTING IAT SENSOR ······································ 4-41 INFORMATION······································ 4-5 VS SENSOR ······································· 4-42 PGM-FI SYMPTOM TROUBLESHOOTING ····························...
  • Page 110 dummyhead dummyhead PGM-FI SYSTEM SERVICE INFORMATION PGM-FI SYSTEM GENERAL • This section covers electrical system service of the PGM-FI system. For other service and fuel supply system, see Fuel System section (page 7-2) • A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
  • Page 111 PGM-FI SYSTEM SYSTEM DIAGRAM CRF1000/A Bl/R ILLUMI STOP 7.5A R/Bl IGNITION SWITCH MAIN FUSE Bl/Gr FAN 20A BATTERY ENGINE STOP ENG STOP 7.5A FI FUSE SWITCH FI RELAY (54-1,54-2) R/Bu BANK ANGLE SENSOR (1-1,1-2) FUEL Lg/Bl PUMP CONTROL...
  • Page 112 dummyhead dummyhead PGM-FI SYSTEM CRF1000D Bl/R ILLUMI STOP 7.5A R/Bl IGNITION SWITCH MAIN FUSE Bl/Gr FAN 20A BATTERY ENGINE STOP ENG STOP 7.5A FI FUSE SWITCH FI RELAY (54-1,54-2) R/Bu BANK ANGLE SENSOR FUEL (83-1,83-2) PUMP POIL CONTROL Y/Bu EOP SENSOR RELAY RELAY EX-AI...
  • Page 113 dummyhead dummyhead PGM-FI SYSTEM PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent.
  • Page 114 dummyhead dummyhead PGM-FI SYSTEM CURRENT DTC/FREEZE DTC The DTC is indicated in two ways according to the failure status. • In case the ECM/PCM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC when the sidestand is lowered.
  • Page 115 dummyhead dummyhead PGM-FI SYSTEM How to clear the DTC with SCS connector 1. Connect the SCS connector to the DLC (page 4-6). 2. Turn the ignition switch ON and engine stop switch " ". 3. Disconnect the SCS connector [1] from the DLC [2]. Connect the SCS connector to the DLC again while the MIL stays ON about 5 seconds (reset receiving pattern).

  • Page 116: Ignition System

    dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 4-9) and begin the appropriate troubleshooting procedure. If there are no DTC stored in the ECM/PCM memory, do the diagnostic procedure for the symptom, in sequence listed below, until you find cause.
  • Page 117 dummyhead dummyhead PGM-FI SYSTEM DTC INDEX • If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC. Refer Function Failure Symptom/Fail-safe function MAP sensor circuit low voltage (less than 0.029 V) •...
  • Page 118 dummyhead dummyhead PGM-FI SYSTEM Refer Function Failure Symptom/Fail-safe function EOP sensor low voltage (less than 0.059 V) • Engine operates normally 83-1* 4-36 • EOP sensor or its circuit malfunction EOP sensor high voltage (more than 4.883 V) • Engine operates normally 83-2* •...
  • Page 119 dummyhead dummyhead PGM-FI SYSTEM DTC TROUBLESHOOTING • If the ECM/PCM is replaced, perform the Key Registration Procedure (page 23-3). • CRF1000D: If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 13-82). DTC 1 (MAP SENSOR) ECM/PCM MAP SENSOR Lg/Bl Gr/Bl Probable cause...
  • Page 120 dummyhead dummyhead PGM-FI SYSTEM 3. MAP Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM/PCM 33P (Black) connector (page 4-39). Check for continuity between the wire harness side 3P (Black) connector [1] and 33P (Black) connector [2].
  • Page 121 dummyhead dummyhead PGM-FI SYSTEM 2. MAP Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the MAP sensor 3P (Black) connector (page 4-41). Turn the ignition switch ON. Measure the voltage at the wire harness side 3P (Black) connector [1]. Connection: Yellow/red (+) –...
  • Page 122 dummyhead dummyhead PGM-FI SYSTEM DTC 7 (ECT SENSOR) ECM/PCM ECT SENSOR Gr/Bl Probable cause • Open or short circuit in the Light green wire between the ECT sensor and ECM/PCM • Open circuit in the Gray/black wire between the ECT sensor and ECM/PCM •...
  • Page 123 dummyhead dummyhead PGM-FI SYSTEM DTC 7-2 (ECT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the ECT sensor 2P (Black), ECM/ PCM 33P (Black) and 33P (Gray) connectors, and recheck the DTC. 1. ECT Sensor System Inspection Check the ECT sensor with the MCS.
  • Page 124 dummyhead dummyhead PGM-FI SYSTEM DTC 8 (TP SENSOR) ECM/PCM TP SENSOR Bu/Y Gr/Bl Probable cause • Open circuit in the Yellow/red or Gray/black wire between the TP sensor and ECM/PCM • Open or short circuit in the Blue/yellow wire between the TP sensor and ECM/PCM •...
  • Page 125 dummyhead dummyhead PGM-FI SYSTEM 4. TP Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM/PCM 33P (Black) connector (page 4-39). Check for continuity between the wire harness side 3P (Black) connector [1] and 33P (Black) connector [2].
  • Page 126 dummyhead dummyhead PGM-FI SYSTEM DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Check the TP sensor with the MCS. Is about 5 V indicated? – GO TO STEP 2. – GO TO STEP 3. 2. TP Sensor System Inspection with throttle operated Check that the TP sensor voltage increases continuously when moving the throttle from fully...
  • Page 127 dummyhead dummyhead PGM-FI SYSTEM DTC 9 (IAT SENSOR) ECM/PCM IAT SENSOR Br/R Gr/Bl Probable cause • Open or short circuit in the Brown/red wire between the IAT sensor and ECM/PCM • Open circuit in the Gray/black wire between the IAT sensor and ECM/PCM •...
  • Page 128 dummyhead dummyhead PGM-FI SYSTEM DTC 9-2 (IAT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Blue), ECM/PCM 33P (Black) and 33P (Gray) connectors, and recheck the DTC. 1. IAT Sensor System Inspection Check the IAT sensor with the MCS.
  • Page 129 From fuse box VS SENSOR Bl/R *: CRF1000D Probable cause • Open circuit in the Black/red (CRF1000/A) or Black (CRF1000D) wire between the fuse box and VS sensor • Open circuit in the Green wire between the VS sensor and ground •...
  • Page 130 Turn the ignition switch ON. Measure the voltage between the wire harness side 3P (Black) connector [1] and ground. Connection: CRF1000/A: Black/red (+) – Green (–) CRF1000D: Black (+) – Green (–) Bl/R or Bl Is there battery voltage? – GO TO STEP 4.
  • Page 131 dummyhead dummyhead PGM-FI SYSTEM DTC 12/DTC 13 (FUEL INJECTOR) ECM/PCM From FI relay FUEL INJECTOR Bl/W No.1: P/Bl No.2: P/Bu Probable cause • Open circuit in the Black/white wire between the FI relay and fuel injector • Open or short circuit in the Pink/black (No.1) or Pink/ blue (No.2) wire between the fuel injector and ECM/ •...
  • Page 132 dummyhead dummyhead PGM-FI SYSTEM 3. Fuel Injector Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the injector side 2P connector [1]. Standard: 11 – 13 Ω (20°C/68°F) Is the resistance within standard value? – GO TO STEP 4. –...
  • Page 133 dummyhead dummyhead PGM-FI SYSTEM DTC 21 (O SENSOR) ECM/PCM SENSOR Gr/Bl Probable cause • Open or short circuit in the Black wire between the ECM/PCM and O sensor • Open circuit in the Gray or Gray/black wire between the O sensor and ECM/PCM •...
  • Page 134 dummyhead dummyhead PGM-FI SYSTEM 3. O Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side 4P (Black) connector [1] and ground. Connection: Black – Ground Is there continuity? – Short circuit in the Black wire –...
  • Page 135 dummyhead dummyhead PGM-FI SYSTEM DTC 23 (O SENSOR HEATER) ECM/PCM From FI relay SENSOR HEATER Bl/W Probable cause • Open circuit in the Black/white wire between the FI relay and O sensor • Open or short circuit in the White wire between the sensor and ECM/PCM •...
  • Page 136 dummyhead dummyhead PGM-FI SYSTEM 3. O Sensor Heater Input Voltage Inspection Turn the ignition switch ON. Measure the voltage between the wire harness side 4P (Black) connector [1] and ground. Connection: Black/white (+) – Ground (–) Is there battery voltage? –...
  • Page 137 dummyhead dummyhead PGM-FI SYSTEM DTC 29 (IACV) ECM/PCM IACV Bl/Y Bl/O Bl/R Bl/G Probable cause • Open or short circuit in Black/yellow, Black/orange, Black/red, or Black/green wire between the IACV and ECM/PCM • Faulty IACV • Faulty ECM/PCM DTC 29-1 (IACV) •...
  • Page 138 dummyhead dummyhead PGM-FI SYSTEM 3. IACV Line Open Circuit Inspection Disconnect the ECM/PCM 33P (Gray) connector (page 4-39). Check for continuity between the wire harness side 4P (Black) connector [1] and 33P (Gray) connector TOOL: Test probe (2 required) 07ZAJ-RDJA110 Connection: Black/yellow –...
  • Page 139 dummyhead dummyhead PGM-FI SYSTEM DTC 54 (BANK ANGLE SENSOR) ECM/PCM From FI relay Bl/W R/Bu BANK ANGLE SENSOR Probable cause • Open circuit in the Black/white wire between the FI relay and bank angle sensor • Open or short circuit in the Red/blue wire between the bank angle sensor and ECM/PCM •...
  • Page 140 dummyhead dummyhead PGM-FI SYSTEM 3. Bank Angle Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM/PCM 33P (Gray) connector (page 4-39). Check for continuity between the wire harness side 2P (Black) connector [1] and 33P (Black) connector [2].
  • Page 141 dummyhead dummyhead PGM-FI SYSTEM 2. Bank Angle Sensor Inspection Replace the bank angle sensor with a known good one (page 4-42). Erase the DTC (page 4-6). Check the bank angle sensor with the MCS. Is about 5 V indicated? – Replace the ECM/PCM with a known good one (page 4-39) and recheck.
  • Page 142 dummyhead dummyhead PGM-FI SYSTEM 3. Rear Wheel Speed Sensor Signal Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: – ABS modulator 18P (Black) connector (page 20- – ECM/PCM 33P (Black) connector (page 4-39) Check for continuity between the wire harness side 18P (Black) connector [1] and 33P (Black) connector [2].
  • Page 143 dummyhead dummyhead PGM-FI SYSTEM DTC 67 (FRONT WHEEL SPEED SENSOR SIGNAL) (CRF1000A/D) ECM/PCM ABS MODULATOR Bu/Y Probable cause • Open or short circuit in the Blue/yellow wire between the ABS modulator and ECM/PCM • Faulty ABS modulator • Faulty ECM/PCM DTC 67-1 (FRONT WHEEL SPEED SENSOR SIGNAL) 1.
  • Page 144 dummyhead dummyhead PGM-FI SYSTEM 4. Front Wheel Speed Sensor Signal Output Line Short Circuit Inspection Check for continuity between the wire harness side 33P (Black) connector [1] and ground. TOOL: Test probe 07ZAJ-RDJA110 Connection: B17 – Ground Is there continuity? –...
  • Page 145 dummyhead dummyhead PGM-FI SYSTEM 2. EOP Sensor Inspection Stop the engine. Disconnect the EOP sensor 3P (Black) connector (page 22-20). Turn the ignition switch ON. Check the EOP sensor with the MCS. Is about 0 V indicated? – GO TO STEP 3. –...
  • Page 146 dummyhead dummyhead PGM-FI SYSTEM 2. EOP Sensor Inspection Turn the ignition switch OFF. Disconnect the EOP sensor 3P (Black) connector (page 22-20). Connect the wire harness side 3P (Black) connector [1] with a jumper wire [2]. Connection: White – Black Turn the ignition switch ON.
  • Page 147 If there is continuity, check for short circuit in the Gray/ blue wire between the DLC and ECM/PCM. If there is no continuity, replace the ECM/PCM with a known good one (page 4-39), and recheck. ECM (CRF1000/A)/PCM (CRF1000D) REMOVAL/ INSTALLATION Remove the fuel tank (page 7-6) CRF1000D shown: Turn the ignition switch OFF.
  • Page 148 dummyhead dummyhead PGM-FI SYSTEM Disconnect the following: CRF1000D shown: – PCM 33P (Blue) connector [1] (CRF1000D) – ECM/PCM 33P (Black) connector [2] – ECM/PCM 33P (Gray) connector [3] Remove the ECM/PCM [4]. Release the junction terminals [5] from the ECM/PCM stay [6] and remove the stay by releasing its tab [7] from the battery box.

  • Page 149: Map Sensor

    dummyhead dummyhead PGM-FI SYSTEM MAP SENSOR REMOVAL/INSTALLATION Remove the air cleaner housing (page 7-11). Disconnect the MAP sensor 3P (Black) connector [1]. Remove the screw [2] and MAP sensor [3] from the throttle body setting plate. Disconnect the MAP sensor hose [4]. Installation is in the reverse order of removal.

  • Page 150: Bank Angle Sensor

    dummyhead dummyhead PGM-FI SYSTEM VS SENSOR REMOVAL/INSTALLATION Remove the battery box (page 21-6). CRF1000D shown: Disconnect the VS sensor 3P (Black) connector [1]. Remove the following: – Bolt [2] – VS sensor [3] – O-ring [4] Installation is in the reverse order of removal. •...
  • Page 151 dummyhead dummyhead PGM-FI SYSTEM Installation is in the reverse order of removal. • Install the bank angle sensor with its "UP" mark [1] facing up. SYSTEM INSPECTION Connect the MCS (page 4-6). 70° BANK ANGLE POSITION Remove the bank angle sensor (page 4-42). Connect the bank angle sensor 2P (Black) connector.
  • Page 152 dummyhead dummyhead PGM-FI SYSTEM RELAY INSPECTION Remove the FI relay (page 4-43). Connect an ohmmeter to the FI relay [1] terminals. Connect a 12 V battery to the starter relay connector terminals as shown. There should be continuity only when 12 V battery is connected.

  • Page 153: Ignition System

    dummytext 5. IGNITION SYSTEM SERVICE INFORMATION························ 5-2 IGNITION SYSTEM INSPECTION ············· 5-6 TROUBLESHOOTING ···························· 5-3 IGNITION COIL ····································· 5-9 SYSTEM LOCATION ······························ 5-4 IGNITION TIMING ································ 5-10 SYSTEM DIAGRAM ······························· 5-5...
  • Page 154 – Ignition switch (page 22-23) – Engine stop switch (page 22-24) – Clutch switch (CRF1000/A) (page 22-25) – Gear position switch (CRF1000/A) (page 22-25) – Sidestand switch (page 22-27) • The following color codes are used throughout this section. Bl = Black...
  • Page 155 Blue/yellow wires between the ignition coil and ECM/PCM 6. Faulty following components: – CRF1000/A: sidestand switch, clutch switch, or gear position switch – CRF1000D: sidestand switch or neutral switch 7. Loose or poor connection or an open circuit in No. 6 related wires –...
  • Page 156 – FI FUSE 15 A NO.2 CYLINDER SUB IGNITION BANK ANGLE COIL SENSOR BATTERY FI RELAY ECM/PCM CLUTCH SWITCH (CRF1000/A) NO.1 CYLINDER MAIN IGNITION COIL NO.1 CYLINDER MAIN SPARK PLUG FUSE BOX 1 NO.1 CYLINDER – NEUTRAL DIODE SENSOR SUB SPARK PLUG (CRF1000/A) –...
  • Page 157 IGNITION SYSTEM SYSTEM DIAGRAM CRF1000/A CLUTCH NEUTRAL SWITCH DIODE Bl/Gr MAIN IGNITION FUSE SWITCH 30 A BATTERY R/Bl ENGINE STOP 7.5 A R/Bu Bu/R Bu/Bl SIDESTAND ENGINE STOP Bl/W SWITCH Bu/Y Bu/W SWITCH FI FUSE COMBINATION FI RELAY...

  • Page 158: Ignition System Inspection

    dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •...
  • Page 159 dummyhead dummyhead IGNITION SYSTEM Remove the air cleaner housing (page 7-11). With the ignition coil primary wire connected, connect Do not disconnect the peak voltage adaptor or Imrie tester to the ignition the ignition coil coil primary terminal and ground. primary wire.
  • Page 160 Test probe 07ZAJ-RDJA110 CONNECTION: C8 (+) – C16 (–) CRF1000/A: Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch " ". Crank the engine with the starter motor and measure the CKP sensor peak voltage.

  • Page 161: Ignition Coil

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL IGNITION COIL TRAY REMOVAL/ INSTALLATION Disconnect the spark plug cap (page 3-6). Remove the air cleaner housing (page 7-11). Release the ignition switch 2P (Brown) [1] and immobilizer receiver 4P (Black) [2] connectors from the ignition coil tray.

  • Page 162: Ignition Timing

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL TRAY DISASSEMBLY/ DISASSEMBLY Remove the ignition coil tray assembly (page 5-9) Remove the PAIR control solenoid valve (page 7-19) Disconnect the ignition coil connectors. Remove the following from the ignition tray [1]: – Bolts [2] –...

