2006

Honda CRF250R
OWNER’S MANUAL & COMPETITION HANDBOOK
Introduction
Congratulations on choosing your Honda CRF As you read this manual, you will find California Proposition 65 Warning
motocross motorcycle. information that is preceded by a NOTICE WARNING: This product contains or emits
symbol. This information is intended to help you chemicals known to the State of California to
When you own a Honda, you’re part of a avoid damage to your Honda, other property, or cause cancer and birth defects or other
worldwide family of satisfied customers-people the environment. reproductive harm.
who appreciate Honda’s reputation for building
quality into every product. Unless you are mechanically qualified and have
the proper tools, you should see your Honda
Your CRF is a high performance racing dealer for the service and adjustment procedures
motorcycle that utilizes the latest motocross discussed in this manual.
technology and is intended for competition use in
sanctioned, closed-course events by experienced The official Honda Service Manual for your CRF
riders only. is available (page 154). It is the same manual
your dealer uses. If you plan to do any service
Be aware that motocross is a physically on your CRF beyond the standard maintenance
demanding sport that requires more than just a procedures in this manual, you will find the
fine motorcycle. To do well, you must be in Service Manual a valuable reference.
excellent physical condition and be a skillful
rider. For the best results, work diligently on If you have any questions, or if you ever need a
your physical conditioning and practice special service or repairs, remember that your
frequently. Honda dealer knows your CRF best and is
dedicated to your complete satisfaction.
Before riding, take time to get acquainted with
your CRF and how it works. To protect your Please report any change of address or ownership
investment, we urge you to take to your Honda dealer so we will be able to
responsibility for keeping your CRF well contact you concerning important production
maintained. Scheduled service is a must, of information.
course. But it’s just as important to observe the
break-in guidelines, and perform all the pre-ride You may also want to visit our website at
and other periodic checks detailed in this manual. www.honda.com

You should also read the owner’s manual before Happy riding!
you ride. It’s full of facts,
instructions, safety information, and helpful tips.
To make it easy to use, the manual
contains a table of contents, a detailed list of
topics at the beginning of each section, and an
index at the back of the book.

Introduction
 A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.

To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages
throughout the manual.

Safety Messages are preceded by a safety alert symbol and one of three signal words: DANGER, WARNING, or CAUTION.

These signal words mean:

DANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

WARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

CAUTION You CAN be HURT if you don’t follow instructions.

Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good
judgement.

Safety Messages
Contents
MOTORCYCLE SAFETY...............................1 Air Cleaner ........................................................43 Specifications ..................................................141
Important Safety Information..............................2 Crankcase Breather ...........................................45 Torque Specifications......................................142
Important Safety Precautions..........................2 High Altitude Carburetor Adjustment .............145
Accessories & Modifications ..............................3 Engine Oxygenated Fuels............................................146
Safety Labels.......................................................4 Throttle ..............................................................46 Competition Logbook .....................................147
Engine Idle Speed .............................................48 Optional Parts List ..........................................149
OPERATING CONTROLS .............................5 Clutch System ...................................................49 Spare Parts & Equipment................................150
Operation Component Locations ........................6 Hot Start Lever..................................................54 Wiring Diagram...............................................151
Spark Plug .........................................................55
BEFORE RIDING ............................................7 Valve Clearance.................................................56 CONSUMER INFORMATION ...................153
Are You Ready to Ride? .....................................8 Piston/Piston Rings/Piston Pin..........................64 Authorized Manuals ........................................154
Is Your Motorcycle Ready to Ride?....................9 Contacting Honda............................................155
Pre-ride Inspection..........................................9 Chassis Your Honda Dealer..........................................156
Suspension.........................................................72 The Honda Rider’s Club (USA only) .............157
BASIC OPERATING INSTRUCTIONS ......11 Brakes................................................................77
Safe Riding Precautions................................12 Wheels...............................................................81 TABLE OF CONTENTS ..............................158
Starting & Stopping the Engine ........................13 Tires & Tubes ....................................................82
Break-in Guidelines ..........................................15 Drive Chain .......................................................84 INDEX ............................................................159
Exhaust Pipe/Muffler ........................................87
SERVICING YOUR HONDA........................17 Additional Maintenance Procedures .................91 QUICK REFERENCE
Before You Service Your Honda Appearance Care ...............................................93
The Importance of Maintenance .......................18
Maintenance Safety...........................................19 ADJUSTMENTS FOR COMPETITION .....95
Important Safety Precautions........................19 Front Suspension Adjustments..........................96
Maintenance Schedule ......................................20 Rear Suspension Adjustments.........................109
General Competition Maintenance ...................22 Suspension Adjustments for Track
Before & After Competition Maintenance........26 Conditions ...................................................113
Between Motos & Practice Maintenance .....26 Suspension Adjustment Guidelines.................114
After Competition Maintenance ...................26 Carburetor Adjustments & Tuning Tips ..........117
Chassis Adjustments........................................129
Service Preparations Gearing ............................................................130
Maintenance Component Locations..................28 Tire Selection for Track Conditions................131
Seat Removal ....................................................29 Personal Fit Adjustments ................................132
Fuel Tank Removal ...........................................30
Subframe Removal............................................32 TIPS ................................................................133
Transporting Your Motorcycle ........................134
Service Procedures Storing Your Honda.........................................135
Fluids & Filters You & the Environment ..................................136
Fuel System.......................................................34 Troubleshooting...............................................137
Engine Oil .........................................................36
Transmission Oil ...............................................39 TECHNICAL INFORMATION ..................139
Coolant ..............................................................41 Vehicle Identification ......................................140

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

Motorcycle Safety 1
Important Safety Information
Dont’t Drink and Ride.
Important Safety Precautions Alcohol and riding don’t mix. Even one drink
can reduce your ability to respond to changing
Your CRF can provide many years of pleasure, if conditions, and your reaction time gets worse
you take responsibility for your own safety and with every additional drink. So don’t drink and
understand the challenges you can meet in ride, and don’t let your friends drink and ride
competitive racing. either.

As an experienced rider, you know there is much Keep your Honda in Safe Condition.
you can do to protect yourself when you ride. Maintaining your CRF properly is critical to your
The following are a few precautions we consider safety. A loose bolt, for example, can cause a
most important. breakdown in which you can be seriously
injured.
Never Carry a Passenger.
Your CRF is designed for one operator only.
Carring a passenger can cause an accident in
which you and others can be hurt.

Wear Protective Gear.

Whether you’re practicing to improve your skills,
or riding in competition, always wear an
approved helmet, eye protection, and proper
protective gear.

Take Time to Get to Know Your CRF.

Because every motorcycle is unique, take time to
become thoroughly familiar with how this one
operates and responds to your commands before
placing your machine, and yourself, in
competition.

Learn and Respect Your Limits.

Never ride beyond your personal abilites or faster
than conditions warrant. Remember that alcohol,
drugs, illness and fatigue can reduce your ability
to perform well and ride safety.

2 Motorcycle Safety
 Accessories & Modifications
Accessories & Modifications

Installing non-Honda accessories, removing

original equipment, or modifying your CRF in
any way that would change its design or
operation, could seriously impair your CRF’s
handling, stability, and braking, making it unsafe
to ride.

WARNING
Improper accessories or modifications
can cause a crash in which you can be
seriously hurt or killed.