  • Page 163: Electric Starter

    6. ELECTRIC STARTER SERVICE INFORMATION························ 6-2 STARTER MOTOR································· 6-5 TROUBLESHOOTING ···························· 6-2 STARTER RELAY SWITCH ····················· 6-7 SYSTEM LOCATION ······························ 6-3 NEUTRAL DIODE (CRF1000/A) ··············· 6-9 SYSTEM DIAGRAM ······························· 6-4 STARTER RELAY (CRF1000D)················ 6-9...
  • Page 164 – Starter switch (page 22-24) – Engine stop switch (page 22-24) – Clutch switch (CRF1000/A) (page 22-25) – Gear position switch (CRF1000/A) (page 22-25) – Sidestand switch (page 22-27) – The following color codes are used throughout this section. Bl = Black...
  • Page 165 SYSTEM LOCATION ENGINE STOP SWITCH STARTER SWITCH IGNITION SWITCH STARTER RELAY SWITCH – MAIN FUSE 30 A STARTER RELAY (CRF1000D) CLUTCH SWITCH (CRF1000/A) BATTERY FUSE BOX 1 – NEUTRAL DIODE STARTER MOTOR (CRF1000/A) – ENG STOP 7.5 A GEAR POSITION SWITCH...
  • Page 166 ELECTRIC STARTER SYSTEM DIAGRAM CRF1000/A Bl: Black G: Green R: Red Y: Yellow Bl/Gr STARTER RELAY SWITCH W: White Gr: Gray STARTER Br: Brown MOTOR BATTERY MAIN Lg: Light green FUSE 30 A STARTER SWITCH To ECM CLUTCH...

  • Page 167: Starter Motor

    dummyhead dummyhead ELECTRIC STARTER STARTER MOTOR REMOVAL/INSTALLATION Remove the battery box (page 21-6). Remove the bolts [1] and starter motor [2]. Remove the O-ring [1]. Installation is in the reverse order of removal. • Replace the O-ring with a new one. •...
  • Page 168 dummyhead dummyhead ELECTRIC STARTER When installing the front cover [1] and rear cover [2] Align onto the motor case [3], align the lines as shown. INSPECTION FRONT COVER Check the oil seal [1] in the front cover for deterioration, wear, or damage. Turn the inner race of bearing [2] in the front cover with your finger.
  • Page 169 dummyhead dummyhead ELECTRIC STARTER STARTER RELAY SWITCH REMOVAL/INSTALLATION Remove the socket bolt [1]. Remove the battery box cover [2] by releasing the tab [3]. Release the starter relay switch [1] from the battery box. Remove the starter relay switch cover [2]. Disconnect the starter relay switch 4P (Black) connector [1].
  • Page 170 dummyhead dummyhead ELECTRIC STARTER STARTER RELAY INPUT VOLTAGE Remove the starter relay switch 4P (Black) connector (page 6-7). Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side 4P (Black) connector [1] and ground (–). CONNECTION: White (+) –...
  • Page 171 ELECTRIC STARTER NEUTRAL DIODE (CRF1000/A) REMOVAL/INSTALLATION Remove the main seat (page 2-4). CRF1000 shown: Open the fuse box cover and remove the neutral diode [1]. Installation is in the reverse order of removal. INSPECTION Check for continuity between the diode terminals.
  • Page 172 dummyhead dummyhead MEMO...

  • Page 173: Fuel System

    dummytext 7. FUEL SYSTEM SERVICE INFORMATION························ 7-2 FUEL PUMP RELAY ···························· 7-10 TROUBLESHOOTING ···························· 7-2 AIR CLEANER HOUSING ····················· 7-11 COMPONENT LOCATION ······················· 7-3 THROTTLE BODY ······························· 7-12 FUEL LINE INSPECTION ························ 7-4 IACV·················································· 7-16 FUEL TANK ·········································· 7-6 FUEL INJECTOR ································· 7-17 FUEL PUMP UNIT··································...
  • Page 174 dummyhead dummyhead FUEL SYSTEM SERVICE INFORMATION FUEL SYSTEM GENERAL • Before disconnecting the fuel feed hose, relieve fuel pressure from the system (page 7-4). • Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of motorcycle control.
  • Page 175 dummyhead dummyhead FUEL SYSTEM COMPONENT LOCATION 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

  • Page 176: Fuel Line Inspection

    dummyhead dummyhead FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING • Before disconnecting the fuel hose, relieve pressure from the system as follows. 1. Turn the ignition switch OFF. 2. Lift and support the fuel tank (page 3-3). 3. Disconnect the fuel pump unit 3P (Black) connector [1].

  • Page 177: Fuel Pressure Test

    dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE NORMALIZATION 1. Connect the fuel pump unit 3P (Black) connector [1]. Connect the battery negative (–) cable (page 21-5). 2. Turn the ignition switch ON and engine stop switch " ". The fuel pump will run for about 2 seconds and fuel pressure will rise.

  • Page 178: Fuel Tank

    dummyhead dummyhead FUEL SYSTEM FUEL FLOW INSPECTION Disconnect the quick connect fitting from the fuel rail (page 7-4). Place the end of the fuel feed hose [1] into an approved Clean up any spilled fuel container. fuel. Temporarily connect the battery negative (–) cable and fuel pump unit 3P (Black) connector.

  • Page 179: Fuel Pump Unit

    dummyhead dummyhead FUEL SYSTEM Installation is in the reverse order of removal. • A pressure release can be heard when opening the fuel cap, but this is not blockage of the passage. If checking for clog in the passage of the fuel tank side is necessary, apply air pressure to the breather hose end with the fuel filler cap opened.
  • Page 180 dummyhead dummyhead FUEL SYSTEM DISASSEMBLY/INSPECTION Remove the screws [1], Black wire terminals [2], and stoppers [3]. Disconnect the White wire connector [4] and Blue wire connector [5]. Remove the fuel pump filter assembly [1] and O-ring [2] from the fuel pump stay [3]. Remove the chamber [1] by releasing the tabs [2].
  • Page 181 dummyhead dummyhead FUEL SYSTEM ASSEMBLY Replace the fuel filter assembly [1] with a new one. Install a new O-ring [2] to the pressure regulator [3]. Install the pressure regulator. Install a new O-ring [1] to the fuel pump [2]. Install the fuel pump. •...

  • Page 182: Fuel Pump Relay

    dummyhead dummyhead FUEL SYSTEM Install the stoppers [1], Black wire terminals [2], and screws [3]. Tighten the screws to the specified torque. TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) Connect the White wire connector [4] and Blue wire connector [5]. INSTALLATION Install a new packing [1] onto the fuel pump unit [2].

  • Page 183: Air Cleaner Housing

    dummyhead dummyhead FUEL SYSTEM RELAY INSPECTION Remove the fuel pump relay (page 7-10). Refer to FI relay inspection (page 4-44). AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the following: Left side shown: – Front cover (page 2-7) – Fuel tank (page 7-6) Release the left/right tabs [1] of the air cleaner duct from the inner cover.

  • Page 184: Throttle Body

    dummyhead dummyhead FUEL SYSTEM Loosen the connecting hose band screws [1] Remove the following: – Bolts [2], collars A [3], and collars B [4] – Bolt/washer [5] Disconnect the connecting hose and pull the air cleaner housing [6] upward. Disconnect the following: –...
  • Page 185 dummyhead dummyhead FUEL SYSTEM Disconnect the MAP sensor 3P (Black) connector [1]. Disconnect the IACV 4P (Black) connector [2]. Disconnect the throttle body by pulling it upward. Disconnect the injector 2P (Black) [1] and 2P (Blue) [2] connectors. Loosen the throttle cable A adjuster lock nut [1] and adjusting nut [2] then disconnect the throttle cable A [3] from the throttle drum and cable stay.
  • Page 186 dummyhead dummyhead FUEL SYSTEM DISASSEMBLY/ASSEMBLY • Do not remove the sensor unit unless it is replaced. • Do not loosen or tighten the white painted nuts and screws [1] and nuts [2] of the throttle body. Loosening or tightening it can cause throttle valve and idle control failure.
  • Page 187 dummyhead dummyhead FUEL SYSTEM Connect the throttle cables [1] to the throttle drum and throttle cable stay. Tighten the throttle cable B lock nut [2] to the specified torque. TORQUE: 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft) Temporarily tighten the throttle cable A adjuster lock nut [3].
  • Page 188 dummyhead dummyhead FUEL SYSTEM Connect the MAP sensor 3P (Black) connector [1]. Connect the IACV 4P (Black) connector [2]. Adjust the throttle grip freeplay (page 3-3). Connect the fuel feed hose to the fuel rail (page 7-4). Install the air cleaner housing (page 7-11). IACV REMOVAL Remove the fuel tank (page 7-6).

  • Page 189: Fuel Injector

    dummyhead dummyhead FUEL SYSTEM INSTALLATION Turn the slide valve [1] clockwise until it is lightly seated on the IACV. Install a new O-ring [1] onto the IACV [2]. Align Install the IACV into the throttle body by aligning the valve slit with the guide pin in the throttle body. Install the setting plate [3] by aligning its cut-out with the tab of IACV.
  • Page 190 dummyhead dummyhead FUEL SYSTEM ASSEMBLY/INSTALLATION Apply engine oil to new O-rings and seal rings. Assemble the following: – Seal rings [1] – Fuel injectors [2] – O-rings [3] – Fuel injector joints [4] – O-rings [5] Align – Fuel rail [6] •...

  • Page 191: Pair Control Solenoid Valve

    dummyhead dummyhead FUEL SYSTEM Temporarily install the fuel tank (page 7-6). Temporarily connect the IAT sensor 2P (Black) connector (page 7-12). Lift the fuel tank (page 3-3) Start the engine and open the throttle slightly to be certain that air is sucked in through the disconnected air suction hose [1].
  • Page 192 dummyhead dummyhead FUEL SYSTEM Measure the resistance at the 2P connector [1] of the PAIR control solenoid valve. STANDARD: 24 – 28 Ω (20°C/68°F) If the resistance is out of the specification, replace the PAIR control solenoid valve. PAIR REED VALVE REMOVAL/ INSTALLATION Remove the cylinder head cover (page 10-4).
  • Page 193 dummyhead dummyhead FUEL SYSTEM PAIR REED VALVE INSPECTION Remove the PAIR reed valves (page 7-20). Check the reed valve [1] for damage or fatigue. Replace if necessary. Replace the PAIR check valve if the rubber seat [2] is cracked, deteriorated or damaged, or if there is clearance between the reed and seat.
  • Page 194 dummyhead dummyhead MEMO...

  • Page 195: Cooling System

    dummytext 8. COOLING SYSTEM SERVICE INFORMATION························ 8-2 THERMOSTAT ······································ 8-5 TROUBLESHOOTING ···························· 8-2 RADIATOR ··········································· 8-6 SYSTEM FLOW PATTERN······················ 8-3 RADIATOR RESERVE TANK················· 8-10 SYSTEM TESTING································· 8-4 WATER PUMP ···································· 8-10 COOLANT REPLACEMENT ···················· 8-4 FAN CONTROL RELAY ························ 8-11...
  • Page 196 dummyhead dummyhead COOLING SYSTEM SERVICE INFORMATION COOLING SYSTEM GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages.

  • Page 197: System Flow Pattern

    dummyhead dummyhead COOLING SYSTEM SYSTEM FLOW PATTERN CRF1000D shown: LEFT RADIATOR CAP RADIATOR RIGHT RADIATOR THERMOSTAT RADIATOR RESERVE TANK WATER PUMP...

  • Page 198: System Testing

    Remove the radiator cap (page 8-4). CRF1000/A: CRF1000D: CRF1000D: Remove the EOP sensor cover (page 13- Remove the drain bolt [1], sealing washer [2], and drain the coolant.
  • Page 199 dummyhead dummyhead COOLING SYSTEM Fill the system with the recommended coolant through the filler opening up to filler neck [1]. Remove the radiator reserve tank cap [2] and fill the reserve tank to the upper level line. Bleed air from the system as follows: 1.
  • Page 200 dummyhead dummyhead COOLING SYSTEM INSPECTION Visually inspect the thermostat [1] for damage. Check the thermostat rubber [2] for damage and replace if necessary. Visually inspect the thermostat [1] for damage. Replace the thermostat if the valve stays open at room temperature.
  • Page 201 dummyhead dummyhead COOLING SYSTEM Release the connector clip [1] from the radiator shroud. Release the air cleaner housing drain hose [2] from the clamp [3]. Loosen the hose band screws [1] and disconnect the upper radiator hose [2] and radiator hose B [3] from the left radiator.
  • Page 202 dummyhead dummyhead COOLING SYSTEM Release the siphon hose [1]. Release the connector clip [2] from the radiator shroud. Release the linear solenoid wire [3] and main wire harness [4] from the clamp [5]. Release the air cleaner housing drain hose [6] from the clamp [7].
  • Page 203 dummyhead dummyhead COOLING SYSTEM DISASSEMBLY/ASSEMBLY FAN MOTORS COOLING FAN MOUNTING NUTS FAN MOTOR SHROUD BOLTS 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft) FAN MOTOR MOUNTING SCREWS 2.7 N·m (0.3 kgf·m, 2.0 lbf·ft) COOLING FANS LEFT RADIATOR GRILL LEFT FAN MOTOR SHROUD PAN SCREWS...

  • Page 204: Radiator Reserve Tank

    Replace the water pump as an assembly if necessary. REMOVAL/INSTALLATION Remove the right crankcase cover. CRF1000D shown: – CRF1000/A (page 12-4) – CRF1000D (page 13-52) Remove the drain bolt [1] and sealing washer [2]. Remove the water pump cover bolts [3] and water pump body [4].
  • Page 205 dummyhead dummyhead COOLING SYSTEM Install a new O-ring [1] into the groove in the water CRF1000D shown: pump body [2]. Install the dowel pins [3] and water pump body. Apply locking agent to the water pump cover bolts CRF1000D shown: threads (page 1-20).
  • Page 206 dummyhead dummyhead MEMO...

  • Page 207: Lubrication System

    9. LUBRICATION SYSTEM SERVICE INFORMATION························ 9-2 OIL PUMP (CRF1000/A)·························· 9-5 TROUBLESHOOTING ···························· 9-2 OIL PUMP (CRF1000D) ·························· 9-7 LUBRICATION SYSTEM DIAGRAM·········· 9-3 OIL STRAINER······································ 9-8 OIL PRESSURE INSPECTION ················· 9-5...
  • Page 208 dummyhead dummyhead LUBRICATION SYSTEM SERVICE INFORMATION LUBRICATION SYSTEM GENERAL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.
  • Page 209 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CRF1000/A CAMSHAFT ROCKER ARM SHAFT PISTON CRANKSHAFT PISTON OIL JETS ALTERNATOR MAINSHAFT EOP SWITCH CLUTCH ENGINE OIL FILTER COUNTERSHAFT SCAVENGE PUMP REAR BALANCER OIL FILTER SCREEN SHAFT ENGINE OIL ENGINE OIL PRESSURE FEED PUMP...
  • Page 210 dummyhead dummyhead LUBRICATION SYSTEM CRF1000D CAMSHAFT ROCKER ARM SHAFT No.1 No.2 LINEAR LINEAR SOLENOID SOLENOID VALVE VALVE No.1 PISTON No.2 CLUTCH CLUTCH SENSOR SENSOR CRANKSHAFT PISTON OIL JETS ALTERNATOR EOP SENSOR MAINSHAFT ENGINE OIL FILTER No.2 No.1 CLUTCH CLUTCH COUNTERSHAFT DCT OIL CLUTCH LINE PUMP...
  • Page 211 5,000 min (rpm)/(80°C/176°F) Stop the engine and remove the tools. Install the engine oil filter cartridge (page 3-12). OIL PUMP (CRF1000/A) REMOVAL/INSTALLATION Remove the oil strainer (page 9-8). Remove the bolts [1] and oil pump [2]. Installation is in the reverse order of removal.
  • Page 212 dummyhead dummyhead LUBRICATION SYSTEM DISASSEMBLY/ASSEMBLY • Dip all parts in clean engine oil. FLANGE BOLT (6 x 75 mm) 12 N·m (1.2 kgf·m, 9 lbf·ft) FLANGE BOLTS (6 x 55 mm) 12 N·m (1.2 kgf·m, 9 lbf·ft) FLANGE BOLT (6 x 35 mm) OIL PUMP BODY A 12 N·m (1.2 kgf·m, 9 lbf·ft) OIL PUMP SHAFT...
  • Page 213 dummyhead dummyhead LUBRICATION SYSTEM OIL PUMP (CRF1000D) REMOVAL/INSTALLATION Remove the oil strainer (page 9-8). Remove the oil pump mounting bolts [1] and oil pump [2]. Installation is in the reverse order of removal. • Align the oil pump driven shaft end with the oil pump drive shaft groove.

  • Page 214: Oil Strainer

    dummyhead dummyhead LUBRICATION SYSTEM OIL PUMP INSPECTION • If any portion of the oil pump is worn beyond the service limit, replace the oil pump as an assembly. Inspection the following parts for damage, abnormal wear, deformation, or burning: – Oil pump shaft –...
  • Page 215 dummyhead dummyhead LUBRICATION SYSTEM Remove the oil strainer [1] and seal ring [2]. Clean the oil strainer and check for damage, replace it if necessary. • Align the oil strainer boss with the oil pump groove. • Always replace the seal ring with a new one. •...
  • Page 216 dummyhead dummyhead MEMO...