Follow all instructions in this owner’s

manual regarding modifications and
accessories.

Motorcycle Safety 3
Safety Labels
Read this label carefully and don’t remove it.

If the label comes off or becomes hard to read, contact your Honda dealer for replacement.

4 Motorcycle Safety
 Operating Controls
Read this section carefully before you ride. It Operation Component Locations .........................6
presents the location of the basic controls on your
CRF.

Operating Controls 5
Operation Component Locations
hot start lever

clutch lever front brake lever

engine stop button throttle grip

choke knob
kickstarter

fuel valve shift lever rear brake pedal

6 Operating Controls
 Before Riding
Before each ride, you need to make sure you and Are You Ready to Ride?.......................................8
your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....................9
you prepared, this section discusses how to Pre-ride Inspection .............................................9
evaluate your riding readiness, and what items
you should check on your CRF.

For information about suspension, carburetor,

and other adjustment for competition, see page
95.

Before Riding 7
Are You Ready to Ride?
Before riding your CRF for the first time, we
strongly recommend that you read this owner’s WARNING
manual, make sure you understand the safety Not wearing a helmet increases the
messages, and know how to operate the controls. chance of serious injury or death in a
crash.
Before each ride, it’s also important to make sure
you and your CRF are both ready to ride. Be sure you always wear a helmet, eye
protection and other protective apparel
For information about suspension, carburetor, when you ride.
and other adjustments, see page 95.

Whether you’re preparing for competition or for

practice, always make sure you are.

• In good physical and mental condition

• Free of alcohol and drugs

• Wearing an approved helmet, eye protection,

and other appropriate riding gear

Although complete protection is not possible,

wearing the proper gear can reduce the chance or
severity of injury when you ride.

8 Before Riding
 Is Your Motorcycle Ready to Ride?
Competitive riding can be tough on a motorcycle,
so it’s important to inspect your CRF and correct Pre-ride Inspection
any problems you find before each ride. Check
the following items (page numbers are at the Check the following before each ride:
right): • Engine oil level .............................................37
• Transmission oil level...................................40
WARNING • Coolant for proper level................................41
• Cooling system and hoses for condition.......42
Improperly maintaining this motorcycle or • Spark plug for proper heat range, carbon
failing to correct a problem before riding fouling and high tension cord terminal for
can cause a crash in which you can be looseness .......................................................55
seriously hurt or killed. • Air cleaner for condition and
contamination................................................43
Always perform a pre-ride inspection • Clutch lever adjustment and freeplay ...........49
before every ride and correct any • Hot start lever freeplay .................................54
problems. • Breather drain for cleaning ...........................45
• Steering head bearing and related parts
for condition..................................................91
• Carburetor throttle operation ........................47
• Tires for damage or improper inflation
pressure ........................................................82
• Spokes for looseness.....................................81
• Rim locks for looseness................................81
• Front and rear suspension for proper
operation ..................................................72,73
• Front and rear brakes, check operation ........77
• Drive chain for correct slack and adequate
lubrication .....................................................84
• Drive chain guide, sliders and drive chain
rollers for damage or wear.......................84,85
• Exhaust pipe/Muffler inspection,
removal and installation.................87,88,89,90
• Every possible part for looseness (such as
cylinder head nuts, engine mounting bolts,
axle nuts, handlebar holder bolts, fork bridge
pinch bolts, drive chain adjuster, drive chain
guide, wire harness connectors, kickstarter
mounting bolt) ..............................142,143,144

Before Riding 9
10 Before Riding
 Basic Operating Instructions
This section gives basic information on how to Safe Riding Precautions .....................................12
start and stop your engine as well as break-in Starting & Stopping the Engine .........................13
guidelines. Preparation ....................................................13
Starting Procedure ........................................13
Flooded Engine .............................................13
How to Stop the Engine................................14
Break-in Guidelines ...........................................15

Basic Operating Instructions 11

Basic Operating Instructions
Safe Riding Precautions

Before riding your CRF for the first time, please

review the Important Safety Precaution
beginning on page 2 and the previous section,
titled Before Riding.

For your safety, avoid starting or operating the

engine in an enclosed area such as a garage.
Your CRF’s exhaust contains poisonous carbon
monoxide gas which can collect rapidly in an
enclosed area and cause illness or death.

12 Basic Operating Instructions

 Starting & Stopping the Engine
Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting
described below. levels before starting the engine (pages 37,40,41). 1. Turn the fuel valve ON.
2. Shift the transmission into neutral.
Your CRF can be kickstarted with the Cold Engine Starting 3. Pull the hot start lever (3) and kick-start the
transmission in gear by pulling in the clutch lever 1. Turn the fuel valve (1) ON. engine. (Do not open the throttle.)
before operating the kickstarter. 2. Shift the transmission into neutral. 4. As soon as the engine starts, release the hot
3. If the temperature is 95°F (35°C) or below, start lever.
pull the choke knob (2) fully out.
Preparation 4. If the temperature is below 32°F (0°C), open
the throttle two or three times. (The engine
Make sure that the transmission is in neutral. requires a richer mixture for starting in cold
Turn the fuel valve ON. weather. When the throttle is so opened, the
accelerator pump will feed extra fuel to the
cylinder, thereby facilitating starting in cold
Starting Procedure weather.)
5. With the throttle closed, operate the (3)
Always follow the proper starting procedure kickstarter starting from the top of the (3) hot start lever
described as follow. kickstarter stroke, kick through to the bottom
with a rapid, continuous motion. Starting the engine after a stall during riding or
(Do not open the throttle, As the carburetor is after a fall
(2)
equipped with an accelerator pump, excessive 1. Shift the transmission into neutral.
fuel will be charged into the engine, and the 2. Pull the hot start lever and kick-start the
(1) spark plug will be fouled if the throttle is engine. (Do not open the throttle).
opened and closed repeatedly. Excessive fuel 3. As soon as the engine starts, release the hot
in the engine makes kickstarting difficult.) start lever.
6. About a minute after the engine starts, push
the choke knob back all the way to fully OFF.
If idling is unstable, open the throttle slightly. Flooded Engine

If the engine fails to start after repeated attempts,

it may be flooded with excess fuel. To clear a
flooded engine:
(1) fuel valve (2) choke knob
1. Shift the transmission into neutral.
2. With the throttle fully opened, repeat
kickstarter operation approximately 10 times
very slowly to discharge excessive fuel from
the engine.
3. Pull the hot start lever and kick-start the
engine (Do not open the throttle.)
4. As soon as the engine starts, release the hot
start lever.

Basic Operating Instructions 13

Starting & Stopping the Engine
How to Stop the Engine

(1)

(2)

(1) throttle grip (2) engine stop button

Normal Engine Stop

1. Shift the transmission into neutral.
2. Turn the fuel valve OFF.
3. Lightly open the throttle (1) 2 – 3 times, and
then close it.
4. Depress and hold the engine stop button (2)
until the engine stops completely.

Failure to close the fuel valve may cause the

carburetor to overflow, result in hard starting.

Emergency Engine Stop

To stop the engine in an emergency, depress the
engine stop button.

14 Basic Operating Instructions

 Break-in Guidelines
Help assure your CRF’s future reliability and
performance by paying extra attention to how
you ride during the first operating day or 15
miles (25 km).
During this period, avoid full-throttle starts and
rapid acceleration.