  • Page 217: Cylinder Head/Valve/Camshaft

    dummytext 10. CYLINDER HEAD/VALVE/CAMSHAFT SERVICE INFORMATION······················ 10-2 ROCKER ARM ···································· 10-6 TROUBLESHOOTING ·························· 10-2 CAM CHAIN TENSIONER LIFTER ·········· 10-8 COMPONENT LOCATION ····················· 10-3 CAMSHAFT ········································ 10-9 CYLINDER COMPRESSION ·················· 10-4 CYLINDER HEAD ······························· 10-13 CYLINDER HEAD COVER····················· 10-4 INSULATOR ······································ 10-19 10-1...
  • Page 218 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT SERVICE INFORMATION CYLINDER HEAD/VALVE/CAMSHAFT GENERAL • This section covers service of the valves, rocker arms and camshaft. These services can be done with the engine installed in the frame. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. •...
  • Page 219 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT COMPONENT LOCATION 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) 83 N·m (8.5 kgf·m, 61 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 18 N·m (1.8 kgf·m, 13 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 10-3...

  • Page 220: Cylinder Compression

    Turn the ignition switch ON. Shift the transmission into the neutral position. CRF1000/A: Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. The maximum reading is usually reached within 4 – 7 seconds.
  • Page 221 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Remove the plug pipe seals [1] and cylinder head cover packing [2]. INSTALLATION Install new plug pipe seals [1]. Install a new cylinder head cover packing [2]. • Install the plug pipe seals with their "OUT SIDE" marks [3] facing up.
  • Page 222 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Insert the cylinder head cover [1] from the right side as shown. Install the cover on the cylinder head securely. Install the bolts [1] and tighten them to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the ignition coil tray (page 5-9).
  • Page 223 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Temporarily install a 6 mm bolt [1]. Remove the rocker arm shaft [2] by pulling it. Remove the rocker arms A [3] and B [4]. Remove the 6 mm bolt. INSPECTION Inspect the following parts for damage, abnormal wear, deformation, burning.
  • Page 224 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Apply molybdenum oil solution to the rocker arm sliding area and thrust surface. Apply molybdenum oil solution to the rocker arm shaft outer surface. Temporarily install a 6 mm bolt [1]. Install the rocker arms A [2] and B [3]. Install the rocker arm shaft [4].
  • Page 225 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Install a new gasket [1] on the cam chain tensioner lifter [2] and install them to the cylinder. Install and tighten the mounting bolts [3]. Remove the tensioner holder B [4]. Install and tighten the plug [5] with a new sealing washer [6].
  • Page 226 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Remove the cam sprocket bolts [1] and disassemble the camshaft [2] and cam sprocket [3]. Release the cam chain [4] from the cam sprocket. Attach a piece of wire to the cam Remove the camshaft. chain to prevent it from falling into the crankcase.
  • Page 227 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Install camshaft holders/dowel pins [1] in the correct locations, being careful not to drop the plastigauge. Apply engine oil to the threads and seating surfaces of the camshaft holder bolts [2] and install them. Tighten the bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Remove the camshaft holders and measure the compressed plastigauge at its widest point on the...
  • Page 228 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Apply molybdenum oil solution to the camshaft journal cam lobes, and thrust surfaces. Put the camshaft [1] onto the cylinder head. Apply engine oil to the cam chain whole surface. Install the cam chain [2] over the cam sprocket [3] Assemble the camshaft and cam sprocket.

  • Page 229: Cylinder Head

    dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Apply engine oil to the camshaft holder bolt [1] threads and seating surfaces and install them. Tighten the bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply the cam chain tension (page 10-8). Install the removed parts in the reverse order of removal.
  • Page 230 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT DISASSEMBLY Install the tappet hole protector into the valve lifter bore. A tool can easily be made from a plastic 35 mm film container or equivalent as shown. TOP VIEW 5 mm 5 mm 31 mm 15 mm Remove the valve cotters [1] using the special tool as To prevent loss of...

  • Page 231: Valve Guide Replacement

    dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT INSPECTION Inspect the following parts for damage, abnormal wear, deformation, burning or clogs in oil passages. – Cylinder head – Valve springs – Valves – Valve guides Measure each part according to CYLINDER HEAD/ VALVE SPECIFICATIONS (page 1-7). Replace any part if it is out of service limit.
  • Page 232 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT VALVE SEAT INSPECTION/REFACING Disassemble the cylinder head (page 10-14). Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool [1].
  • Page 233 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT ASSEMBLY VALVE COTTERS SPRING RETAINER STEM SEAL (EXHAUST SIDE) VALVE SPRING STEM SEAL (INTAKE SIDE) SPRING SEAT VALVE GUIDE EXHAUST VALVE INTAKE VALVE Blow through the oil passage in the cylinder head with compressed air. Install the spring seats [1]. Apply engine oil to the inside of new stem seals (intake side) [2]/(exhaust side) [3] and install them.
  • Page 234 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Install the tappet hole protector into the valve lifter bore (page 10-14). Install the valve cotters [1] using the special tool as shown. TOOLS: Valve spring compressor [2] 07757-0010000 • To prevent loss of tension, do not compress the valve springs more than necessary.
  • Page 235 dummyhead dummyhead CYLINDER HEAD/VALVE/CAMSHAFT Route the cam chain [1] through the cylinder head and install the cylinder head [2] onto the cylinder. Apply molybdenum oil solution to the cylinder head bolts threads and seating surface. Apply engine oil to the cylinder head bolt washers. Install and tighten the cylinder head bolts [3] in a crisscross pattern in 2 or 3 steps to the specified torque.
  • Page 236 dummyhead dummyhead MEMO...

  • Page 237: Alternator/Starter Clutch

    dummytext 11. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION······················ 11-2 STATOR/CKP SENSOR························ 11-7 TROUBLESHOOTING ·························· 11-2 FLYWHEEL ········································ 11-7 COMPONENT LOCATION ····················· 11-3 STARTER CLUTCH ····························· 11-9 ALTERNATOR COVER························· 11-4 11-1...
  • Page 238 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH GENERAL • This section covers service of the alternator and starter clutch. All service can be done with the engine installed in the frame. • For alternator inspection (page 21-9). • For CKP sensor inspection (page 5-7). •...
  • Page 239 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION 137 N·m (14.0 kgf·m, 101 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 11-3...
  • Page 240 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL/INSTALLATION (CRF1000/A) Drain the engine oil (page 3-12). Remove the left rear cover (page 2-10). Remove the gearshift spindle cover (page 12-17). Disconnect the EOP switch terminal (page 22-19). Disconnect the VS sensor 3P (Black) connector (page 4-42).
  • Page 241 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Remove the dowel pins [1] and oil joint [2]. • Install the oil joint with the narrow hole side facing out. Clean off any sealant from the alternator cover mating surfaces. Installation is in the reverse order of removal. •...
  • Page 242 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Disconnect the EOP sensor 3P (Black) connector [1]. Remove the following: – Dipstick [2] – Alternator cover bolts (6 x 28 mm) [3] – Alternator cover bolt (6 x 30 mm) [4] and alternator assembly wire cover stay A [5] –...
  • Page 243 ALTERNATOR/STARTER CLUTCH STATOR/CKP SENSOR REMOVAL/INSTALLATION Remove the alternator cover. – CRF1000/A (page 11-4) – CRF1000D (page 11-5) Release the wire grommet [1] from the alternator cover groove. Remove the CKP sensor mounting bolts [2]. Remove the stator mounting bolts [3].
  • Page 244 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Remove the flywheel [1] using the special tool. TOOL: Rotor puller [2] 07733-0020001 Remove the needle bearing [1]. Remove the woodruff key [2]. • Be careful not to damage the key groove and crankshaft. INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deformation.

  • Page 245: Starter Clutch

    Install the starter reduction gear A [1] and shaft [2]. Install the starter reduction gear B [3] and shaft [4]. Install the alternator cover. – CRF1000/A (page 11-4) – CRF1000D (page 11-5) STARTER CLUTCH REMOVAL Remove the flywheel (page 11-7).
  • Page 246 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Hold the flywheel [1] using the special tool and remove the starter clutch torx bolt [2]. TOOL: Flywheel holder [3] 07725-0040001 Remove the starter clutch assembly [1]. Remove the starter one-way clutch [2] from the starter clutch outer [3].
  • Page 247 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Hold the flywheel [1] using the special tool. TOOL: Flywheel holder [2] 07725-0040001 Apply locking agent to the starter clutch socket bolt threads (page 1-21). Install and tighten the starter clutch torx bolt [3] to the specified torque.
  • Page 248 dummyhead dummyhead MEMO...

  • Page 249: Clutch/Gearshift Linkage (Crf1000/A)

    12. CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) SERVICE INFORMATION······················ 12-2 CLUTCH ············································ 12-8 TROUBLESHOOTING ·························· 12-2 PRIMARY DRIVE GEAR ······················ 12-15 COMPONENT LOCATION ····················· 12-3 GEARSHIFT LINKAGE ························ 12-17 RIGHT CRANKCASE COVER ················ 12-4 GEARSHIFT PEDAL ··························· 12-21 12-1...
  • Page 250 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) SERVICE INFORMATION CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) GENERAL • This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
  • Page 251 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) COMPONENT LOCATION 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 252 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-12). Drain the coolant (page 8-4). Remove the bolts [1] and engine right side rear cover [2]. Loosen the lock nuts [1] and release the clutch cable [2] from the clutch lifter lever [3].
  • Page 253 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the dowel pins [1] and gasket [2]. Remove the O-ring [1]. CLUTCH LIFTER LEVER Remove the clutch lifter lever [1] and return spring [2]. Remove the oil seal [3]. Check the needle bearings [4] and replace if necessary.
  • Page 254 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary. – Clutch lifter lever – Return spring INSTALLATION Clean the right crankcase cover mating surfaces thoroughly. Apply liquid sealant (TB1207B manufactured by Three Bond or equivalent) to the right crankcase cover mating surface as shown.
  • Page 255 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the crankshaft hole cap and the timing hole [1]/[2] cap (page 3-8). Rotate the crankshaft counterclockwise and align the "T1" mark on the flywheel with the index mark on the alternator cover (page 3-8).
  • Page 256 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Connect the water hoses [1] and tighten the hose band screws [2] to the specified range (page 8-8). Connect the clutch cable [1] with the clutch lifter lever [2]. Install the bolts [1] and engine right side rear cover [2] and tighten the bolts to the specified torque.
  • Page 257 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the following: – Clutch pressure plate [1] [10] [11] – Clutch spring seats [2] – Clutch disc B [3] – Clutch plate C [4] – Clutch lifter pin [5] – Clutch discs A [6] (2 pcs) –...
  • Page 258 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Line up the primary drive gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Hold the primary drive gear and sub-gear with a 6 mm bolt [2]. Remove the washer [1] and clutch outer [2].
  • Page 259 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Check the following of the clutch center [1] for scratch, damage, abnormal wear and deformation. – Cam areas [2] – Grooves – Disc sliding surface Replace the clutch center if necessary. Check the following of the clutch outer [1] for scratch, damage, abnormal wear and deformation.
  • Page 260 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) CLUTCH OUTER NEEDLE BEARING REPLACEMENT Remove the needle bearing [1] out using a hydraulic press and special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 42 mm [3] 07QAD-P0A0100 Coat a new needle bearing with engine oil.
  • Page 261 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Apply molybdenum oil solution to the clutch outer guide entire surface. Install the clutch outer guide [1] and washer [2]. Apply engine oil to the clutch outer needle bearing. Apply molybdenum oil solution to the primary driven gear teeth and clutch outer sliding area.
  • Page 262 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Stake the clutch center lock nut [1] into the mainshaft Be careful not to groove. damage the mainshaft threads. Stake Apply molybdenum oil solution to the entire surface of judder spring seat and judder spring.
  • Page 263 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Install the clutch springs [1], set plate [2] and set plate bolts [3]. Tighten the set plate bolts in a crisscross pattern in 2 or [1]/[3] 3 steps to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 0.9 lbf·ft)
  • Page 264 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the timing sprocket [1]. Remove the primary drive gear and sub-gear [2]. Remove the 6 mm bolt [3]. DISASSEMBLY/ASSEMBLY Remove the primary drive sub-gear [1] and springs [2]. Installation is in the reverse order of removal.
  • Page 265 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Install the timing sprocket [1] with its punch mark [2] facing out as shown Temporarily install the clutch outer [1]. Apply engine oil to the primary drive gear bolt threads and seating surface. Install the washer [2] and primary drive gear bolt [3].
  • Page 266 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the bolt [1] and set plate [2]. Pull the gearshift spindle assembly [1] and thrust washer [2] out of the crankcase. Remove the shift drum center bolt [1]. Remove the shift drum center [1] while holding the stopper arm [2] using a screwdriver as shown.
  • Page 267 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the following: – Dowel pin [1] – Shift drum stopper arm pivot bolt [2] – Shift drum stopper arm [3] – Return spring [4] – Washer [5] [2]/[5] Remove the oil seal [1]. INSPECTION Inspect the following parts for damage, abnormal wear and deformation.
  • Page 268 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Apply locking agent to the shift drum stopper arm bolt threads (page 1-20). Install the washer [1], return spring [2], shift drum stopper arm [3], and pivot bolt [4]. Tighten the pivot bolt to the specified torque.
  • Page 269 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Apply locking agent to the set plate bolt threads (page 1-20). Install the set plate [1] and bolt [2] and tighten the bolt to Install the set plate the specified torque. with its punch mark [3] facing out.
  • Page 270 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) When adjusting the gearshift pedal height, perform procedures as follows: Loosen the lock nuts [1]. The gearshift arm side lock nut has Adjust the tie-rod [2] length so that the distance left hand threads. between the ball joint ends is standard length as shown.

  • Page 271: Dual Clutch Transmission (Dct) (Crf1000D)