This same procedure should be followed each

time when:

• piston is replaced
• piston rings are replaced
• cylinder is replaced
• crankshaft or crank bearings are replaced

Basic Operating Instructions 15

16 Basic Operating Instructions
 Servicing Your Honda
Keeping your CRF well maintained is absolutely Before You Service Your Honda Chassis
essential to your safety. It’s also a good way to The Importance of Maintenance ........................18 Suspension..........................................................72
protect your investment, get maximum Maintenance Safety ............................................19 Front Suspension Inspection........................72
performance, avoid breakdowns, and have more Important Safety Precautions........................19 Rear Suspension Inspection.........................73
fun. Maintenance Schedule .......................................20 Fork Oil Change ..........................................74
General Competition Maintenance ....................22 Brakes.................................................................77
To help keep your CRF in good shape, this Before & After Competition Maintenance.........26 Wheels ................................................................81
section includes a Maintenance Schedule for Between Motos & Practice Maintenance .....26 Tires & Tubes .....................................................82
required servicing and step-by-step instructions After Competition Maintenance ...................26 Drive Chain ........................................................84
for specific maintenance tasks. You’ll also find Exhaust Pipe/Muffler .........................................87
important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ..................91
and tips for keeping your Honda looking good. Maintenance Component Locations...................28
Seat Removal .....................................................29 Appearance Care ................................................93
An ICM (Ignition Control Module) system is Fuel Tank Removal ............................................30
used on this motorcycle; consequently, routine Subframe Removal.............................................32
ignition timing adjustment is unnecessary. If you
want to check the ignition timing, refer to the Service Procedures
Honda Service Manual (page 154).
Fluids & Filters
An optional tool kit may be available. Check Fuel System ........................................................34
with your Honda dealer’s parts department. Engine Oil ..........................................................36
Transmission Oil ................................................39
Coolant ...............................................................41
Air Cleaner .........................................................43
Crankcase Breather ............................................45

Engine
Throttle ...............................................................46
Engine Idle Speed ..............................................48
Clutch System ....................................................49
Hot Start Lever...................................................54
Spark Plug ..........................................................55
Valve Clearance..................................................56
Piston/Piston Rings/Piston Pin...........................64

Servicing Your Honda 17

The Importance of Maintenance
Keeping your CRF well-maintained is absolutely
essential to your safety. It’s also a good way to
get maximum performance during each moto.
Careful pre-ride inspections and good
maintenance are especially important because
your CRF is designed to be ridden in off-road
competition.

Remember, proper maintenance is your

responsibility. Be sure to inspect your CRF
before each ride and follow the Maintenance
Schedule in this section.

WARNING
Improperly maintaining this motorcycle or
failing to correct a problem before you
ride can cause a crash in which you can
be seriously hurt or killed.

Always follow the inspection and

maintenance recommendations and
schedules in this owner’s manual.

18 Servicing Your Honda

 Maintenance Safety
This section includes instructions on how to • Read the instructions before you begin, and
perform some important maintenance tasks. make sure you have the tools and skills
Some of the most important safety precautions required.
follow. However, we cannot warn you of every
conceivable hazard that can arise in performing • To help prevent the motorcycle from falling
maintenance. Only you can decide whether or over, park it on a firm, level surface, using the
not you should perform a given task. optional work stand or a maintenance stand to
provide support.
WARNING • To reduce the possibility of a fire or
Failure to properly follow maintenance explosion, be careful when working around
instructions and precautions can cause gasoline. Use only a non-flammable (high
you to be seriously hurt or killed. flash point) solvent such as kerosene —not
gasoline— to clean parts. Keep cigarettes,
Always follow the procedures and sparks, and flames away from all fuel-related
precautions in this owner’s manual. parts.

Important Safety Precautions

• Make sure the engine is off before you begin

any maintenance or repairs.
This will help eliminate several potential
hazards:

Carbon monoxide poisoning from engine

exhaust. Be sure there is adequate ventilation
whenever you operate the engine.

Burns from hot motorcycle parts. Let the

engine and exhaust system cool before
touching.

Injury from moving parts. Do not run the

engine unless instructed to do so.

Servicing Your Honda 19

Maintenance Schedule
To maintain the safety and reliability of your Perform the pre-ride inspection (page 9) at each
CRF, regular inspection and service is required as scheduled maintenance period.
shown in the Maintenance Schedule that follows.
Summary of Maintenance Schedule Notes and
The Maintenance Schedule lists items that can be Procedures:
performed with basic mechanical skills and hand
tools. Procedures for these items are provided in Notes:
this manual. 1. Clean after every heat for dusty riding
conditions.
The Maintenance Schedule also includes items 2. Replace every 2 years. Replacement requires
that involve more extensive procedures and may mechanical skill.
require special training, tools, and equipment. 3. Replace after the first break-in ride.
Therefore, we recommend that you have your 4. Inspect after the first break-in ride.
Honda dealer perform these tasks unless you 5. Replace the transmission oil, if the clutch
have advanced mechanical skills and the required discs and plates are replaced.
tools. Procedures for items in this schedule are
provided in a service manual available for Maintenance Procedures:
purchase from your Honda dealer (page 156). I: inspect and clean, adjust, lubricate, or replace,
if necessary
Service intervals in the maintenance schedule are C: clean
expressed in terms of races and riding hours. To L: lubricate
avoid overlooking required service, we urge you R: replace
to develop a convenient way to record the
number of races and/or hours you ride.

If you do not feel capable of performing a given

task or need assistance, remember that your
Honda dealer knows your CRF best and is fully
equipped to maintain and repair it. If you decide
to do your own maintenance, use only genuine
Honda parts or their equivalents for repair or
replacement to ensure the best quality and
reliability.

20 Servicing Your Honda

 Maintenance Schedule
Perform the Pre-ride Inspection at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.

FREQUENCY
Each race Every 3 races Every 6 races Every 9 races Every 12 races
NOTE or about or about or about or about or about Ref. Page
2.5 hours 7.5 hours 15.0 hours 22.5 hours 30.0 hours
ITEMS
THROTTLE OPERATION I 46
HOT START SYSTEM I 54
AIR FILTER (NOTE 1) C 43
CRANKCASE BREATHER I 45
SPARK PLUG I 55
RADIATOR COOLANT (NOTE 2) I 41
VALVE CLEARANCE / DECOMPRESSOR SYSTEM (NOTE 4) I 57
ENGINE OIL (NOTE 3) I R 37
ENGINE OIL FILTER (NOTE 3) R 37
ENGINE IDLE SPEED I 48
PISTON AND PISTON RINGS R 66
PISTON PIN R 66
TRANSMISSION OIL (NOTE 5) I R 40
COOLING SYSTEM I 42
DRIVE CHAIN I,L R 84
DRIVE CHAIN SLIDER I 84
DRIVE CHAIN ROLLER I 85
DRIVE SPROCKET I 86
DRIVEN SPROCKET I 86
BRAKE FLUID (NOTE 2) I 78
BRAKE PADS WEAR I 80
BRAKE SYSTEM I 77
CLUTCH SYSTEM (NOTE 5) I 49
CONTROL CABLES I,L 91
EXHAUST PIPE/MUFFLER I 87
SUSPENSION I 72
SWINGARM/SHOCK LINKAGE L 25, 73
FORK TUBE/SLIDER (NOTE 3) R 74
FORK OIL
DAMPER R 100
NUTS, BOLTS, FASTENERS I 92,142
WHEELS/TIRES I 81,82
STEERING HEAD BEARINGS I 91

This maintenance schedule is based upon average riding condition. Machines subjected to severe use require more frequent servicing.