    dummytext 13. DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SERVICE INFORMATION······················ 13-2 LINEAR SOLENOID VALVE ················· 13-60 DCT SYMPTOM TROUBLESHOOTING ··· 13-3 DUAL CLUTCH/PRIMARY DRIVEN GEAR ··············································· 13-63 COMPONENT LOCATION ····················· 13-4 PRIMARY DRIVE GEAR ······················ 13-70 SYSTEM LOCATION ···························· 13-5 SHIFT CONTROL MOTOR/REDUCTION GEARS ·············································...
  • Page 272 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SERVICE INFORMATION DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) GENERAL • This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (DCT). • A faulty DCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding. •...
  • Page 273 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DCT SYMPTOM TROUBLESHOOTING Check the shift indicator "–" blinking of the combination meter (page 13-7). If the shift indicator "–" is blinking, refer to the DTC index (page 13-10) and begin the appropriate troubleshooting procedure. If there are no "–"...
  • Page 274 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) COMPONENT LOCATION 31 N·m (3.2 kgf·m, 23 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 118 N·m (12.0 kgf·m, 87 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 5 N·m (0.5 kgf·m, 3.7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 275 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SYSTEM LOCATION N-D SWITCH A/M SWITCH LINEAR SOLENOID VALVE OUTER MAINSHAFT SHIFT SPINDLE SENSOR ANGLE SENSOR VS SENSOR DCT_M 30 A SHIFT UP SWITCH SHIFT DOWN SWITCH FRONT WHEEL SPEED SENSOR No.1 CLUTCH FUSE BOX 1 EOP SENSOR –...
  • Page 276 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SYSTEM DIAGRAM ILLUMI/STOP FRONT BRAKE LIGHT SWITCH 7.5A Bl/R Bl/R REAR BRAKE LIGHT SWITCH Bl/R IGNITION MAIN FUSE SWITCH ENG STOP 7.5A Bl/Gr R/Bl R/Bl ENGINE STOP SWITCH R/Bl Bl/W FI FUSE FI RELAY ILLUMI/STOP 7.5A DCT MAIN...
  • Page 277 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DCT TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the shift indicator "–" does not come on, check for poor contact or loose pins at all connectors related to the circuit that you are troubleshooting. If the shift indicator "–" was on, but then went out, the original problem may be intermittent.
  • Page 278 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Shift indicator "–" Blink Pattern • If the MCS is not available, the DTC can be read from the PCM memory by the shift indicator "–" blink pattern. • The number of shift indicator "–" blinks is the equivalent of the main code of the DTC (the sub code cannot be displayed by the shift indicator "–").
  • Page 279 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) ERASING DTC Connect the MCS to the DLC (page 4-6). Erase the DTC with the MCS while the engine is stopped. To erase the DTC without MCS, refer to the following procedure. How to erase the DTC without MCS 1.
  • Page 280 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC INDEX • If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC. Refer to Function Failure Symptom/Fail-safe function page TP sensor low voltage (less than 0.112 V) •...
  • Page 281 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Refer to Function Failure Symptom/Fail-safe function page Shift switch malfunction • Shift switch does not work • Loose or poor contact of the shift switch connector 42-1 13-27 • Shift switch or its circuit malfunction •...
  • Page 282 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Refer to Function Failure Symptom/Fail-safe function page No.1 linear solenoid valve current failure • Gearshift function does not work • Loose or poor contact of the No.1 linear solenoid valve connector 55-1 • No.1 linear solenoid valve or its circuit malfunction •...
  • Page 283 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Refer to Function Failure Symptom/Fail-safe function page No.1 clutch oil pressure high • Gearshift function does not work • No.1 clutch EOP sensor malfunction 62-1 • Faulty clutch oil circuit • No.1 linear solenoid valve malfunction •...
  • Page 284 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Refer to Function Failure Symptom/Fail-safe function page No.1 clutch operation malfunction (clutch slips) • Gearshift function does not work • VS sensor malfunction 68-1 13-47 • Faulty No.1 clutch • Faulty PCM No.2 clutch operation malfunction (clutch slips) •...
  • Page 285 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC TROUBLESHOOTING • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 13-82) DTC 9-1 (CLUTCH LINE EOP SENSOR LOW VOLTAGE) 1. Clutch Line EOP Sensor System Inspection Connect the MCS and start the engine.
  • Page 286 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 5. Clutch Line EOP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side 3P (Gray) connector [1] and ground. Connection: Red/green –...
  • Page 287 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Clutch Line EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side 3P (Gray) connector [1] and 33P (Blue) connector [2].
  • Page 288 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. CKP sensor Line Short Circuit Inspection Check for continuity between the wire harness side 6P (Black) connector [1] and ground Connection: Yellow – Ground Is there continuity? – Short circuit in the Yellow wire –...
  • Page 289 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Shift Spindle Angle Sensor Ground Line Open Circuit Inspection Check for continuity between the wire harness side 3P (Blue) connector [1] and 33P (Black) connector [2]. TOOL: Test probe 07ZAJ-RDJA110 Connection: Gray/black – B13 Is there continuity? Gr/Bl –...
  • Page 290 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 21-2 (SHIFT SPINDLE ANGLE SENSOR HIGH VOLTAGE) 1. Shift Spindle Angle Sensor System Inspection Check the shift spindle angle sensor with the MCS. Is about 5 V indicated? – GO TO STEP 2. –...
  • Page 291 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Shift Spindle Angle Sensor System Inspection Remove the shift spindle angle sensor with the connector connected (page 13-79). Turn the ignition switch ON. While turning the shift spindle angle sensor shaft, check the shift spindle angle sensor voltage with the MCS.
  • Page 292 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 24-1 (SHIFT CONTROL MOTOR DRIVE CIRCUIT) 1. Shift Control Motor Line Open Circuit Inspection Disconnect the following: – PCM 33P (Blue) connector (page 4-39) – Shift control motor 2P (Black) connector (page 13-71) Check for continuity between the wire harness side P/Bu...
  • Page 293 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 27-1 (SHIFT DRUM POSITION MALFUNCTION) 1. TR Sensor System Inspection Check the TR sensor with the MCS. Is Low voltage (about 0 V) or High voltage (about 5 V) indicated? – • About 0 V: See DTC 51-1 (page 13-34). •...
  • Page 294 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 6. DTC Recheck Recheck the DTC with the MCS. Is DTC 27-1 indicated? – Replace the PCM with a known good one (page 4-39) and recheck. – Intermittent failure DTC 31-1 (SHIFT CONTROL MOTOR LOW VOLTAGE) •...
  • Page 295 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 32-1 (FAIL SAFE RELAY CIRCUIT MALFUNCTION) • Before starting the inspection, check for loose or poor contact on the PCM 33P (Blue) connector, and recheck the DTC. 1. Shift Control Motor Power Supply Voltage Inspection Check the shift control motor power supply voltage with the MCS.
  • Page 296 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 41-1 (N-D SWITCH MALFUNCTION) 1. N-D Switch Power Input Voltage Inspection Disconnect the right handlebar switch 6P (Black) connector (page 22-24). Turn the ignition switch ON with the engine stop switch " ". Measure the voltage between the wire harness side 6P (Black) connector [1] and ground.
  • Page 297 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. N-D Switch Output Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side 6P (Black) connector [1] and 33P (Blue) connector [2].
  • Page 298 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Shift Switch Power Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). Check for continuity between the wire harness side 12P (Black) connector [1] and 33P (Black) connector [2].
  • Page 299 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 5. Shift Switch Input Line Short Circuit Inspection Check for continuity between the wire harness side 12P (Black) connector [1] and ground. Connection: Green/blue – Ground Light green/red – Ground G/Bu Is there continuity? –...
  • Page 300 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 44-2 (EOT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the EOT sensor 2P (Black) and PCM 33P (Blue) connectors, and recheck the DTC. 1. EOT Sensor System Inspection Check the EOT sensor with the MCS.
  • Page 301 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 47-1 or 48-1 (No.1 or No.2 CLUTCH EOP SENSOR LOW VOLTAGE) 1. Clutch EOP Sensor System Inspection Connect the MCS and start the engine. Check the clutch EOP sensor with the MCS. Is about 0 V indicated? –...
  • Page 302 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 5. Clutch EOP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side sensor 3P connector [1] and ground. Connection: No.1 clutch EOP sensor: Y/G or Bl/G...

  • Page 303: Oil Pressure

    dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. Clutch EOP Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). Check for continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and PCM 33P (Black) connector [2].
  • Page 304 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. Clutch Line Oil Filter Condition Inspection Check the clutch oil filter (page 3-13). Is the oil filter in good condition? – GO TO STEP 4. – Replace the clutch oil filter. 4. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one (page 13-80).
  • Page 305 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. TR Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). Check for continuity between the wire harness side 3P (Black) connector [1] and 33P (Black) connector [2].
  • Page 306 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 7. TR Sensor Inspection Replace the TR sensor with a known good one (page 13-79). Connect the 3P (Black) connector, 33P (Black) connector and 33P (Blue) connector. Check the TR sensor with the MCS. Is about 0 V indicated? –...
  • Page 307 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. Neutral Switch Inspection Replace the neutral switch with a known good one (page 13-82). Connect the PCM 33P (Black) connector. Turn the ignition switch ON. Recheck the DTC with the MCS. Is DTC 52-1 indicated? –...
  • Page 308 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Inner Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the inner mainshaft sensor 3P (Black) connector (page 13-78). Turn the ignition switch ON. Measure the voltage at the wire harness side 3P (Black) connector [1].
  • Page 309 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 5. Inner Mainshaft Sensor Output Line Inspection Measure the voltage between the wire harness side 3P (Black) connector [1] and ground. Connection: Pink (+) – Ground (–) Is the voltage within 4.75 – 5.25 V? –...
  • Page 310 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 54-1 (OUTER MAINSHAFT SENSOR SPEED LOW) • Before starting the inspection, check for loose or poor contact on the outer mainshaft sensor 3P (Black), (Blue) (Black) connectors, and recheck the DTC. 1. DTC Recheck Erase the DTC (page 13-9).
  • Page 311 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Outer Mainshaft Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector (page 4-39). Check for continuity between the wire harness side 3P (Black) connector [1] and 33P (Black) connector TOOL: Test probe 07ZAJ-RDJA110...
  • Page 312 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 7. Outer Mainshaft Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side 3P (Black) connector [1] and ground Connection: Pink – Ground Is there continuity? – Short circuit in the Pink wire –...
  • Page 313 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. No.1 Linear Solenoid Valve Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side 4P (black) connector [1] and 33P (Blue) connector [2].
  • Page 314 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. No.2 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side 4P (black) connector [1] and 33P (Blue) connector [2].
  • Page 315 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Clutch Oil Line Inspection Check the clutch oil passages in the right crankcase cover and mainshaft for clogging. Is the oil passage clogged? – Clean the oil passage. – Replace the PCM with a known good one (page 4-39) and recheck.
  • Page 316 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. No.2 Clutch EOP Sensor Inspection Replace the No.2 clutch EOP sensor with a known good one (page 13-80). Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MCS. Is DTC 63-1, 63-2, 63-3, 63-4, 64-1 or 64-2 indicated? –...
  • Page 317 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. VS Sensor Condition Inspection Remove the VS sensor (page 4-42). Check the VS sensor for damage or contaminated. Is the VS sensor in good condition? – Replace the PCM with a known good one (page 4-39) and recheck.
  • Page 318 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 71-1, 72-1 (INNER, OUTER MAINSHAFT/COUNTERSHAFT SPEED RATIO FAILURE) 1. DTC Recheck 1 Check the DTC with the MCS. Is DTC 53-1, 54-1 or 66-1 indicated? – • DTC 53-1 is indicated (page 13-37). •...
  • Page 319 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) A/M SWITCH TROUBLESHOOTING If the engine can be started but AT/MT mode cannot be changed, perform this troubleshooting. • Before starting the inspection, check for loose or poor contact on the right handlebar switch and PCM 33P connectors, and recheck the A/M switch operation.
  • Page 320 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) CLUTCH OIL FEED PIPE REMOVAL Remove the following: [1]/[2] – Bolts [1] – Sealing washers [2] – Feed pipe cover [3] – O-ring [4] – Inner clutch oil feed pipe [1] • Be careful not to bend or damage the inner clutch oil feed pipe.
  • Page 321 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) INSPECTION Inspect the following parts for scratches, bending or clogging. – Inner clutch oil feed pipe – Outer clutch oil feed pipe Measure each part according to DUAL CLUTCH TRANSMISSION SPECIFICATIONS (page 1-8). Replace any part if it is out of service limit.
  • Page 322 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Install the inner clutch oil feed pipe [1] to the feed pipe guide plate by aligning the feed pipe bosses with the guide plate grooves. Apply engine oil to a new O-ring [2] and install it to the feed pipe cover groove.
  • Page 323 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the bolts [1] and clutch EOP sensor cover [2]. Disconnect the following: – Clutch line EOP sensor 3P (Gray) connector [1] – No.1 Clutch EOP sensor 3P (Gray) connector [2] – No.2 Clutch EOP sensor 3P (Black) connector [3] Remove the bolt [4] and wire stay [5].
  • Page 324 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the bolts [1]. Loosen the hose band screw [2]. Disconnect the water pipe [3] and remove the O-ring [4]. Remove the bolts [1] and right crankcase cover [2]. Do not allow dust or dirt to enter the oil passages.
  • Page 325 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Check the bearings and replace if necessary (page 13- 55). – Bearing (40 x 52 x 7 mm) [1] – Bearing (6304) [2] BEARING REPLACEMENT Remove the bearings using special tools. TOOLS: Remover weight 07741-0010201 Bearing (40 x 52 x 7 mm) [1]: Bearing remover shaft...
  • Page 326 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Apply engine oil to new O-rings [1] and new back up rings [2] and install them onto the oil joint [3] as shown. Install the oil joint into the crankcase hole. Install the dowel pins [1] and new gasket [2]. Coat a new O-ring [1] with engine oil and install it onto the groove of the water pump cover.
  • Page 327 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Rotate the water pump shaft and align the shaft slit with Align the pump cover index line as shown. Install the right crankcase cover [1]. Install the bolts [2] and tighten them in a crisscross pattern in 2 or 3 steps to the specified torque.
  • Page 328 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Connect the radiator lower hose [1]. Tighten the hose band screw [2] to the specified range (page 8-8). Install the clutch oil feed pipe (page 13-51). Connect the linear solenoid valve 4P (Black) connector [1].
  • Page 329 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Apply engine oil to a new O-ring [1] and install it onto the shift spindle angle sensor [2]. Install the shift spindle angle sensor. • Align the flat surfaces of the shift spindle angle sensor and gearshift spindle end.
  • Page 330 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) LINEAR SOLENOID VALVE REMOVAL • Keep dust and dirt away from all the parts. • Be careful not to damage the mating surfaces of the valve body components. Drain the engine oil (page 3-12). Remove the right middle cowl (page 2-6).
  • Page 331 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DISASSEMBLY/ASSEMBLY VALVE BODY STOPPER PLATE GASKET STOPPER PLATE BOLT COVER BOLTS LINEAR SOLENOID VALVE BODY 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) VALVES COVER • Clean all the parts with compressed air. Make sure that there is no dust or lint on any parts.
  • Page 332 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Coat a new packing [1] with engine oil and install it onto [1]/[2] the spool valve filter [2]. Install the spool valve filter/packing onto the right crankcase cover as shown. Install the O-ring [3]. Install the linear solenoid valve body [4].
  • Page 333 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DUAL CLUTCH/PRIMARY DRIVEN GEAR REMOVAL Remove the right crankcase cover (page 13-52). Align the gear teeth of the primary drive gear and sub- gear [1] by prying the gears through the holes [2] and hold them with a 6 mm bolt [3].
  • Page 334 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the clutch assemblies [1] and O-rings [2] from the primary driven gear. • The No.1 clutch assembly (for inner mainshaft) and No.2 clutch assembly (for outer mainshaft) are the same parts. Remove the following: –...
  • Page 335 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the return spring retainer [1], O-ring [2], and return spring [3]. Wrap a shop towel around the clutch guide [1]. Apply air pressure to the oil hole [2] while closing the Be careful not to other holes with a tape [3] to remove the clutch piston damage the piston [4].
  • Page 336 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) ASSEMBLY CLUTCH PLATES A (2 pcs) CLUTCH DISCS (3 pcs) CLUTCH PLATE B END PLATE PRIMARY DRIVEN GEAR SNAP RING NEEDLE BEARING O-RINGS O-RINGS CLUTCH GUIDE RETURN SPRING CLUTCH PISTON O-RING SNAP RING WAVE SPRING RETURN SPRING RETAINER Clean the inner surface of the clutch guide thoroughly...
  • Page 337 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Coat a new O-ring [1] with engine oil and install it into the return spring retainer groove. Install the return spring [2] and spring retainer [3] in the clutch guide. Place the snap ring [1] onto the clutch. Set the special tools onto the clutch as shown and To prevent loss of install the snap ring into the clutch guide groove [2] by...
  • Page 338 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Coat new O-rings [1] with engine oil and install them into the grooves in the primary driven gear [2]. Apply molybdenum oil solution to the primary driven gear teeth, friction springs, and boss sliding area. Install the clutch assemblies [3] onto the primary driven gear.
  • Page 339 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the snap ring and end plate (page 13-63). Measure the flange thickness of the end plate [1] at several points and record it. Calculate the new plate thickness using the equation below. Choose a new plate as close to this dimension as possible.
  • Page 340 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) PRIMARY DRIVE GEAR REMOVAL Remove the right crankcase cover (page 13-52). Hold the primary drive gear and sub-gear with a 6 mm bolt (page 13-63). Install the special tool between the primary drive and driven gears, and loosen the primary drive gear nut (left-hand thread) [1].
  • Page 341 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Apply engine oil to the primary drive gear nut threads and seating surface. Install the washer [1] and primary drive gear nut [2]. Install the special tool between the primary drive and driven gears, and tighten the nut (left-hand thread) to the specified torque.
  • Page 342 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the dowel pins [1] and gasket [2]. Remove the reduction gears [3]. Check the bearings and replace if necessary. – Radial ball bearing (699ZZ) [1] – Radial ball bearing (607ZZ) [2] – Radial ball bearing (696ZZ) [3] Heat the reduction gear cover to 80°C (176°F) evenly Do not use a torch using a heat gun.
  • Page 343 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) INSTALLATION Apply 2 – 4 g (0.07 – 0.14 oz) of specified grease to the reduction gear journals [1] and teeth. SPECIFIED GREASE: UNIREX N3 manufactured by ExxonMobil or equivalent Install the reduction gear B [2] by aligning the gear ends with the ribs of the crankcase.
  • Page 344 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Coat a new O-ring [1] with engine oil and install it into the groove in the shift control motor [2]. Install the shift control motor onto the shift control motor cover. Install the torx bolts [1] and tighten it to the specified torque.
  • Page 345 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) – Bolts [1] – Drum shifter guide plate/drum shifter assembly [2] – Guide plate distance collar [1] – Dowel pin [2] (if necessary) – Stopper arm side collar [3] – Shift drum center bolt [4] –...
  • Page 346 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deformation. – Gearshift spindle, spindle arm, return spring – Drum shifter guide plate – Drum shifter – Ratchet pawls – Plungers – Plunger springs Replace if necessary.
  • Page 347 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Hold the shift drum stopper arm [1] with a screwdriver and install the shift drum center [2] by aligning the groove [3] with the dowel pin [4]. Apply locking agent to the threads of the shift drum center bolt [1] (page 1-21).
  • Page 348 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Install the drum shifter collar [1] onto the drum shifter. Align Install the washer [2] onto the gearshift spindle [3] and insert the spindle into the crankcase while aligning the return spring ends with spring pin and the spindle arm hole with the drum shifter collar.
  • Page 349 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) TR SENSOR REMOVAL/INSTALLATION Remove the left rear cover (page 2-10). Remove the shift control motor cover (page 13-71). Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground. Remove the rear shock absorber (page 18-8).
  • Page 350 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the bolts [1] and engine right side rear cover [2]. Remove the bolt [1], shift spindle angle sensor [2], and O-ring [3]. Installation is in the reverse order of removal. • Always replace the O-ring [1] with a new one. •...
  • Page 351 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Disconnect the following: – Clutch line EOP sensor 3P (Gray) connector [1] – No.1 Clutch EOP sensor 3P (Gray) connector [2] – No.2 Clutch EOP sensor 3P (Black) connector [3] Remove the clutch EOP sensors [4] and O-rings from the right crankcase cover.

  • Page 352: Neutral Switch

    dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) NEUTRAL SWITCH REMOVAL/INSTALLATION Release the rubber cap [1]. Remove the nut [2] and disconnect the neutral switch terminal [3]. Remove the neutral switch [4] and sealing washer [5]. Installation is in the reverse order of removal. •...
  • Page 353 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Turn the ignition switch ON with the engine stop switch " " while pushing the D switch [1] of the N-D switch. The MIL [2] will come on. Release the D switch after the MIL goes off. •...
  • Page 354 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Start the engine and let it idle. The "–" [1] on the shift indicator starts blinking an interval of 2 seconds. The Clutch Initialize Learning is successful, when the "–", "D" and "S" indicators [2] go off. Stop the engine.