NOTE: 1.Clean after every heat for dusty riding conditions.

2.Replace every 2 years. Replacement requires mechanical skill.
3.Replace after the first break-in ride.
4.Inspect after the first break-in ride.
5.Replace the transmission oil, if the clutch discs and plates are replaced.

Servicing Your Honda 21

General Competition Maintenance
Perform maintenance on firm, level ground using
the optional workstand, or equivalent
support.

When tightening bolts, nuts or screws, start with

the larger diameter or inner fasteners, and tighten
them to the specified torque using a crisscross
pattern.

Use genuine Honda parts or their equivalent

when servicing your CRF.

Clean parts in non-flammable (high flash point)

cleaning solvent (such as kerosene) when
disassembling. Lubricate any sliding surface,
O-rings, and seals before reassembling. Grease
parts by coating or filling where specified.

After any engine disassembly, always install new

gaskets, O-rings, cotter pins, piston pin clips,
snap rings, etc. when reassembling. After
reassembly, check all parts for proper installation
and operation.

All Pre-ride Inspection Items

Refer to Pre-ride Inspection page 9.

22 Servicing Your Honda

 General Competition Maintenance
Spark Plug Air Cleaner
Some non-resistor plugs may cause ignition problems. Refer Clean and oil your air cleaner regularly because the volume
to the recommendations elsewhere in this manual for specific of air able to pass through it has a great effect on
types so you will be sure to use the proper reach and heat performance. Both engine performance and long term
range. Replace periodically as specified in the Maintenance durability may be affected by an air cleaner that has
Schedule. (page 20). deteriorated and allows dirt to pass. Inspect the cleaner
closely each time it’s serviced for evidence of small tears or
seam separation. Keep a spare air cleaner oiled and ready to
install, sealed in a plastic bag. Riding in dusty conditions
may require servicing the air cleaner or replacing it with a
pre-serviced air cleaner between motos. Be careful not to
over oil the air cleaner. While it is important to oil the air
cleaner thoroughly, over oiling will cause an overall rich
running condition, probably more noticeable off idle and in
low rpm performance. Follow the servicing instructions in
the Maintenance section. Use Pro Honda Foam Filter Oil or
an equivalent. Be sure to grease the air cleaner flange where
it contacts the air cleaner housing. Honda White Lithium
Grease, or an equivalent, is handy for this because any dirt
that penetrates this sealing area will show up clearly (page
43).
Use the Honda genuine air cleaner or an equivalent air
Engine Oil and Filter cleaner specified for your model.
Drain and replace engine oil often to ensure the greatest Using the wrong Honda air cleaner or a non-Honda air
service life of the piston, cylinder and crankshaft. cleaner which is not of equivalent quality may cause
Also replace engine oil filter often to ensure the greatest premature engine wear or performance problems.
service life. Frequent changes will also assure consistent
performance of power and response. (page 37).

Transmission Oil Air cleaner Housing Sealing

Drain and replace transmission oil often to ensure the Remove and reseal the air cleaner housing boot where it
greatest service life of the transmission and clutch. Frequent connects to the air cleaner housing with silicone sealer if
changes will also assure consistent performance of both there is any doubt to its sealing integrity. Use Hondalock or
shifting and clutch action (page 40). an equivalent on the attaching studs. Inspect the air cleaner
and air intake tract regularly for signs of deterioration or dirt
penetration.

Servicing Your Honda 23

General Competition Maintenance
Handgrips Gaskets Fuel Filter
Always use Honda Hand Grip Cement (U.S.A only) or Always use new gaskets when reassembling components. Periodically drain the fuel from the fuel tank, remove and
Honda Bond A when replacing handgrips. clean the fuel valve/filter. Replace the fuel joint O-ring if
Cylinder Removal there are any signs of damage or deterioration (page 35).
Throttle Grip Put a little grease on the cylinder mounting dowels to
Align the index mark on the throttle grip with the edge of the prevent corrosion from dissimilar metals. The tolerances are Fuel Contamination
throttle cable guide. Left handlebar grip: Align the “∆” mark quite tight, so it’s important to keep these dowels absolutely Refer to Fuel System in your Owner’s Manual, page 34, and,
on the left handlebar grip with the paint mark on the clean (page 66). in this supplement, Fuel System, page 34.
handlebar. Check the fuel lines for deterioration, damage, or leakage.
Refer to the Service Manual for installation Replace the fuel lines, if necessary.
instructions. Periodically drain the fuel from the fuel tank, remove and
clean the fuel valve and fuel filter. Replace the fuel joint O-
ring if there are any signs of damage or deterioration (page
35).
Loosen the drain screw and examine the fuel that flows out
of the float bowl. If you notice anything in the fuel, such as
water or dirt, remove the float bowl and inspect its contents
(page 121).
For maximum efficiency, drain and replace fuel that has
remained in your fuel tank for more than a month.

For added security, you may choose to safety wire the hand
grips to the handlebar and throttle to prevent the possibility
of them loosening. Position the twisted wire ends away from
your palms and be sure to bend the wire ends well into the
grip rubber so they will not snag your glove.

Electrical Connectors
Clean electrical connectors and wrap them with electrical
tape to reduce the possibility of unwanted disconnections,
water shorts or corrosion. Additional corrosion protection is
offered by using Honda Dielectoric Grease on all electrical
connections.

Throttle Control
Remove the throttle control every few rides, clean the inside
of the drum and the handlebar thoroughly, and apply a light
coating of silicone lubricant. Inspect the cable carefully for
kinks or other damage that may restrict throttle control in
Engine Mounting Bolts and Nuts
any way. Move the handlebar from lock to lock to be sure
Make sure the engine mounting bolts and nuts are tightened
there is no cable interference. Check to be sure the top of the
to the proper torque specification. For added peace of mind,
carburetor is screwed on tight. Make certain the throttle
remove the nuts, clean the threads, and apply Honda Thread
operation is perfect after servicing and inspecting.
Lock or an equivalent prior to torquing the nuts.

24 Servicing Your Honda

 General Competition Maintenance
Suspension Linkage Lubrication Brake Fluid Replacement Steering Head Bearings
Disassemble, clean, inspect and lubricate all pivot bearings Refer to Brake Pad Wear in your Owner’s Manual, page 80. Periodically clean, inspect and regrease the steering head
after each 7.5 hours of running time in order to maintain Brake Caliper Inspection: Be sure both the front and rear bearings — especially if wet, muddy or extremely dusty
proper suspension performance and minimize component calipers are able to move freely on the caliper bracket pins. courses are encountered often.
wear. Use Honda Moly 60 paste (U.S.A. only) or Check pad thickness periodically and replace when
molybdenum disulfide paste (containing more than 40% minimum thickness is reached. If the brakes fade when they
molybdenum disulfide additive). are hot, inspect the pads for glazing or damage, and replace
if necessary.
Brake Fluid Replacement: Replace the hydraulic fluid in the
brake system every two years. Replace the fluid more
frequently if you subject your brakes to severe use. Heavy
braking heats the brake fluid and it may deteriorate sooner
than expected. Any type of riding, that requires frequent use
of the brakes, such as in tight woods, can shorten the service
life of brake fluid.