  • Page 355: Crankcase/Transmission/Balancer

    dummytext 14. CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION······················ 14-2 CRANKCASE SEPARATION ················ 14-13 TROUBLESHOOTING ·························· 14-3 TRANSMISSION································· 14-15 COMPONENT LOCATION ····················· 14-4 CRANKCASE ASSEMBLY ··················· 14-27 BALANCER ········································ 14-6 14-1...
  • Page 356 CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION CRANKCASE/TRANSMISSION/BALANCER GENERAL (CRF1000/A) • The crankcase must be separated to service the following: – Transmission – Crankshaft (page 15-4) – Piston/cylinder (page 15-12) • The following components must be removed before separating the crankcase: – Engine (page 16-5) –...
  • Page 357 • Bent shift fork shaft • Bent shift fork claw • Damaged shift drum groove • Bent gearshift spindle – CRF1000/A (page 12-17) – CRF1000D (page 13-74) Transmission jumps out of gear • Worn gear dogs • Worn gear shifter groove •...
  • Page 358 CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION CRF1000/A: 43 N·m (4.4 kgf·m, 32 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft)
  • Page 359 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER CRF1000D: 43 N·m (4.4 kgf·m, 32 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 360 Remove the front balancer driven gear [2]. Remove the left front balancer [1]. Remove the right crankcase cover. – CRF1000/A (page 12-4) – CRF1000D (page 13-52) Remove the front balancer bearing set plate bolts [1] and set plate [2].
  • Page 361 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER FRONT BALANCER DRIVEN GEAR DISASSEMBLY Remove the front balancer driven gear (page 14-6). Set the special tools onto the front balancer driven gear To prevent loss of [1] as shown and remove the snap ring [2] by spring tension, do compressing the return spring assembly.
  • Page 362 Install the front balancer bearing set plate bolts [4] and tighten them to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the right crankcase cover. – CRF1000/A (page 12-6) – CRF1000D (page 13-55) Install the left front balancer [1] by aligning its wide Align tooth with the front balancer shaft clinched tooth.
  • Page 363 Remove the right crankcase cover. CRF1000D shown: – CRF1000/A (page 12-4) – CRF1000D (page 13-52) CRF1000/A: Line up the primary drive gear and sub gear teeth (page 12-10). Remove the bolts [1] and rear balancer shaft holder [2]. Remove the dowel pins [1].
  • Page 364 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Disassemble the following: – Collar [1] – Thrust spring [2] – Washers A [3] – Thrust bearing [4] – Rear balancer shaft [5] – Needle bearing [6] – Rear balancer driven gear assembly [7] – Washer B [8] –...
  • Page 365 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deformation. – Balancer driven gear – Balancer sub driven gear – Springs – Balancer shaft – Bearings Replace if necessary. REAR BALANCER DRIVEN GEAR ASSEMBLY Assemble the following: –...
  • Page 366 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER If you are replacing the rear balancer driven gear and/or needle bearing, record the corresponding balancer driven gear I.D. code [1] from the balancer weight. If you are reusing the rear balancer driven gear, measure the balancer journal I.D. with a micrometer. Cross-reference the balancer journal I.D.

  • Page 367: Crankcase Separation

    Install the bolts [1] and rear balancer shaft holder [2] CRF1000D shown: and tighten the bolts to the specified torque. TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft) CRF1000/A: Remove the 6 mm bolt from the primary drive gear. Install the right crankcase cover. – CRF1000/A (page 12-6) –...
  • Page 368 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the cam chain tensioner pivot bolt [1], cam CRF1000D: chain tensioner [2], and washer [3]. Remove the bolts [4], cam chain guide plate [5], cam chain [6], and timing sprocket [7]. [1]/[3] Place the engine upside down. Loosen the crankcase bolts in a crisscross pattern in 2 or 3 steps, and remove the bolts and washers.
  • Page 369 To remove a snap ring, expand the snap ring and pull it off using the gear behind it. SHIFT FORK/SHIFT DRUM Remove the countershaft (page 14-15). CRF1000/A: Remove the shift drum bearing setting bolt [1] and washer [2]. Remove the countershaft (page 14-15).
  • Page 370 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the following: CRF1000D: – Countershaft shift fork shaft [1] – Countershaft shift forks [2] – Mainshaft shift fork shaft [3] – Mainshaft shift forks [4] Remove the shift drum bearing setting bolt [1] and CRF1000D shown: washer [2].
  • Page 371 – Transmission bearings – Shift drum/bearing – Shift forks – Shift fork shafts Measure each part according to CRANKCASE/ TRANSMISSION SPECIFICATIONS. – CRF1000/A (page 1-8) – CRF1000D (page 1-9) Replace any part if it is out of service limit. 14-17...
  • Page 372 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER UPPER CRANKCASE BEARING REPLACEMENT Remove the following: – Transmission (page 14-15) – Crankshaft (page 15-4) – Piston (page 15-12) LEFT MAINSHAFT BEARING Remove the left mainshaft bearing [1] using the special tools. TOOLS: Bearing remover shaft set, 07936-ZV10100 25 mm Remover weight...
  • Page 373 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER SHIFT CONTROL MOTOR REDUCTION GEAR BEARING (CRF1000D) Heat the upper crankcase to 80°C (176°F) evenly using Do not use a torch a heat gun. to heat the upper crankcase; it may Tap the upper crankcase lightly and remove the cause warping.

  • Page 374: Transmission Assembly

    Apply engine oil to the gear teeth, rotating surface and bearing. Apply molybdenum oil solution to the spline bushing outer surface, bushing inner and outer surface, shift fork grooves. Assemble the mainshaft and countershaft. MAINSHAFT (CRF1000/A) M6 GEAR (32T) M2 GEAR (18T) M6 GEAR SPLINE BUSHING LOCK WASHER...
  • Page 375 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER MAINSHAFT (CRF1000D) NEEDLE BEARING SEAL RINGS OUTER MAINSHAFT/M2 GEAR (21T) NEEDLE BEARING THRUST WASHER M6 GEAR BUSHING SPLINE WASHER M6 GEAR (34T) SNAP RING M4 GEAR (30T) SPECIAL WASHER M3 GEAR (24T) SNAP RING SPLINE WASHER M5 GEAR BUSHING M5 GEAR (37T) THRUST WASHER...
  • Page 376 CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT (CRF1000/A) THRUST WASHER C1 GEAR (43T) C1 GEAR BUSHING NEEDLE BEARING THRUST WASHER C5 GEAR (33T) C4 GEAR (32T) C3 GEAR (37T) COLLAR LOCK WASHER C4 GEAR BUSHING SPLINE WASHER SNAP RING SPLINE WASHER SPLINE WASHER...
  • Page 377 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT (CRF1000D) THRUST WASHER NEEDLE BEARING C2 GEAR (37T) C2 GEAR BUSHING THRUST WASHER C6 GEAR (30T) SNAP RING C4 GEAR (34T) C4 GEAR SPLINE BUSHING WASHER LOCK WASHER SPLINE WASHER SPLINE WASHER C3 GEAR SPLINE BUSHING SNAP RING C3 GEAR (33T) C1 GEAR (41T)
  • Page 378 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER • Align the lock washer tabs with the spline washer grooves. CORRECT INCORRECT • Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load. • Install the snap rings [1] so that the end gap aligns with the groove of the splines.
  • Page 379 [2]. Tighten the bolt to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) The shift forks have the following identification marks: CRF1000/A: 1000/A: – "C" mark [1]: mainshaft shift fork – No mark [2]: left/right countershaft shift fork CRF1000D: –...
  • Page 380 CRANKCASE/TRANSMISSION/BALANCER Apply molybdenum oil solution to the shift fork shaft CRF1000/A: outer surface. Install the mainshaft shift fork [1] into the M3/M4 gear with the identification marks facing toward the right side of the engine. Install the countershaft shift forks [2] with the identification marks facing toward the left side of the engine.

  • Page 381: Crankcase Assembly

    dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT Install the dowel pin [1] onto the upper crankcase hole. CRF1000D shown: Install the countershaft assembly [2]. • Align the needle bearing cap hole with the dowel pin. • Align the set ring [3] with the upper crankcase groove.
  • Page 382 [2]. Install the water hose flange and bolts [3] and tighten the bolts securely. Install the following: CRF1000/A: – Primary drive gear (page 12-16) – Clutch (page 12-12) – Gearshift linkage (page 12-19) –...

  • Page 383: Crankshaft/Piston/Cylinder

    dummytext 15. CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION······················ 15-2 MAIN JOURNAL BEARING ··················· 15-6 TROUBLESHOOTING ·························· 15-2 CRANKPIN BEARING ·························· 15-9 COMPONENT LOCATION ····················· 15-3 PISTON/CYLINDER ···························· 15-12 CRANKSHAFT ···································· 15-4 15-1...
  • Page 384 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION CRANKSHAFT/PISTON/CYLINDER GENERAL • The crankcase must be separated to service the crankshaft and pistons and connecting rods. • Mark and store the connecting rods, bearing caps, and bearing inserts to be sure of their correct locations for reassembly. •...
  • Page 385 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATION CRF1000D shown: 22 N·m (2.2 kgf·m, 16 lbf·ft) + 120° 15-3...
  • Page 386 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKSHAFT Separate the crankcase halves (page 14-13). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. SERVICE LIMIT: 0.35 mm (0.014 in) If the clearance exceeds the service limit, replace the connecting rod. Recheck and if still out of limit, replace the crankshaft. REMOVAL Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassembly.
  • Page 387 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER INSTALLATION Apply molybdenum oil solution to the main journal bearing [1] sliding surfaces on the upper crankcase and crankpin bearing [2] sliding surfaces on the connecting rods. Apply molybdenum oil solution to the thrust surfaces of the crankshaft as shown. Install the crankshaft [1] onto the upper crankcase and Be careful not to Align...
  • Page 388 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER MAIN JOURNAL BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 15-4). BEARING INSPECTION Inspect the main journal bearing inserts [1] on the upper and lower crankcase halves for unusual wear or peeling.
  • Page 389 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Install the lower crankcase onto the upper crankcase. Make sure that the upper and lower crankcase are seated securely. Apply molybdenum oil solution to the crankcase main journal bolt threads and seating surfaces. Install the crankcase main journal bolts [1]. Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque.
  • Page 390 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Cross-reference the main journal and bearing support codes to determine the replacement bearing color code [1]. MAIN JOURNAL BEARING THICKNESS: A: Blue: Thickest B: Black: C: Brown: D: Green: E: Yellow: Thinnest MAIN JOURNAL BEARING SELECTION TABLE: BEARING SUPPORT I.D.
  • Page 391 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKPIN BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 15-4). BEARING INSPECTION Check the bearing inserts [1] for unusual wear or peeling.
  • Page 392 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Apply engine oil to the crankpin bearing cap bolt (reuse) threads and seating surfaces. Install and tighten the crankpin bearing cap bolts [1] to the specified torque in 2 or 3 steps alternately. Further tighten the bolts 90°. TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) + 90°...
  • Page 393 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Cross-reference the connecting rod and crankpin codes to determine the replacement bearing color code [1]. CRANKPIN BEARING THICKNESS: A: Blue: Thickest B: Black: C: Brown: D: Green: E: Yellow: Thinnest CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD I.D. CODE 47.000 –...

  • Page 394: Piston Removal

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER PISTON/CYLINDER PISTON/CONNECTING ROD REMOVAL • Before piston removal, place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve. • Do not try to remove the piston/connecting rod assembly from bottom of the cylinder; the assembly will get stuck in the gap between the cylinder liner and the upper crankcase.

  • Page 395: Piston Ring Installation

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER INSPECTION Inspect the following parts for scratches, damage, abnormal wear, or deformation. – Cylinder – Piston – Piston rings – Piston pin – Connecting rod small end Measure each part and calculate the clearance according CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS (page 1-9). Replace any part if it is out of service limit.
  • Page 396 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Apply molybdenum oil solution to the piston pin outer surface. Install the piston pin [1] and secure it using new piston pin clips [2]. • Make sure that the piston pin clips are seated securely. • Do not align the piston pin clip end gap with the piston cut-out [3].

  • Page 397: Engine Removal/Installation

    dummytext 16. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION······················ 16-2 ENGINE REMOVAL ····························· 16-5 COMPONENT LOCATION ····················· 16-3 ENGINE INSTALLATION ····················· 16-10 16-1...
  • Page 398 – Camshaft (page 10-9) – Clutch (CRF1000/A) (page 12-8) – Dual clutch (CRF1000D) (page 13-63) – Primary drive gear (CRF1000/A) (page 12-15) – Primary drive gear (CRF1000D) (page 13-70) – Shift control motor/reduction gears (CRF1000D) (page 13-71) – Gearshift linkage (CRF1000/A) (page 12-17) –...
  • Page 399 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION CRF1000/A 32 N·m (3.3 kgf·m, 24 lbf·ft) 80 N·m 32 N·m 44 N·m (8.2 kgf·m, 59 lbf·ft) (3.3 kgf·m, 24 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) (4.5 kgf·m, 32 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 44 N·m...
  • Page 400 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION CRF1000D 32 N·m (3.3 kgf·m, 24 lbf·ft) 80 N·m 44 N·m 32 N·m (8.2 kgf·m, 59 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) (3.3 kgf·m, 24 lbf·ft) (4.5 kgf·m, 32 lbf·ft) 44 N·m 44 N·m 44 N·m (4.5 kgf·m, 32 lbf·ft) (4.5 kgf·m, 32 lbf·ft) (4.5 kgf·m, 32 lbf·ft)

  • Page 401: Engine Removal

    – Rear brake switch 2P (Gray) connector [1] – Sidestand switch 2P (Black) connector [2] – Alternator assembly 6P (Black) connector [3] – Gear position switch 8P (Black) (CRF1000/A) [4] – Shift spindle angle sensor 3P (Blue) connector (CRF1000D) [5] –...
  • Page 402 Release the fuel tank drain hose [1] and breather hose [2] from the bracket [3]. Remove the bolts [4] and bracket. Release the alternator assembly wire from the frame: – CRF1000/A (page 11-4) – CRF1000D (page 11-5) Disconnect the following: CRF1000/A: –...
  • Page 403 [2]. Disconnect the ECT sensor 2P (Black) connector [3]. Remove the bolt [1] and clutch cable holder [2]. CRF1000/A: Disconnect the clutch cable [3] from the clutch lifter lever [4]. Disconnect linear solenoid 4P (Black) connector [1].
  • Page 404 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the following: CRF1000D: – Clutch line EOP sensor 3P (Gray) connector [1] – No.1 clutch EOP sensor 3P (Gray) connector [2] – No.2 clutch EOP sensor 3P (Black) connector [3] Remove the bolt [4] and stay [5]. CRF1000D: Disconnect the EOT sensor 2P (Black) connector [1].
  • Page 405 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the following: – Front lower bolt (10 x 138 mm) [1] – Front lower nut (10 mm) [2] – Right lower frame bolts (front side, 10 x 20 mm, 10 x 40 mm) [3] – Right lower frame bolts (rear side, 10 x 60 mm, 10 x 75 mm) [4] –...

  • Page 406: Engine Installation

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the following: Left side: Right side: – Rear upper bolt (8 x 217 mm) [1] – Collar (left side) [2] – Rear upper nut (8 mm) [3] – Collar (right side, long) [4] – Rear upper bolts (8 x 25 mm) [5] –...
  • Page 407 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten the swingarm pivot nut to the specified torque. TORQUE: 80 N·m (8.2 kgf·m, 59 lbf·ft) • Apply engine oil to the swingarm pivot nut [1] threads and seating surface. • Apply a thin coat of grease to the swingarm pivot bolt [2] sliding surface.
  • Page 408 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten the front upper bolt (right side) [1] first, then the left side bolts [2] to the specified torque. TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) Tighten the rear upper bolts (8 x 25 mm) [1] to the specified torque.
  • Page 409 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the stay [1] and bolt [2], and tighten the bolt securely. Install the O sensor 4P (Black) connector clip [3] to the stay. CRF1000D: Install the EOT sensor [4] and a new sealing washer [5], and tighten it to the specified torque. TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) CRF1000D: Connect the EOT sensor 2P (Black) connector [6].
  • Page 410 ENGINE REMOVAL/INSTALLATION Connect the clutch cable [1] to the clutch lifter arm [2]. CRF1000/A: Install the clutch cable holder [3] and bolt [4] and tighten the bolt securely. Connect the ECT sensor 2P (Black) connector [1]. Connect the radiator upper hose [2] and tighten the hose band screw [3] to the specified range (page 8-8).
  • Page 411 – Rear brake switch 2P (Gray) connector [3] – Sidestand switch 2P (Black) connector [4] – Alternator assembly 6P (Black) connector [5] – Gear position switch 8P (Black) (CRF1000/A) [6] – Shift spindle angle sensor 3P (Blue) connector (CRF1000D) [7] –...
  • Page 412 – Radiator (page 8-6) – Radiator reserve tank (page 8-10) – Shift pedal (CRF1000/A) (page 12-21) – Gearshift spindle cover (CRF1000/A) (page 12-21) – Rear brake pedal (page 19-15) – Battery box (page 21-6) – EOP switch (CRF1000/A) (page 22-19) –...