Fork Oil/Performance
Swingarm Pivot Lubrication Disassemble, clean and inspect the fork and replace the oil
Clean, inspect and lubricate when servicing suspension regularly. Contamination due to the tiny metal particles
linkage pivots. Be sure all of the suspension pivot seals are produced from the normal action of the fork, as well as
in good condition. Use Honda Moly 60 paste (U.S.A. only) normal oil breakdown, will deteriorate the performance of
or molybdenum disulfide paste (containing more than 40% the suspension. Refer to the Honda Service Manual. Use
molybdenum disulfide additive). only Pro Honda HP Fork Oil 5W (U.S.A. only) or
equivalent which contains special additives to assure
maximum performance of your CRF’s front suspension.

Frame
Because your CRF is a high-performance machine, the frame
should not be overlooked as part of your overall competition
maintenance program. Periodically inspect the frame
closely for possible cracking or other damage. It makes
Swingarm good racing sense.
Do not attempt to weld or otherwise repair a damaged
swingarm. Welding will weaken the swingarm. Spokes
Check spoke tension frequently between the first few rides.
Footpegs As the spokes, spoke nuts and rim contact points seat-in, the
Worn footpeg teeth can be repaired by filing the grooves spokes may need to be retightened. Once past this initial
between the teeth with a triangular shaped file. seating-in period, the spokes should hold their tension. Still,
Water Leakage Check Hole
Be aware that filing them too sharp will reduce boot sole be sure your race maintenance program includes checking
After every race, check the leakage check hole, located just
lifespan. Sharpen only the points of the teeth. Filing the spoke tension and overall wheel condition on a regular basis
below the water pump cover on the right crankcase cover.
grooves deeper will weaken the footpegs. Be sure the pegs (page 81).
Clean away any clogged dirt or sand, if necessary. Look for
are free to pivot freely and that the pivot pin retaining cotter coolant or oil leakage. Leaking coolant indicates a worn or
pins are in good condition. Nuts, Bolts, Etc
damaged water seal. Leaking oil indicates a bad
Application of a thread locking agent to essential fasteners
transmission oil seal. If replacement is necessary, both seals
offers added assurance and security. Remove the nuts, clean
should be replaced.
the threads of both the nuts and bolts, apply Honda Thread
Lock or an equivalent and tighten to the specified torque.

Servicing Your Honda 25

Before & After Competition Maintenance
Between Motos & Practice Maintenance After Competition Maintenance

After practice or between motos you have a It is important to the long term performance of
chance to make additional checks and your CRF to practice a consistent maintenance
adjustments. (1) program. Right after the event is a good time to
begin your next maintenance cycle.
• Clean accumulated dirt from under the
fenders and off the wheels, suspension After Race Lubrication
components, hand grips, controls, and Apply a light coating of rust-inhibiting oil to the
footpegs. A stiff, nylon parts cleaning brush drive sprocket and any steel portions of the
works well. chassis or engine where the paint has worn away.
• Check tire air pressure. (1) chain adjuster index marks This will prevent rusting of the exposed metal.
• Check spoke tension and rim lock nut security. Apply rust-inhibiting oil more heavily if the
• Suspend the front wheel above the ground and event was particularly wet or muddy. Take care
use the pressure release screws (2) to release to avoid spraying any oil near the brake pads or
the built-up pressure (in excess of normal brake disc.
atmospheric pressure: 0 psi) in the fork tubes.
This pressure is caused by normal fork action Take care to prevent catching your fingers
while riding. (If you are riding at altitude, between the chain and sprocket.
remember that fork pressure of 0 at sea level
will increase as elevation increases.) Remove the drive chain, clean it, and lubricate
the chain and sprockets. Be sure the chain is
wiped clean and is dry before applying the chain
(2)
lube.

• Check sprocket bolt and nut security.

• Clean the sides of the drive chain with a stiff,
nylon parts-cleaning brush. Lubricate and
adjust the chain as necessary.

Do not perform maintenance while engine is

running.
Injury to your fingers or hands may result.

• After adjustment, check that the chain adjuster (2) pressure release screws
index marks (1) are in the same position on
each side. This will ensure that the rear wheel
is in proper alignment and allow
maximum performance from the rear disc
brake. Maintaining proper wheel alignment
will also extend brake pad wear.

26 Servicing Your Honda

 Before & After Competition Maintenance
Routine Cleaning
If your CRF is only slightly dirty, it is best to
clean it by hand with the aid of a stiff bristled
nylon brush and some clean rags.

Take care to prevent catching your fingers

between the chain and sprocket.

A variety of reasonably priced cleaning brushes

are available from variety, drug, food, and
hardware stores. Some of these brushes are
extremely useful in removing dirt from the many
tight contours of the metal pieces of your CRF.
Avoid using stiff, abrasive brushes on the plastic
or rubber parts.

If your CRF was exposed to sea air or salt water,

rinse it as soon as possible after the event, dry it,
and apply a spray lubricant to all metal parts.

If you decide to wash your CRF or use cleaners,

refer to Appearance Care (page 93).

Servicing Your Honda 27

Maintenance Component Locations
hot start lever front brake fluid reserver

clutch lever front brake lever

throttle grip
radiator cap

fuel fill cap

rear suspension high speed

damping adjuster front suspension compression
air cleaner rear suspension low speed damping adjuster
crankcase breather tube damping adjuster

rear suspension spark plug

choke knob
spring pre-load adjuster

front brake caliper rear brake

caliper

transmission oil
engine oil drain bolt filler cap transmission oil
check bolt
transmission oil
engine oil filler cap/ drain bolt drive chain rear suspension front suspension rebound
dipstick engine idle speed rebound damping adjuster damping adjuster

28 Servicing Your Honda

 Seat Removal
Refer to Safety Precautions on page 19. Installation
1. Install the seat while aligning the front prong
Removal (3) with the seat braket (4) and rear prong (5)
1. Remove the seat bolts (1). with the tab (6) of the subframe.
2. Remove the seat (2) by sliding it backward. 2. Install and tighten the seat bolts to the
specified torque:
(2) 19 lbf·ft (26 N·m, 2.7 kgf·m)
(5)
(3)

(1)

(1) seat bolts (2) seat (4) (6)

(3) front prong

(4) seat bracket
(5) rear prong
(6) tab

Servicing Your Honda 29

Fuel Tank Removal
Refer to Safety Precautions on page 19. 5. Pull the breather tube (5) out of steering stem 8. Disconnect the fuel line (9) from the fuel
nut. valve. The fuel line leading to the
Removal 6. Unhook the fuel tank band (6) and air cleaner carburetor must be disconnected, not the fuel
1. Turn the fuel valve (1) OFF. cover rubber (7). line leading to the fuel tank.
7. Remove the fuel tank bolt (8). 9. Remove the fuel valve bolt (10) and fuel
valve.
10. Remove the fuel tank.
(5)