  • Page 413: Front Wheel/Suspension/Steering

    dummytext 17. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION······················ 17-2 FRONT WHEEL·································· 17-10 TROUBLESHOOTING ·························· 17-2 FORK ··············································· 17-14 COMPONENT LOCATION ····················· 17-3 STEERING STEM ······························· 17-22 HANDLEBAR ······································ 17-4 17-1...
  • Page 414 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION FRONT WHEEL/SUSPENSION/STEERING GENERAL • When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist. • Aluminum taper handle is equipped in this motorcycle. The scratches or bend of the handlebar may cause breakage. Replace the damaged handlebar with a new one.
  • Page 415 FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION CRF1000D (ED model) shown: CRF1000: 32 N·m (3.3 kgf·m, 24 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 25 N·m (2.5 kgf·m, 18 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft)
  • Page 416 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the rearview mirrors [1]. Remove the knuckle guards (page 2-5). Remove the wire clamp [1] and disconnect the front brake light switch connectors [2]. Remove the bolts [1], holder [2], and front brake master cylinder [3].
  • Page 417 FRONT WHEEL/SUSPENSION/STEERING Remove the wire clamp [1] and disconnect the clutch CRF1000/A: switch connectors [2]. Remove the wire clamp [1] and disconnect the parking CRF1000D: brake switch connectors [2]. Remove the bolts [1], holder [2], and clutch lever CRF1000/A: assembly [3].
  • Page 418 HANDLEBAR WEIGHT REMOVAL/ INSTALLATION Remove the following: CRF1000: – Handlebar weight bolt [1] – Rubber [2] (except CRF1000) – Handlebar weight A [3] – Snap ring [4] – Handlebar weight rubbers [5] – Handlebar weight B [6] – O-ring [7] Installation is in the reverse order of removal.
  • Page 419 • Route the hoses, cables, and wires properly (page 1-26). Clean the inside surface of the handlebar grip [1]. Apply Honda Bond A or an equivalent to the inside surface of the grip and outside surface of the handlebar [2].
  • Page 420 TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) Align Install the clutch lever assembly [1] by aligning its end CRF1000/A: with the paint mark [2] on the handlebar. Install the holder [3] with its punch mark [4] facing up. Tighten the upper bolt [5] first, then the lower bolt [6].
  • Page 421 FRONT WHEEL/SUSPENSION/STEERING Install the wire clamp [1] and connect the clutch switch CRF1000/A: connectors [2]. Install the wire clamp [1] and connect the parking brake CRF1000D: switch connectors [2]. Apply grease to the throttle pipe flange groove. Install the right handlebar switch housing/throttle pipe [1] aligning its location pin with the hole in the handlebar.

  • Page 422: Front Wheel

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the front brake master cylinder [1] by aligning its end with the paint mark [2] on the handlebar. Install the holder [3] with its "UP" mark [4] facing up. Tighten the upper bolt [5] first, then the lower bolt [6] to the specified torque.
  • Page 423 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING ED model: Remove the axle cap [1]. Right side: Left side: Remove the front axle nut [2]. Loosen the left front axle holder pinch bolts [3]. Loosen the right front axle holder pinch bolts [4]. Support the motorcycle using a safety stand or hoist, raise the front wheel off the ground.
  • Page 424 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY/ASSEMBLY FRONT BRAKE DISC BOLTS 20 N·m (2.0 kgf·m, 15 lbf·ft) DUST SEAL BEARING (6004UU) PULSER RING BOLTS (Except CRF1000) 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft) RIGHT BRAKE DISC DISTANCE COLLAR BEARING (6004UU) PULSER RING (Except CRF1000) DUST SEAL FRONT BRAKE DISC BOLTS 20 N·m (2.0 kgf·m, 15 lbf·ft)
  • Page 425 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING WHEEL CENTER ADJUSTMENT Place the rim [1] on a work bench. Place the hub [2] in the center of the rim, and begin the lacing with new spokes. 28.5 – 30.5 mm Adjust the hub position so the distance from the hub left ( 1.12 –...
  • Page 426 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the side collars [1] to the front wheel. Right side: Left side: Apply a thin coat of grease to the front axle sliding surface. Install the front wheel between the forks. Install the front axle [2] from right side. Align the surfaces of the axle and right Tighten the right front axle holder pinch bolts [4] to the...
  • Page 427 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING When disassembling the fork, turn the pre-load adjuster [1] and rebound adjuster [2] counterclockwise to the softest position (be sure to record the number of turns from the starting position). DISASSEMBLY Remove the fork bolt [1]. Be careful not to damage the fork bolt when removing...
  • Page 428 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen the fork bolt [1] while holding the lock nut [2]. Be careful not to damage the fork bolt when loosening Remove the following: – Fork bolt assembly [1] – O-ring [2] – Spring seat stopper [3] Remove the stopper plate [4] and spring collar holder [5].
  • Page 429 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the fork damper assembly [1] and centering plate [2]. Remove the dust seal [1]. Remove the oil seal stopper ring [2]. Do not scratch the fork pipe sliding surface. Pull the slide pipe assembly [1] out until you feel resistance from the slider bushing.
  • Page 430 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSPECTION Inspect the following parts for damage, abnormal wear, deformation, looseness or bend. – Fork bolt assembly – Outer pipe/slide pipe assembly – Fork dumper – Spring seat stopper – Spring collar – Fork spring – Guide bushing –...
  • Page 431 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Apply fork fluid to new dust seal and oil seal lips. Install the dust seal [1], stopper ring [2] and oil seal [3]. Install the oil seal with its marked side Install the back-up ring [4], guide bushing [5]. facing toward the Install the slider bushing [6] if it is removed.
  • Page 432 TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Pour the specified amount of recommended fork fluid. RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W (SS-47) FORK FLUID CAPACITY: 721 ± 2.5 cm (24.4 ± 0.1 US oz, 25.4 ± 0.1 Imp oz) Bleed the air from the fork as follows: 1.
  • Page 433 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the fork spring [1] into the slide pipe assembly with the tightly wound side facing down. Install the spring collar [2] and spring seat stopper [3]. Down Clench the lock nut [1] until it is fully seated. Attach the special tool to the spring collar holes [2].

  • Page 434: Steering Stem

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the fork bolt [1]. Tighten the fork bolt after installing the fork slider into the steering stem. INSTALLATION Install the forks through the bottom bridge and top bridge so that the end of the outer pipe [1] is aligned with the top bridge [2] upper surface.
  • Page 435 Release the following: – Handlebar switch wire clips [1] – Front brake hose A [2] – Throttle cables [3] – Clutch cable [4] (CRF1000/A) – Parking brake cable [4] (CRF1000D) Remove the steering stem nut [1]. Remove the forks (page 17-14).
  • Page 436 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen and remove the steering stem adjusting nut [1] using the special tool. TOOL: Steering stem socket [2] 07916-KA50100 Remove the following: – Upper dust seal [1] – Upper inner race [2] – Upper bearing [3] –...
  • Page 437 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Temporarily install the steering stem nut [1] onto the steering stem [2] to prevent the threads from being damaged when removing the lower inner race [3] from the steering stem. Remove the lower inner race with a chisel or equivalent tools, being careful not to damage the steering stem.
  • Page 438 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION STEERING STEM NUT : BEARINGS, BEARING RACES, DUST SEALS LOWER OUTER RACE STEERING STEM ADJUSTING LOWER BEARING UPPER DUST LOWER INNER RACE SEAL LOWER DUST SEAL UPPER INNER RACE UPPER BEARING UPPER OUTER RACE FRONT BRAKE HOSE CLAMP MOUNTING BOLT STEERING STEM 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply specified grease (page 1-23) to the upper and...
  • Page 439 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Move the steering stem [1] right and left, lock-to-lock, five times to seat the bearings. Retighten the steering stem adjusting nut [1] to the specified torque using a special tool. TOOL: Steering stem socket [2] 07916-KA50100 TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) Recheck that the steering stem moves smoothly without play or binding.
  • Page 440 FRONT WHEEL/SUSPENSION/STEERING Install the following: – Clutch cable [1] (CRF1000/A) – Parking brake cable [1] (CRF1000D) – Throttle cables [2] – Front brake hose A [3] – Handlebar switch wire clips [4] Install the stay [1]. • Align the boss of stay with the hole of the frame.

  • Page 441: Rear Wheel/Suspension

    dummytext 18. REAR WHEEL/SUSPENSION SERVICE INFORMATION······················ 18-2 SHOCK ABSORBER ···························· 18-8 TROUBLESHOOTING ·························· 18-2 CUSHION LINKAGE····························· 18-9 COMPONENT LOCATION ····················· 18-3 SWINGARM······································· 18-12 REAR WHEEL····································· 18-4 18-1...
  • Page 442 • After the rear wheel installation, check the brake operation by applying the brake pedal. • Use Honda Genuine replacement bolts and nuts for all suspension pivot and mounting point. • For brake system information (page 19-2).
  • Page 443 dummyhead dummyhead REAR WHEEL/SUSPENSION COMPONENT LOCATION 54 N·m (5.5 kgf·m, 40 lbf·ft) 80 N·m (8.2 kgf·m, 59 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 100 N·m (10.2 kgf·m, 74 lbf·ft)

  • Page 444: Rear Wheel

    dummyhead dummyhead REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground. Fully slacken the drive chain (page 3-16). Push the rear wheel forward. Derail the drive chain [1] from the driven sprocket. Remove the rear axle nut [2], washer [3], and right adjusting plate [4].
  • Page 445 dummyhead dummyhead REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY Install the driven sprocket on the driven flange with the stamped mark facing out. DRIVEN FLANGE PULSER RING BOLTS BEARING 63/22 BRAKE DISC BOLTS DUST SEAL (CRF1000A/D) 42 N·m 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft) (4.3 kgf·m, 31 lbf·ft) DRIVEN REAR WHEEL...
  • Page 446 dummyhead dummyhead REAR WHEEL/SUSPENSION WHEEL BEARING REPLACEMENT Drive out the rear wheel distance collar B [1] by using the special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 22 x 24 mm [3] 07746-0010800 Pilot, 17 mm [4] 07746-0040400 Drive out the bearing [5]. Install the bearing remover head [1] into the bearing.
  • Page 447 dummyhead dummyhead REAR WHEEL/SUSPENSION Drive in the bearing/collar [1] squarely with its collar side facing down until it is fully seated. TOOLS: Driver [2] 07749-0010000 Attachment, 52 x 55 mm [3] 07746-0010400 Pilot, 22 mm [4] 07746-0041000 INSTALLATION Install the brake bracket [1] to the swingarm. •...

  • Page 448: Shock Absorber

    dummyhead dummyhead REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION Remove the regulator/rectifier (page 21-8). Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground. Remove the lower cushion arm bolt [1] and nut [2]. Remove the shock absorber lower mounting bolt [3] and nut [4].
  • Page 449 dummyhead dummyhead REAR WHEEL/SUSPENSION CUSHION LINKAGE REMOVAL Support the motorcycle using a safety stand or hoist, [5]/[6] raise the rear wheel off the ground. Remove the sidestand (page 2-19). Remove the following: – Cushion connecting rod mounting nut [1] and bolt [2] –...
  • Page 450 dummyhead dummyhead REAR WHEEL/SUSPENSION BEARING REPLACEMENT CUSHION ARM Remove the needle bearings (17 x 24 x 30 mm) [1] and (20 x 26 x 20 mm) [2] using the special tools. TOOLS: Remover weight [3] 07741-0010201 Remover handle [4] 07936-3710100 Needle bearing (17 x 24 x 30 mm): Bearing remover set, 17 mm [5] 07936-3710300 Needle bearing (20 x 26 x 20 mm):...
  • Page 451 dummyhead dummyhead REAR WHEEL/SUSPENSION CUSHION CONNECTING ROD Remove the needle bearings (17 x 24 x 30 mm) [1]. TOOLS: Bearing remover set, 17 mm [2] 07936-3710300 Remover weight [3] 07741-0010201 Remover handle [4] 07936-3710100 Apply molybdenum disulfide grease to new needle Never install the old [3]/[4] bearings rotating area.
  • Page 452 dummyhead dummyhead REAR WHEEL/SUSPENSION Assemble the cushion arm [1] and connecting rod [2] by installing the lower cushion arm nut [3] and bolt [4] as shown. • Assemble the cushion arm and connecting rod with "UP" mark [5] of the arm facing up. Tighten the nut to the specified torque.
  • Page 453 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the socket bolts [1] and left/right heel guards Left side shown: [2]. Remove the bolt [1] and brake hose clamp [2]. Remove the screws [3] and brake hose guide [4]. Remove the screw [5] and brake hose clamp [6]. Remove the bolt [1] and parking brake cable guide [2].
  • Page 454 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the swingarm pivot nut [1], pivot bolt [2], and [1]/[2] swingarm [3]. DISASSEMBLY/ASSEMBLY PIVOT DISTANCE RIGHT COLLAR NEEDLE BEARING DUST SEAL (24 x 31 x 28 mm) Front SNAP RING BEARING DUST SEAL DUST SEAL 6003 LOCK NUTS 27 N·m (2.8 kgf·m, 20 lbf·ft)
  • Page 455 dummyhead dummyhead REAR WHEEL/SUSPENSION INSPECTION Inspect the following parts for damage, abnormal wear, or deformation and replace if necessary. – Dust seals – Pivot collars – Swingarm – Bearings – Drive chain slider PIVOT BEARING REPLACEMENT Remove the snap ring [1] from the right pivot. Remove the ball bearing 6003 [1] out of the right pivot using a hydraulic press and special tool.
  • Page 456 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the needle bearing [1] out of the left pivot using a hydraulic press and special tool. TOOLS: Driver [2] 07749-0010000 [3]/[4] Attachment, 32 x 35 mm [3] 07746-0010100 Pilot, 25 mm [4] 07746-0040600 Apply molybdenum disulfide grease to a new needle bearing rotating area.
  • Page 457 dummyhead dummyhead REAR WHEEL/SUSPENSION Install the snap ring [1] into the right pivot groove securely. • Do not reuse the snap ring which could easily spin in the groove. • Make sure that the snap ring is firmly seated in the groove.
  • Page 458 dummyhead dummyhead REAR WHEEL/SUSPENSION Install brake hose clamp [1] and a new screw [2] and Route the hose, tighten the screw to the specified torque. wire, and cable properly (page 1- TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) 26). Install brake hose guide [3] and new screws [4] and tighten the screws to the specified torque.

  • Page 459: Hydraulic Brake

    dummytext 19. HYDRAULIC BRAKE SERVICE INFORMATION······················ 19-2 REAR BRAKE PEDAL························· 19-15 TROUBLESHOOTING ·························· 19-2 REAR MASTER CYLINDER·················· 19-16 COMPONENT LOCATION ····················· 19-3 FRONT BRAKE CALIPER ···················· 19-18 BRAKE FLUID REPLACEMENT/AIR REAR BRAKE CALIPER······················ 19-20 BLEEDING ········································· 19-6 PARKING BRAKE LEVER BRAKE PAD/DISC ·······························...
  • Page 460 dummyhead dummyhead HYDRAULIC BRAKE SERVICE INFORMATION HYDRAULIC BRAKE GENERAL Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilling brake fluid will severely damage instrument lenses and painted surface.
  • Page 461 dummyhead dummyhead HYDRAULIC BRAKE COMPONENT LOCATION FRONT: 34 N·m (3.5 kgf·m, 25 lbf·ft) Left side shown: 45 N·m (4.6 kgf·m, 33 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 19-3...
  • Page 462 dummyhead dummyhead HYDRAULIC BRAKE REAR: 10 N·m (1.0 kgf·m, 7 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 14 N·m (1.4 kgf·m, 10 lbf·ft) 35 N·m (3.6 kgf·m, 26 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 19-4...
  • Page 463 dummyhead dummyhead HYDRAULIC BRAKE CRF1000D: 31 N·m (3.2 kgf·m, 23 lbf·ft) 9 N·m (0.9 kgf·m, 6.6 lbf·ft) 31 N·m (3.2 kgf·m, 23 lbf·ft) 19-5...
  • Page 464 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Turn the handlebar until the reservoir is parallel to the Front brake: ground. Remove the following: – Screws [1] – Reservoir cap [2] – Set plate [3] – Diaphragm [4] Support the motorcycle in an upright position.
  • Page 465 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir with DOT 4 brake fluid to the upper Front: Rear: level line [1] from a sealed container. Connect a commercially available brake bleeder to the bleed valve [2]. Operate the brake bleeder and loosen the bleed valve. If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low.
  • Page 466 dummyhead dummyhead HYDRAULIC BRAKE Install the diaphragm [1], set plate [2], and reservoir cap Front brake: [3] and tighten the screws [4] to the specified torque. TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Remove the mounting bolt [1] and rear brake reserve Rear brake: tank [2].
  • Page 467 dummyhead dummyhead HYDRAULIC BRAKE Remove the brake pads [1]. Right side shown: Check the pad spring [2] and replace if necessary. Install new brake pads to the brake caliper so their ends Align the pad lugs seat against the pad spring. with the caliper grooves.
  • Page 468 dummyhead dummyhead HYDRAULIC BRAKE Install new brake pads [1] to the brake caliper so their Make sure that the ends seat against the retainer. retainer and pad spring are installed Lower the caliper. to the brake caliper. Loosely install a new rear brake caliper mounting bolt [2].
  • Page 469 dummyhead dummyhead HYDRAULIC BRAKE Remove the brake caliper mounting bolts [1] and caliper [2] from the bracket. Remove the pad pins [1] and pads [2]. INSTALLATION Make sure the pad spring is installed in position. Install new parking brake pads [1]. Install new pad pins [2].

  • Page 470: Brake Disc Inspection

    dummyhead dummyhead HYDRAULIC BRAKE Install the parking brake caliper cover [1] and socket bolts [2] and tighten the bolts to the specified torque. TORQUE: 9 N·m (0.9 kgf·m, 6.6 lbf·ft) Tighten the pad pins [1] to the specified torque. TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft) Check the parking brake lock operation (page 3-21).

  • Page 471: Front Master Cylinder

    dummyhead dummyhead HYDRAULIC BRAKE FRONT MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake fluid from the front brake line hydraulic system (page 19-6). Disconnect the brake light switch connectors [1]. Remove the brake hose oil bolt [2], sealing washers [3], When removing the and brake hose [4].
  • Page 472 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • When removing and installing the snap ring, use the special tool. TOOL: Snap ring pliers 07914-SA50001 • Install the snap ring with the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove.

  • Page 473: Rear Brake Pedal

    dummyhead dummyhead HYDRAULIC BRAKE REAR BRAKE PEDAL REMOVAL/INSTALLATION JOINT PIN BRAKE PEDAL PINCH BOLT COTTER PIN BRAKE PEDAL MIDDLE ARM RETURN SPRING RIGHT STEP BRACKET STEP BRACKET MOUNTING BOLTS DUST SEALS 35 N·m (3.6 kgf·m, 26 lbf·ft) • Align the brake pedal slit with the middle arm punch mark.

  • Page 474: Rear Master Cylinder

    dummyhead dummyhead HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL/INSTALLATION Drain the rear brake line hydraulic system (page 19-6). Remove the bolt [1] and heel guard [2]. Remove the oil bolt [1], sealing washers [2] and brake Avoid spilling fluid hose [3]. on painted, plastic, or rubber parts.
  • Page 475 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • When removing and installing the snap ring, use the special tool. TOOL: Snap ring pliers 07914-SA50001 • Install the snap ring with the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove.

  • Page 476: Front Brake Caliper

    dummyhead dummyhead HYDRAULIC BRAKE INSPECTION Check the following parts for scoring, scratches, deterioration, or damage. – Master cylinder – Master piston – Piston cups – Spring – Boot Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-10). Replace any part if it is out of service limit. FRONT BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the front brake line hydraulic...
  • Page 477 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • Be careful not to damage each piston. • Do not use high pressure air or bring the nozzle too close to the inlet. • Mark the pistons to ensure correct reassembly. • Be careful not to damage the piston sliding surface. •...

  • Page 478: Rear Brake Caliper

    dummyhead dummyhead HYDRAULIC BRAKE REAR BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the pedal brake line hydraulic system (page 19-6). Remove the oil bolt [1], sealing washers [2] and brake Avoid spilling fluid hose [3]. on painted, plastic, or rubber parts. Remove the brake pads (page 19-9).
  • Page 479 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • Be careful not to damage the piston sliding surface • When removing the caliper piston with compressed air, place a shop towel over the piston to prevent damaging the piston and caliper body. Do not use high pressure or bring the nozzle too close to the fluid inlet.
  • Page 480 dummyhead dummyhead HYDRAULIC BRAKE PARKING BRAKE LEVER (CRF1000D) REMOVAL Remove the knuckle guard (page 2-5). Remove the rearview mirror (page 17-4). Disconnect the parking brake switch connectors [1]. Remove the bolts [1], holder [2], and parking brake lever assembly [3]. Loosen the lock nut [4] and disconnect the parking brake cable by turning the adjuster [5].
  • Page 481 dummyhead dummyhead HYDRAULIC BRAKE INSTALLATION Install the parking brake lever assembly [1] by aligning its end with the paint mark [2] on the handlebar. Install the holder [3] with its punch mark [4] facing up. Tighten the upper bolt [5] first, then the lower bolt [6]. Connect the parking brake cable [7] to the brake lever.
  • Page 482 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY Remove the caliper pin bolt [1]. Remove the following: – Caliper bracket [1] – Pad spring [2] – Bracket pin boot [3] – Caliper pin boot [4] – Collar [5] Remove the adjuster lock nut [1] while holding the brake arm [2].
  • Page 483 dummyhead dummyhead HYDRAULIC BRAKE Remove the dust seal [1]. Clean the caliper cylinder and brake shaft sliding surface. INSPECTION Inspect the following parts for scoring, scratches, or damage. – Caliper cylinder – Caliper piston Replace if necessary. ASSEMBLY 0.4 g (0.01 oz) minimum PUSH ROD PAD SPRING BRACKET...
  • Page 484 dummyhead dummyhead HYDRAULIC BRAKE Apply silicone grease to new dust seal lips. Install the dust seal [1] into the seal groove in the caliper. Apply 0.4 g minimum of silicone grease to the parking brake shaft outer surface. Install the parking brake shaft [1] to the caliper [2] and screw it in completely.
  • Page 485 dummyhead dummyhead HYDRAULIC BRAKE Install the adjuster lock nut [1]. Tighten the adjuster lock nut to the specified torque while holding the brake arm [2]. TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft) Apply 0.4 g minimum of silicone grease to the bracket and caliper pin boot insides.
  • Page 486 dummyhead dummyhead MEMO...

  • Page 487: Anti-Lock Brake System (Abs) (Crf1000A/D)

    dummytext 20. ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) SERVICE INFORMATION······················ 20-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING ························· 20-10 SYSTEM LOCATION ···························· 20-3 DTC TROUBLESHOOTING ·················· 20-12 SYSTEM DIAGRAM ····························· 20-4 WHEEL SPEED SENSOR ···················· 20-20 ABS TROUBLESHOOTING INFORMATION···································· 20-5 ABS MODULATOR ····························· 20-24 DTC INDEX·········································...
  • Page 488 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) SERVICE INFORMATION ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) GENERAL • The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive voltage may damage the control unit. Always turn off the ignition switch before servicing. •...
  • Page 489 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) SYSTEM LOCATION REAR ABS SWITCH CRF1000A: FUSE BOX 3 – ABS MAIN 7.5 A ABS MAIN 30 A CRF1000D: FUSE BOX 1 – ABS MAIN 7.5 A BATTERY FRONT WHEEL SPEED SENSOR MODULATOR REAR WHEEL SPEED SENSOR 20-3...
  • Page 490 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) SYSTEM DIAGRAM MAIN FUSE 30 A FRONT BRAKE LIGHT SWITCH IGNITION Bl/R Bl/G SWITCH BRAKE/TAIL ILLUMI STOP LIGHT 7.5A R/Bl Bl/R REAR BRAKE LIGHT SWITCH ABS MAIN 7.5A R/Bl Bl/R (6-1, 6-2) Bl/Gr W/Bu INDICATOR REAR ABS...
  • Page 491 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the associated part can be detected by reading the Diagnostic Trouble Code (DTC). When the motorcycle is running, pulse signals generated at the front and rear wheel speed sensors are sent to the ABS control unit.
  • Page 492 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) DTC READOUT • The DTC is not erased by turning the ignition switch to OFF while the DTC is being output. Note that turning the ignition switch ON again does not indicate the DTC. To show the DTC again, repeat the DTC readout procedures from the beginning. •...
  • Page 493 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) How to erase the DTC without MCS 1. Connect the SCS connector to the DLC (page 4-6). 2. Turn the ignition switch ON and engine stop switch " " while squeezing either brake lever. The ABS indicator should come on for 2 seconds and go off.
  • Page 494 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) DTC INDEX • The ABS indicator might blink in the following cases. Correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the motorcycle were installed (incorrect tire size). – Deformation of the wheel or tire. •...
  • Page 495 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) Detection Refer Function failure Symptom/Fail-safe function Power supply relay malfunction • Stops ABS operation • Power supply relay (ABS modulator) or related 20-17 wires • Fuse ABS MAIN 30 A Power circuit under voltage •...
  • Page 496 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) • Before starting this inspection, check the initial function of the combination meter (page 22-12). 1. Indicator Operation Inspection Turn the ignition switch OFF.
  • Page 497 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 2. Indicator Signal Line Open Circuit Inspection Short the wire harness side 18P (Black) connector [1] to the ground with a jumper wire [2]. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: 13 – Ground Turn the ignition switch ON and engine stop switch "...
  • Page 498 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 6. Power Input Line Open Circuit Inspection Install the sub fuse ABS MAIN 7.5 A. Turn the ignition switch ON. Measure the voltage between the wire harness side 18P (Black) connector [1] and ground. TOOL: Test probe 07ZAJ-RDJA110...
  • Page 499 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 2. Front Wheel Speed Sensor Line Short Circuit Inspection Disconnect modulator (Black) connector (page 20-7). Check for continuity between each terminal of the wire harness side 2P (Black) connector [1] and ground. CONNECTION: White – Ground Blue –...
  • Page 500 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) DTC 1-3, 1-4, 2-3, or 4-3 (Rear Wheel Speed Sensor Circuit/Rear Wheel Speed Sensor/Rear Pulser Ring/Rear Wheel Lock) • The ABS indicator might blink under unusual riding conditions (page 20-8). This is temporary failure. Erase the DTC (page 20-6).
  • Page 501 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 4. Failure Reproduction with a New Speed Sensor Replace the rear wheel speed sensor with a new one (page 20-22). Connect the 18P (Black) and 2P (Black) connectors. Erase the DTC (page 20-6). Test-ride the motorcycle above 10 km/h (6 mph).
  • Page 502 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 3. Rear Wheel Speed Sensor Line Short Circuit Inspection (at sensor side) Disconnect the rear wheel speed sensor 2P (Black) connector (page 20-22). Check for continuity between each terminal of the sensor side 2P (Black) connector [1] and ground. CONNECTION: White –...
  • Page 503 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) DTC 5-1 or 5-4 (Pump Motor Lock/ Power Supply Relay) 1. Fuse Inspection Turn the ignition switch OFF. CRF1000A: Remove the battery box cover (page 6-7). Remove the fuse case cover and check for a blown fuse ABS MAIN 30 A.
  • Page 504 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 4. Failure Reproduction Turn the ignition switch OFF. Connect the 18P (Black) connector. Erase the DTC (page 20-6). Test-ride the motorcycle above 10 km/h (6 mph). Recheck the DTC (page 20-6). Is the DTC 5-1 or 5-4 indicated? –...
  • Page 505 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) DTC 8-1 (ABS Control Unit) 1. Failure Reproduction Erase the DTC (page 20-6). Test-ride the motorcycle above 10 km/h (6 mph). Recheck the DTC (page 20-6). Is the DTC 8-1 indicated? – Faulty ABS modulator –...
  • Page 506 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) 4. Rear ABS Off Indicator Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the combination meter 32P (Gray) connector (page 22-12). Check tor continuity between the wire harness side 18P (Black) [1] and 32P (Gray) [2] connectors. TOOL: Test probe 07ZAJ-RDJA110...
  • Page 507 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) Release the wire clips [1]. Release the sensor wire [2] from the clamp [3]. Release the sensor wire [1] from the clamps [2]. Remove the bolt [3] and release the sensor wire from the brake hose clamp [4].
  • Page 508 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) REAR WHEEL SPEED SENSOR REMOVAL Drain the brake fluid from the brake hydraulic system (page 19-6) Remove the rear wheel (page 18-4). [2]/[3] Disconnect the rear brake hose B [1] from the ABS modulator by removing the oil bolt [2] and sealing washers [3].
  • Page 509 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) REAR WHEEL SPEED SENSOR INSTALLATION • Route the hose, cable, and wire properly (page 1- 26). Install rear wheel speed sensor [1] and a new bolt [2]. Tighten the bolt to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the rear brake bracket on the swingarm.
  • Page 510 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) ABS MODULATOR REMOVAL/INSTALLATION Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. • When removing the oil bolt, cover the end of the brake hose to prevent contamination.

  • Page 511: Battery/Charging System

    dummytext 21. BATTERY/CHARGING SYSTEM SERVICE INFORMATION······················ 21-2 BATTERY··········································· 21-5 TROUBLESHOOTING ·························· 21-3 CHARGING SYSTEM INSPECTION ········ 21-7 SYSTEM LOCATION ···························· 21-4 REGULATOR/RECTIFIER ····················· 21-8 SYSTEM DIAGRAM ····························· 21-4 ALTERNATOR CHARGING COIL ··········· 21-9 21-1...
  • Page 512 dummyhead dummyhead BATTERY/CHARGING SYSTEM SERVICE INFORMATION BATTERY/CHARGING SYSTEM GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 513 dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 21-5). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery good condition? –...
  • Page 514 dummyhead dummyhead BATTERY/CHARGING SYSTEM SYSTEM LOCATION STARTER RELAY SWITCH – MAIN FUSE 30 A BATTERY ALTERNATOR REGULATOR/RECTIFIER SYSTEM DIAGRAM MAIN FUSE 30 A Bl/Gr REGULATOR/RECTIFIER BATTERY ALTERNATOR Bl: Black G: Green R: Red Y: Yellow 21-4...
  • Page 515 dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY BATTERY REMOVAL/INSTALLATION Remove the bolts [1]. Remove the tool box band [2] by releasing tab [3] from the guide [4]. Remove the tool box [5]. Open the battery box lid [1]. Always turn the ignition switch OFF Remove the bolts [2] and disconnect the negative (-) before removing the ground terminal [3] first.

  • Page 516: Voltage Inspection

    Remove the bolt/washers [1]. CRF1000D shown: Release the following from the battery box: – CRF1000/A: Siphon hose [2] – CRF1000D: Parking brake cable [2] Remove the battery box [3]. Installation is in the reverse order of removal.

  • Page 517: Battery Testing

    dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY TESTING Remove the battery (page 21-5). Refer to the instructions that are appropriate to the battery testing equipment available to you. TOOL: Battery tester BM-210 or BATTERY MATE or equivalent CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Open the battery box lid (page 21-5).

  • Page 518: Charging Voltage Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING VOLTAGE INSPECTION Make sure the battery is in good condition before performing this test. Start the engine and warm it up to the operating temperature; then stop the engine. Open the battery box lid (page 21-5). Connect the multimeter between the positive terminal [1] and negative terminal [2] of the battery.

  • Page 519: Alternator Charging Coil

    dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY CHARGING LINE INSPECTION Turn the ignition switch OFF. Disconnect the regulator/rectifier 3P (Black) connector (page 21-8). Measure the voltage between the regulator/rectifier 3P (Black) connector [1] at the wire side and ground. CONNECTION: Red (+) – Ground (–) STANDARD: Battery voltage There should be battery voltage at all times.
  • Page 520 dummyhead dummyhead BATTERY/CHARGING SYSTEM Check for continuity between the alternator 3P (Gray) connector [1] terminals at the wire side and ground. CONNECTION: Yellow – Ground STANDARD: No continuity Replace the stator if the resistance is out of specification, or if any wire has continuity to ground. For stator replacement (page 11-7).

  • Page 521: Lights/Meters/Switches

    IGNITION SWITCH······························ 22-23 TURN SIGNAL LIGHT/RELAY HANDLEBAR SWITCHES ···················· 22-23 (CRF1000A/D) ····································· 22-8 BRAKE LIGHT SWITCH······················· 22-24 LICENSE LIGHT ·································22-11 CLUTCH SWITCH (CRF1000/A) ············ 22-25 BRAKE/TAILLIGHT·····························22-11 GEAR POSITION SWITCH COMBINATION METER ·······················22-12 (CRF1000/A) ······································ 22-25 SPEEDOMETER/VS SENSOR ··············22-16 SIDESTAND SWITCH·························· 22-27 TACHOMETER···································22-16...
  • Page 522 dummyhead dummyhead LIGHTS/METERS/SWITCHES SERVICE INFORMATION LIGHTS/METERS/SWITCHES GENERAL • Check the battery condition before performing any inspection that requires proper battery voltage. • Use an electric heating element to heat the water/coolant mixture for the ECT sensor inspection. Keep flammable materials away from the electric heating element.
  • Page 523 REAR BRAKE LIGHT SWITCH – CLUTCH SWITCH (CRF1000/A) – PARKING BRAKE SWITCH (CRF1000D) HORN ECT SENSOR TURN SIGNAL LIGHT RELAY – EOP SWITCH (CRF1000/A) SIDESTAND SWITCH – EOP SENSOR (CRF1000D) (CRF1000A/D) TURN SIGNAL LIGHT RELAY GEAR POSITION SWITCH (CRF1000) (CRF1000/A) 22-3...
  • Page 524 – Blown sub fuse ILLUMI STOP 7.5 A – Loose or poor contact on the headlight 2P, headlight 2P (Black), and left handlebar switch 12P (Gray) (CRF1000)/10P (Gray) (CRF1000A/D) connectors • If any LED in the headlight [1] does not turn on, replace the headlight unit (page 22-4).