(8) WARNING
Gasoline is highly flammable and
(6)
explosive. You can be burned or
(7) seriously injured when handling fuel.
(1)
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
(1) fuel valve • Wipe up spills immediately.
(5) breather tube
2. Remove the seat (page 29). (6) fuel tank band (10)
3. Remove the shroud A bolts/collars (2). (7) air cleaner cover rubber
4. Remove the shroud B bolts (3) and shrouds (4). (8) fuel tank bolt

(4) (3)

(9)

(9) fuel line (10) fuel valve bolt

(2)

(2) shroud A bolts/collars

(3) shroud B bolts
(4) shroud

30 Servicing Your Honda

 Fuel Tank Removal
Installation 8. Install the shroud tab (8) onto the subframe
1. Install the fuel tank on the frame. (9).
2. Install the fuel valve (1) and tighten the bolt
(2). (8)
3. Connect the fuel line (3) to the fuel valve.
(2)

(1) (9)

(3) (8) shroud tab (9) sub-frame

9. Install the shrouds (10) and shroud B bolts

(11).
(1) fuel valve (2) fuel valve bolt
(3) fuel line
10. Install and tighten the shroud A bolts/collars
(12).
4. Install the collar and bolt (4), then tighten it. 11. Tighten the shroud B bolts to the specified
5. Hook the air cleaner cover rubber (5). torque:
6. Hook the fuel tank band (6). 3.7 lbf·ft (5 N·m, 0.5 kgf·m)
7. Put the breather tube (7) in the steering stem
nut. (11)
(10)
(4)
(7)

(5)

(6)

(12)

(10) shroud
(11) shroud B bolts
(12) shrouds A bolts/collars
(4) fuel tank bolt
(5) air cleaner cover rubber 12. Install the seat (page 29).
(6) fuel tank band
(7) breather tube

Servicing Your Honda 31

Subframe Removal
Refer to Safety Precautions on page 19. 4. Disconnect the crankcase breather tube (1). 8. Remove the subframe lower mounting bolts
5. Unhook the fuel tank band (2). (6) and upper mounting bolt (7). Then
Removal 6. Unhook the air cleaner cover rubber (3). removing the subframe (8) by pulling it
1. Remove the muffler (page 87). 7. Loosen the screw (4) on the air cleaner straight backward.
2. Remove the exhaust joint pipe (page 89). connecting tube clamp (5).
3. Remove the seat (page 29). (7)
(3)
(5)
(2)
(4)

(8)

(6)

(1)
(6) lower mounting bolts
(1) crankcase breather tube (7) upper mounting bolt
(2) fuel tank band (8) subframe
(3) air cleaner cover rubber
(4) screw
(5) air cleaner connecting tube clamp

32 Servicing Your Honda

 Subframe Removal
Installation 2. Tighten the screw (4) on the air cleaner 6. Install the seat (page 29).
1. Loosely attach the upper and lower ends of connecting tube clamp (5). 7. Install and tighten the exhaust joint pipe and
the subframe (1) to the mainframe while 3. Hook the air cleaner cover rubber (6). muffler (pages 88–89).
connecting the air cleaner connecting tube to 4. Hook the fuel tank band (7).
the carburetor. 5. Connect the crankcase breather tube (8).
Be careful not to bend the subframe.
Install the subframe upper mounting bolt (2) (6)
(5)
and lower mounting bolts (3). (7)
Tighten the upper mounting bolt and lower (4)
mounting bolts to each specified torque:
upper bolt: 22 lbf·ft (30 N·m, 3.1 kgf·m)
lower bolt: 36 lbf·ft (49 N·m, 5.0 kgf·m)

(2)

(8)

(4) screw
(1) (5) air cleaner connecting tube clamp
(6) air cleaner cover rubber
(7) fuel tank band
(8) crankcase breather tube
(3)

(1) subframe
(2) upper mounting bolt
(3) lower mounting bolts

Servicing Your Honda 33

Fuel System
Refer to Safety Precautions on page 19.
Refueling Procedure Fuel Valve and Hose
Fuel Recommendation Fuel Tank Capacity: 1.9 US gal (7.3 liter)
(3)
Type Unleaded (1)

Pump Octane Number 91 (or higher) (3)

(2)
We recommend that you use unleaded fuel
because it produces fewer engine deposits and
extends the life of exhaust system components.
(1)
Your engine is designed to use any gasoline that (2)
has a pump octane number of 91 or higher.
Gasoline pumps at service stations normally
display the pump octane number. For (3)
information on the use of oxygenated fuels, see (1) fuel fill cap (3) steering stem nut
(2) breather tube
page 146.
1. To open the fuel fill cap (1), pull the breather
Use of lower octane gasoline can cause persistent
tube (2) out of the steering stem nut (3). Turn
“pinging” or “spark knock” (a louder rapping
the fuel fill cap counterclockwise and remove
noise) which, if severe, can lead to engine
it.
damage. (Light pinging experienced while
2. Add fuel until the level reaches the bottom of
operating under a heavy load, such as climbing a
the filler neck. Avoid overfilling the tank.
hill, is no cause for concern.)
There should be no fuel in the filler neck.
3. Close the fuel fill cap and insert the breather
If pinging or spark knock occurs at a steady
tube in the steering stem nut. (1) fuel valve (3) fuel line
engine speed under normal load, change brands (2) fuel filter
of gasoline. If pinging or spark knock persists,
consult your Honda dealer. WARNING 1. Check the fuel valve (1) and fuel filter (2) for
Gasoline is highly flammable and contamination.
Never use stale or contaminated gasoline. Avoid explosive. You can be burned or 2. Check for leaks.
getting dirt, dust or water in the fuel tank. seriously injured when handling fuel. 3. Check the fuel line (3) for cracks,
deterioration, damage or leakage. Replace the
• Stop the engine and keep heat, sparks fuel line, if necessary.
and flame away. 4. Check for interference between the frame and
• Handle fuel only outdoors. fuel tank and adjust if necessary.
• Wipe up spills immediately.

34 Servicing Your Honda

 Fuel System
Fuel Filter

The fuel filter is mounted on the bottom left side

of the fuel tank. Dirt accumulated in the filter
will restrict the flow of the fuel to the carburetor.

To service the fuel filter:

1. Drain the fuel from the fuel tank into an
approved gasoline container.
2. Remove the fuel tank (page 30).
3. Remove the fuel joint (1) from the fuel tank
by removing the bolts (2). Wash the fuel filter
(3) in high flash-point cleaning solvent.
4. Reassemble the fuel filter in the reverse order
of removal. Make sure the O-ring (4) is in
good condition and install it onto the fuel
joint.
5. Install the fuel joint in the fuel tank.
6. Install the fuel tank (page 31) and refill the
fuel.
Turn the fuel valve to ON; check for leaks.