  • Page 525: Headlight Relay

    RELAY INSPECTION Remove the headlight relay (page 22-5). Refer to FI relay inspection (page 4-44). TURN SIGNAL LIGHT/RELAY/DIODE (CRF1000) BULB REPLACEMENT Remove the screw [1], turn signal lens [2], and seal rubber [3]. While pushing in, turn the bulb [4] counterclockwise to remove it and replace with a new one.
  • Page 526 dummyhead dummyhead LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT REMOVAL/ INSTALLATION FRONT Remove the inner panel cover (page 2-8). Right side shown: Disconnect the front turn signal light 2P connector [1]. – Right side: light blue – Left side: orange Remove the following: –...
  • Page 527 – Handlebar switch operation • If the sub fuse is blown again, check for the short circuit in the related wires. – CRF1000 (page 24-2) Turn the ignition switch ON and operate the turn signal light switch. Check each turn signal light operation.
  • Page 528 dummyhead dummyhead LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT DIODE REMOVAL/INSTALLATION Remove the pillion seat (page 2-11). Remove the turn signal light diode [1]. Installation is in the reverse order of removal. INSPECTION Check for continuity between the turn signal light diode [1] terminals. When there is continuity, a small resistance value will register.
  • Page 529 dummyhead dummyhead LIGHTS/METERS/SWITCHES REAR Remove the rear carrier (page 2-12). Right side Disconnect the rear turn signal light 2P connector. shown: – Right side: light blue [1] – Left side: orange [2] Remove the following: – Nut [3] – Collar [4] –...
  • Page 530 dummyhead dummyhead LIGHTS/METERS/SWITCHES Turn signal blinks two times faster than usual (One of the unit does not blink). • When there is open or short circuit in turn signal light wire(s), other turn signal light blink faster than usual in order to notify the rider of the problem. Check for loose or poor contact in the turn signal light 2P connector.

  • Page 531: License Light

    dummyhead dummyhead LIGHTS/METERS/SWITCHES LICENSE LIGHT BULB REPLACEMENT Remove the screws [1], license light cover [2], and seal rubber [3]. Pull out the license light bulb [4] without turning from the bulb socket and replace it with a new one. Installation is in the reverse order of removal. TORQUE: 3.8 N·m (0.4 kgf·m, 2.8 lbf·ft) BRAKE/TAILLIGHT REMOVAL/INSTALLATION...

  • Page 532: Combination Meter

    dummyhead dummyhead LIGHTS/METERS/SWITCHES COMBINATION METER REMOVAL/INSTALLATION Remove the inner panel cover (page 2-8). Remove the headlight (page 22-4). Release the connector cover [1]. Disconnect combination meter (Gray) connector [2]. Remove the screw/washers [3] and combination meter [4]. Installation is in the reverse order of removal. TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) COMBINATION METER SYSTEM INSPECTION...
  • Page 533 dummyhead dummyhead LIGHTS/METERS/SWITCHES POWER INPUT LINE Measure the voltage at the wire harness side 32P (Gray) connector [1] and ground. CONNECTION: Black/red (+) – Ground (–) STANDARD: Battery voltage There should be battery voltage with the ignition switch Bl/R turned ON. If there is no voltage, check the following: –...
  • Page 534 dummyhead dummyhead LIGHTS/METERS/SWITCHES TXD LINE INSPECTION • Check the following items before starting the inspection: – Check for loose or poor contact on the combination meter 32P (Gray) connector and ECM/PCM 33P connectors, then recheck the DTC. Turn the ignition switch ON with the engine stop switch "...
  • Page 535 dummyhead dummyhead LIGHTS/METERS/SWITCHES 3. ECM/PCM inspection Connect the 32P (Gray) connector. Replace the ECM/PCM with a known good one (page 22-12), and recheck. Is the combination meter display normal? – Faulty original ECM/PCM – Faulty combination meter COMBINATION METER DIGITAL CLOCK SET PROCEDURE 1.
  • Page 536 dummyhead dummyhead LIGHTS/METERS/SWITCHES SPEEDOMETER/VS SENSOR SYSTEM INSPECTION If the speedometer does not operate, check the following: – Combination meter initial operation (page 22-12) – MIL blinking: If the MIL blinks 11 (DTC 11-1), check the VS sensor system (page 4-21) If the above items are OK, open circuit in the Pink wire.
  • Page 537 dummyhead dummyhead LIGHTS/METERS/SWITCHES TACHOMETER SIGNAL LINE OPEN CIRCUIT INSPECTION Disconnect the following: – ECM/PCM 33P (Gray) connector (page 4-39) – Combination meter 32P (Gray) connector (page 22- Check for continuity between the ECM/PCM 33P (Gray) [1] and 32P (Black) [2] connectors. TOOL: Test probe 07ZAJ-RDJA110...
  • Page 538 dummyhead dummyhead LIGHTS/METERS/SWITCHES INSPECTION Remove the open air temperature sensor 2P (Black) connector (page 22-17). Measure the resistance at the 2P connector [1] of the sensor side. Standard: 4.9 – 5.1 kΩ (25°C/77°F) Replace the open air temperature sensor if it is out of specification.
  • Page 539 – Engine oil level (page 3-11) – TXD line (page 22-14) – Engine oil pressure (page 9-5) – EOP switch line (CRF1000/A) (page 22-19) – MIL blinking: If the MIL blinks 83 (DTC 83-1, 83-2), check the EOP sensor system (CRF1000D) (page 4- If the above items are OK, replace the combination meter (page 22-12).
  • Page 540 dummyhead dummyhead LIGHTS/METERS/SWITCHES Release the rubber cap [1]. [2]/[3] Remove the bolt/washer [2] and disconnect the EOP switch terminal [3]. Remove the EOP switch [4]. Installation is in the reverse order of removal. • Apply sealant to the EOP switch threads as shown. •...

  • Page 541: Fuel Level Sensor Inspection

    dummyhead dummyhead LIGHTS/METERS/SWITCHES Installation is in the reverse order of removal. TORQUE: EOP sensor: 22 N·m (2.2 kgf·m, 16 lbf·ft) • Replace the O-ring with a new one. • Apply engine oil to the O-ring [1]. • Route the wire properly (page 1-26). Fill the engine oil with the recommended engine oil (page 3-12).
  • Page 542 dummyhead dummyhead LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR REMOVAL/ INSTALLATION Remove the fuel tank (page 7-6). Remove the nuts [1]. Remove the fuel reserve sensor [2] and O-ring [3]. Installation is in the reverse order of removal. • Replace the O-ring with a new one. •...

  • Page 543: Ignition Switch

    INSPECTION Remove the left middle cowl (page 2-6). CRF1000D shown: Disconnect the following: – CRF1000: 12P (Gray) [1] and 4P (Black) [2] connectors – CRF1000A: 10P (Gray) [1] and 6P (Black) [2] connectors – CRF1000D: 10P (Gray) [1] and 12P (Black) [2]...

  • Page 544: Right Handlebar Switch

    INSPECTION Remove the right middle cowl (page 2-6). CRF1000D shown: Disconnect the following: – CRF1000/A: 8P (Gray) connector [1] – CRF1000D: 8P (Gray) [1] and 6P (Black) [2] connectors Check for continuity between the wire terminals of the handlebar switch connector in each switch position.
  • Page 545 [1]. There should be continuity with the clutch lever applied, and there should be no continuity with the clutch lever released. GEAR POSITION SWITCH (CRF1000/A) REMOVAL/INSTALLATION Remove the left rear cover (page 2-10). Remove the rear shock absorber (page 18-8).

  • Page 546: Switch Inspection

    dummyhead dummyhead LIGHTS/METERS/SWITCHES SYSTEM INSPECTION If the gear position switch indicator does not operate properly, check the combination meter initial operation (page 22-12). If the combination meter system inspection is OK, check the gear position switch line as follows: Disconnect combination meter (Gray)

  • Page 547: Sidestand Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES SIDESTAND SWITCH REMOVAL/INSTALLATION Remove the left rear cover (page 2-10). CRF1000D shown: CRF1000D: Remove the shift control motor cover (page 13-71). Remove the connector cover (page 5-8). Disconnect the sidestand switch 2P (Black) connector [1]. Remove the bolt [1] and sidestand switch [2]. Installation is in the reverse order of removal.
  • Page 548 dummyhead dummyhead LIGHTS/METERS/SWITCHES HORN REMOVAL/INSTALLATION Turn the ignition switch OFF. Disconnect the wire connectors [1] from the horn [2]. Remove the bolt [3] and horn. Installation is in the reverse order of removal. • Rest the horn stay [4] against the stopper [5]. INSPECTION Disconnect the wire connectors from the horn (page 22- 28).
  • Page 549 LIGHTS/METERS/SWITCHES HSTC (Honda Selectable Torque Control) SYSTEM • The HSTC system utilizes various PGM-FI/ABS components. If any of the related items and/or circuit has problem, the system will fail and the torque control indicator remains on in order to notify the rider of the problem.
  • Page 550 dummyhead dummyhead LIGHTS/METERS/SWITCHES REAR ABS SWITCH (CRF1000A/D) • For the rear ABS off mode system technical feature (page 1-50). • If the rear ABS switch and related circuit has problem, the system will get back the normal ABS mode. In order to notify the rider of the problem, the rear ABS off indicator goes off and ABS indicator comes on.
  • Page 551 dummyhead dummyhead LIGHTS/METERS/SWITCHES REAR ABS SWITCH INSPECTION Remove the right middle cowl (page 2-6). CRF1000D shown: Disconnect the following: – CRF1000A: Rear ABS switch 2P (Black) connector – CRF1000D: Rear ABS/G switch (Black) connector [1] Check for continuity between the switch side terminals. Connection: CRF1000A: Red –...
  • Page 552 dummyhead dummyhead LIGHTS/METERS/SWITCHES Remove the right middle cowl (page 2-6). Disconnect the rear ABS/G switch 4P (Black) connector [1]. Check for continuity between the switch side terminals. Connection: Blue/black – Green/black There should be continuity with the switch pushed, and there should be no continuity with the switch released.

  • Page 553: Immobilizer System (Hiss)

    23. IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION······················ 23-2 TROUBLESHOOTING ·························· 23-8 SYSTEM LOCATION ···························· 23-2 HISS INDICATOR ······························· 23-10 SYSTEM DIAGRAM ····························· 23-3 ECM (CRF1000/A)/PCM (CRF1000D) ····· 23-10 KEY REGISTRATION PROCEDURES ····· 23-3 IMMOBILIZER RECEIVER···················· 23-10 DIAGNOSTIC CODE INDICATION ·········· 23-7 23-1...
  • Page 554 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION IMMOBILIZER SYSTEM (HISS) GENERAL • When checking the HISS, follow the steps in the troubleshooting flow chart (page 23-8). • Keep the immobilizer key away from the other motorcycle's immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed.
  • Page 555 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM MAIN CLOCK COMBINATION METER FUSE TURN 30 A 7.5 A HISS INDICATOR Bl/Gr ENGINE IGNITION STOP STOP SWITCH SWITCH 7.5 A BATTERY R/Bl R/Bl FI FUSE 15 A RELAY CKP SENSOR Gr/Bl Gr/Bl Bl/W Bu/O Bu/O...
  • Page 556 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 7. Turn the ignition switch ON with a new key or the spare key. (Never use the key registered in previous steps.) The indicator comes on for two seconds then it blinks four times repeatedly. 2 sec.
  • Page 557 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 10.Turn the ignition switch OFF and disconnect the red clip of the inspection adaptor from the battery positive (+) terminal. 11.Turn the ignition switch ON (with the first key registered in step 9). The HISS indicator comes on for two seconds then it goes off. •...
  • Page 558 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) When the ECM/PCM is faulty: 1. Obtain a new ECM/PCM and two new transponder keys. 2. Grind the keys in accordance with the shape of the original key (or use the key number plate when all key have been lost). 3.
  • Page 559 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE INDICATION Remove the main seat (page 2-4). Release the main harness wire clip [1] from the hole [2] of the ETC tray. Release the HISS 2P (Red) connector [3] from the stay [4] of the ETC tray and disconnect it. Connect the special tools to the wire harness side 2P (Red) connector.
  • Page 560 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) When the system (ECM/PCM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is The key is Use a new key or overlapped already cancelled key registered properly 10 sec. Code signals Communication Follow the...
  • Page 561 Check the immobilizer receiver ground line (page 23-11). Is the ground line normal? – GO TO STEP 3. – • CRF1000/A: Open circuit in the Gray/black wire • CRF1000D: Open circuit in the Gray wire 3. Immobilizer Receiver Signal Line Inspection Check the immobilizer receiver signal lines (page 23-11).
  • Page 562 HISS INDICATOR POWER INPUT LINE INSPECTION Inspect the combination meter power/ground line (page 22-12). HISS INDICATOR LINE INSPECTION Inspect the combination meter TXD line (page 22-14). ECM (CRF1000/A)/PCM (CRF1000D) CKP SENSOR LINE INSPECTION Disconnect the following: CRF1000/A: – CRF1000/A: Alternator...
  • Page 563 Check for continuity between the immobilizer receiver 4P (Black) connector [1] and ground at the wire side. CONNECTION: CRF1000/A: Gr/Bl (+) – Ground (–) CRF1000D: Gr (+) – Ground (–) Gr/Bl or Gr There should be continuity at all times.
  • Page 564 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) Check for continuity between the PCM 33P (Gray) connector [1] and ground at the wire side. CONNECTION: C21 – Ground TOOL: Test probe 07ZAJ-RDJA110 There should be no continuity. REMOVAL/INSTALLATION Remove the top bridge (page 17-22). Remove the harness cover [1].

  • Page 565: Wiring Diagram

    24. WIRING DIAGRAM WIRING DIAGRAM (CRF1000)··············· 24-2 WIRING DIAGRAM (CRF1000D)············· 24-4 WIRING DIAGRAM (CRF1000A)············· 24-3 24-1...
  • Page 566 WIRING DIAGRAM WIRING DIAGRAM (CRF1000) WIRING DIAGRAM ENGINE STOP & STARTER HAZARD SWITCH SWITCH IGNITION SWITCH BAT1 HAZARD FRONT ENGINE BRAKE SWITCH STARTER STOP LIGHT SWITCH SWITCH SWITCH PUSH LOCK 3P Lb IGNITION IMMOBILIZER FUEL RIGHT FRONT Lb/W Lb/W...
  • Page 567 dummytext WIRING DIAGRAM WIRING DIAGRAM (CRF1000A) ENGINE STOP & STARTER REAR ABS SWITCH HAZARD SWITCH SWITCH IGNITION SWITCH MODE GND BAT1 FREE PUSH FRONT ENGINE BRAKE PUSH LOCK 2P Lb HAZARD STARTER STOP LIGHT RIGHT FRONT TURN SIGNAL SWITCH SWITCH SWITCH SWITCH Bl/G...
  • Page 568 dummytext WIRING DIAGRAM WIRING DIAGRAM (CRF1000D) ENGINE STOP & STARTER G SWITCH REAR ABS SWITCH N-D SWITCH A/M SWITCH HAZARD SWITCH SWITCH IGNITION SWITCH MODE GND MODE GND VCC MOD BAT1 FREE FREE FREE PUSH PUSH FREE PUSH FRONT ENGINE BRAKE PUSH LOCK...
  • Page 569 dummytext MEMO...
  • Page 570 ENGINE OIL FILTER ··········································· 3-12 MAINTENANCE ·············································· 3-21 ENGINE OIL PRESSURE INDICATOR/EOP SWITCH BRAKE LOCK OPERATION (CRF1000D) ················ 3-21 (CRF1000/A)/EOP SENSOR (CRF1000D) ············· 22-19 BRAKE PAD/DISC ·············································· 19-8 ENGINE REMOVAL············································· 16-5 BRAKE PADS WEAR··········································· 3-20 EOT SENSOR (CRF1000D) ································ 13-81 BRAKE SYSTEM ················································...
  • Page 571 SERVICE RULES ················································· 1-2 MODEL IDENTIFICATION······································ 1-3 SHIFT CONTROL MOTOR/REDUCTION GEARS MUFFLER/EXHAUST PIPE ·································· 2-16 (CRF1000D) ····················································· 13-71 NEUTRAL DIODE (CRF1000/A) ······························ 6-9 SHIFT SPINDLE ANGLE SENSOR (CRF1000D) ····· 13-79 NEUTRAL SWITCH (CRF1000D)··························13-82 SHOCK ABSORBER ············································18-8 NUTS, BOLTS, FASTENERS································ 3-25 SIDE COVER······················································2-11...
  • Page 572 ALTERNATOR/STARTER CLUTCH ···················· 11-2 REAR WHEEL/SUSPENSION ··························· 18-2 BATTERY/CHARGING SYSTEM ························ 21-3 TURN SIGNAL LIGHT/RELAY (CRF1000A/D) ·········· 22-8 CLUTCH/GEARSHIFT LINKAGE ························ 12-2 TURN SIGNAL LIGHT/RELAY/DIODE (CRF1000) ····· 22-5 COOLING SYSTEM ···········································8-2 VALVE CLEARANCE·············································3-8 CRANKCASE/TRANSMISSION/BALANCER········· 14-3 VS SENSOR ······················································ 4-42 CRANKSHAFT/PISTON/CYLINDER···················· 15-2 WATER PUMP ···················································...
  • Page 573 Honda Motor Co., Ltd. 2015 Published by Honda Motor Co., Ltd. Book number : 62MJP000 Printed in Japan 2015.09.G...

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