(4)

(3)

(1)

(2)

(1) fuel joint (3) fuel filter

(2) bolts (4) O-ring

Servicing Your Honda 35

Engine Oil
Refer to Safety Precautions on page 19. • Your CRF does not need oil additives.
Oil Recommendation Use the recommended oil.
Using the proper oil, and regularly checking, • Do not use API SH or higher 4-stroke engine
adding, and changing oil will help extend the API SG or higher except oils oils displaying a circular API “energy
service life of the engine. Even the best oil wears classification labeled as energy conserving conserving” service label on the container. They
out. Changing oil helps get rid of dirt and on the circular API service may affect lubrication.
deposits. Operating the engine with old or dirty label
oil can damage your engine. Running the engine viscosity SAE 10W–40
with insufficient oil can cause serious damage to (weight)
the engine. JASO T 903 MA or MB
suggested oil* Pro Honda GN4, HP4 NOT RECOMMENDED OK
(without molybdenum
additives) or HP4M (with Other viscosities shown in the following chart
molybdenum additives)
4-stroke oil or an equivalent* may be used when the average temperature in
your riding area is within the indicated range.
* Suggested 4-stroke engine oils are equal
performance to SJ oils that are not labeled as
energy conserving on the circular API service
label.

36 Servicing Your Honda

 Engine Oil
JASO T 903 standard
The JASO T 903 standard is an index for engine Checking & Adding Oil Changing Engine Oil & Filter
oils for 4-stroke motorcycle engines.
There are two classes: MA and MB. 1. Run the engine at idle for 3 minutes, then shut
Oil conforming to the standard is labeled on the it off.
oil container. For example, the following label (1) 2. Support the CRF in an upright position on a
shows the MA classification. level surface.
(2)
3. Remove the engine oil filler cap/dipstick (1)
(1)
from the left crankcase cover.
4. Place an oil drain pan under the engine to
catch the oil. Then remove the engine oil
drain bolt (2) and sealing washer (3).
(2) 5. With the engine stop button pushed, repeat
(3) (1) kickstarter operation approximately 5 times to
drain the engine oil completely.
(1) engine oil filler cap/dipstick 6. After the oil has drained, apply flesh engine
(2) upper level mark oil to the engine oil drain bolt threads.
(1) code number of the sales company of the oil (3) lower level mark 7. Install and tighten the engine oil drain bolt
(2) oil classification with a new sealing washer to the specified
1. Run the engine at idle for 3 minutes, then shut torque:
it off. 16 lbf·ft (22 N·m, 2.2 kgf·m)
2. Wait 3 minutes after shutting off the engine to
allow the oil to properly distribute itself in the (1)
engine. (3)
3. Support the CRF in an upright position on a
level surface.
4. Remove the engine oil filler cap/dipstick (1),
wipe it clean, and insert the engine oil filler
cap/dipstick without screwing it in. Remove
the oil filler cap/dipstick.
5. Check that the oil level is between the upper
(2) and lower (3) level marks on the engine
oil filler cap/dipstick. (2)
• If the oil is at or near the upper level mark,
you do not have to add oil. (1) engine oil filler cap/dipstick
(2) engine oil drain bolt
• If the oil is below or near the lower level (3) sealing washer
mark and add the recommended oil until
the upper level mark. (Do not overfill) 8. It is recommended to replace the oil and filter
Reinstall the engine oil filler cap/dipstick. every 6 races or about every 15.0 hours.
Repeat steps 1–5. However, if you replace only the oil before
6. Reinsert the engine oil filler cap/dipstick. the recommended interval, see page 21.
7. Check for oil leaks. (cont’d)

Servicing Your Honda 37

 Engine Oil
9. Remove the left engine guard bolt (4) and left 13.Apply grease to the filter side of the spring
engine guard (5). end, then install the spring (10) into the new
oil filter.
(5) 14.Position the spring against the engine
crankcase and install a new oil filter with the
rubber seal (11) facing out, away from the
engine. You should see the “OUT-SIDE” mark
(12) on the filter body, near the seal.
Use a new genuine Honda oil filter or a filter
of equal quality specified for your model.

NOTICE
(4)
If the oil filter is not installed properly, it will
cause serious engine damage.
(4) left engine guard bolt
(5) left engine guard
15.Apply engine oil to a new O-ring and install it
10. Remove the oil filter cover bolts (6) and oil to the oil filter cover.
filter cover (7). 16.Install the oil filter cover being careful not to
11. Remove the oil filter (8) from the oil filter cover. damage the O-ring, then tighten the oil filter
12. Check that the oil filter cover O-ring (9) is in cover bolts to the specified forque:
good condition. 9 lbf·ft (12 N·m, 1.2 kgf·m)
17.Install the left engine guard and bolt, then
tighten it.
18.Fill the crankcase with the recommended oil.
(8) Capacity: 0.73 US qt (0.69R)
at oil and filter change
(11) 0.70 US qt (0.66R)
(7) at oil change
19.Install the engine oil filler cap/dipstick.
20.Check the engine oil level by following the
steps in Checking & Adding oil (page 37).
(10)

(12)
(9)
(6)
(6) oil filter cover bolts
(7) oil filter cover
(8) oil filter
(9) oil filter cover O-ring
(10) spring
(11) rubber seal
(12) “OUT-SIDE” mark

38 Servicing Your Honda

 Transmission Oil
Refer to Safety Precautions on page 19. • Your CRF does not need oil additives. Use the
Oil Recommendation recommended oil.
Using the proper oil, and regularly checking, • Do not use oils with graphite or molybdenum
adding, and changing oil will help extend the type transmission oil or 4-stroke additives. They may adversely affect clutch
service life of the transmission and clutch. Even engine oil operation.
the best oil wears out. Changing oil helps get rid • Do not use API SH or higher 4-stroke engine
API classification SG or higher except oils
of dirt and deposits. Operating the engine with (4-stroke engine oil labeled as energy
oils displaying a circular API “energy
old or dirty oil can damage your engine. only) conserving on the circular conserving” service label on the container. They
Running the engine with insufficient oil can API service label may affect lubrication and clutch performance.
cause serious damage to the engine and
Viscosity SAE 10W–40
transmission. (weight)

JASO T903 MA
standard

others without friction modifiers as NOT RECOMMENDED OK

molybdenum additives
Other viscosities shown in the following chart
suggested oil* Pro Honda HP Trans oil,
Pro Honda GN4 or HP4 may be used when the average temperature in
(without molybdenum your riding area is within the indicated range.
additives) 4-stroke engine
oil or an equivalent*

* Suggested 4-stroke engine oils are equal

performance to SJ oils that are not labeled as
energy conserving on the circular API service
label.

(cont’d)

Servicing Your Honda 39

Transmission Oil
JASO T 903 standard
The JASO T 903 standard is an index for engine Checking & Adding Oil Replacing Transmission Oil
oils for 4-stroke motorcycle engines.
There are two classes: MA and MB. 1. Run the engine at idle for 3 minutes, then shut
Oil conforming to the standard is labeled on the it off.
oil container. For example, the following label (3) 2. Support the CRF in an upright position on a
shows the MA classification. level surface.
3. Remove the transmission oil filler cap (1)
(1) from the right crankcase cover.
4. Place an oil drain pan under the engine to
catch the oil. Then remove the transmission
oil drain bolt (2) and sealing washer (3).
(1) (2)
(2) 5. After the oil has drained, apply flesh engine
oil to the transmission oil drain bolt threads.
6. Install and tighten the transmission oil drain
(1) transmission oil filler cap (3) sealing washer bolt with a new sealing washer to the
(2) oil check bolt specified torque:
16 lbf·ft (22 N·m, 2.2 kgf·m)
(1) code number of the sales company of the oil 1. Run the engine at idle for 3 minutes, then shut
it off. 7. Fill the crankcase with recommended oil.
(2) oil classification Capacity: 0.63 US qt (0.60R) at oil change
2. Wait 3 minutes after shutting off the engine to
allow the oil to properly distribute itself in the 8. Check the transmission oil level by following
clutch and transmission. the steps in checking & Adding Oil (this
3. Support the CRF in an upright position on a page).
level surface.
4. Remove the transmission oil filler cap (1), oil
check bolt (2) and sealing washer (3) from the
right crankcase cover. A small amount of oil
should flow out of the oil check bolt hole.
Allow any excess oil to flow out of the oil
check bolt hole.
If no oil flows out of the oil check bolt hole,
add oil slowly through the transmission oil
filler hole until oil start to flow out of the oil (2)
check bolt hole. (3)
Install the oil check bolt with a new sealing (1)
washer and transmission oil filler cap. Repeat
step 1–4. (1) transmission oil filler cap
5. After inspection the oil level or adding oil, (2) transmission oil drain bolt
(3) sealing washer
tighten the oil check bolt to the specified
torque:
Oil Check Bolt: 7 lbf·ft (10 N·m, 1.0 kgf·m)
6. Install the transmission oil filler cap securely.

40 Servicing Your Honda

 Coolant
Your CRF’s liquid cooling system dissipates Increasing the concentration of antifreeze is not
engine heat through the coolant jacket that recommended because it decreases cooling WARNING
surrounds the cylinder and cylinder head. system performance. Higher concentrations of Removing the radiator cap while the
antifreeze (up to 60%) should only be used to engine is hot can allow the coolant to
Maintaining the coolant will allow the cooling provide additional protection against freezing. spray out, seriously scalding you.
system to work properly and prevent freezing, Check the cooling system frequently during
overheating, and corrosion. freezing weather. Always let the engine and radiator cool
down before removing the radiator cap.

Coolant Recommendation Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is
low.
Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing.
quality ethylene glycol antifreeze containing A coolant loss of 0.7 - 2.0 US oz (20 - 60
corrosion protection inhibitors specifically 1. With the engine cold, remove the radiator cap cm3) through the over flow tube is normal. If
recommended for use in aluminum engines. (1) and check coolant level. The coolant level coolant loss is more than this, inspect the
Check the antifreeze container label. is correct when it is at the bottom of the cooling system.
radiator filler neck (2). Capacity:
Use only distilled water as a part of the coolant 1.06 US qt (1.00R) at disassembly
solution. Water that is high in mineral content or 0.98 US qt (0.93R) at coolant change
(1)
salt may be harmful to the aluminum engine. 3. Install the radiator cap securely.

NOTICE NOTICE
Using coolant with silicate inhibitors may cause If the radiator cap is not installed properly, it
premature wear of radiator pump seals or (2) will cause excessive coolant loss and may result
blockage of radiator passages. Using tap water in overheating and engine damage.
may cause engine damage.

The factory provides a 50/50 solution of

antifreeze and water in this motorcycle. This
coolant solution is recommended for most (1) radiator cap
operating temperatures and provides good (2) filler neck
corrosion protection.

Decreasing the concentration of antifreeze to less

than 40% will not provide proper corrosion
protection.

Servicing Your Honda 41

Coolant
Cooling System Inspection (1) (2) Coolant Replacement

1. Check the cooling system for leaks (see the Refer to Safety Precautions on page 19.
Honda Service Manual for troubleshooting of
leaks). Coolant should be replaced by your Honda
2. Check the water hoses (1) for cracks, dealer, unless you have the proper tools and
deterioration, and clamp bands for looseness. service data and are mechanically qualified.
3. Check the radiator mount for looseness. Refer to the Honda Service Manual
4. Make sure the overflow tube (2) is connected (page 154).
and not clogged.
5. Check the radiator fins for clogging.
6. Check the water leakage check hole (3) below
WARNING
the water pump cover (4) for leakage. Make Removing the radiator cap while the
sure the hole remains open. If water leaks engine is hot can allow the coolant to
through the check hole, the water pump seal is spray out, seriously scalding you.
damaged. If oil leaks through the check hole,
the engine oil seal is damaged. See the Always let the engine and radiator cool
Honda Service Manual or consult your Honda down before removing the radiator cap.
dealer for replacing the water pump seal or
the engine oil seal. Both seals should be
replaced at the same time. To properly dispose of drained coolant, refer to
You & the Environment, page 136.

NOTICE
Improper disposal of drained fluids is harmful to
the environment.

(3)
(4)

(1) water hoses

(2) overflow tube
(3) water leakage check hole
(4) water pump cover

42 Servicing Your Honda

 Air Cleaner
Refer to Safety Precautions on page 19. 5. Remove the air cleaner element (5) from the
Cleaning air cleaner holder (6).
The air cleaner uses polyurethane inner and outer
pieces which can’t be separated. 1. Remove the seat (page 29). (8) (7)
A dirty air cleaner will reduce engine power. (5)
2. Remove the air cleaner retaining bolt (1).
3. Align the two access top tabs (2) of the air
Proper air cleaner maintenance is very important cleaner assembly (3) and “∆” mark (4) of the
for off-road vehicles. A dirty, water-soaked, air cleaner housing by rotating the air cleaner
worn-out, or defective air cleaner will allow dirt, assembly counterclockwise.
dust, mud, and other impurities to pass into the
engine. (4) (1) (9)

Service the air cleaner more frequently if you

ride in unusually wet or dusty areas. Your Honda
dealer can help you determine the correct service
interval for your riding conditions. (6)
(5) air cleaner element (8) hole
Your CRF’s air cleaner has very specific (6) air cleaner holder (9) air cleaner tab
performance requirements. Use a new genuine (7) holder tab
Honda air cleaner specified for your model or an
air cleaner of equal quality. (2) (3) 6. Wash the air cleaner element in clean non-
flammable cleaning solvent. Then wash in
Proper air cleaner maintenance can prevent (1) air cleaner retaining bolt hot, soapy water, rinse well, and allow to dry
premature engine wear or damage, expensive (2) two access top tabs thoroughly.
repairs, low engine power, poor gas mileage, and (3) air cleaner assembly The air cleaner is made in two pieces: inner
(4) “∆” mark and outer, which cannot be separated.
spark plug fouling.
7. Clean the inside of the air cleaner housing.
4. Remove the air cleaner keeping the two 8. Allow the air cleaner element to dry
NOTICE access top tabs up. thoroughly. After drying, soak the air cleaner
Improper or lack of proper air cleaner in clean Pro Honda Foam Filter Oil or an
maintenance can cause poor performance and equivalent air cleaner oil.
premature engine wear. Apply air cleaner oil to the entire surface,
inner and outer, and rub it with both hands to
saturate the air cleaner with oil. Squeeze out
excess oil.
9. Apply a thin coat of Honda White Lithium
Grease to the sealing surface.
10. Assemble the air cleaner element and holder.
Install the holder tab (7) of the holder in the
hole (8) of the air cleaner tab (9).

(cont’d)

Servicing Your Honda 43

Air Cleaner
11.Install the assembly into the air cleaner NOTICE
housing keeping the two access top tabs (2)
up. Improper installation of the air cleaner assembly
12.Carefully position the sealing flange of the may allow dirt and dust to enter the engine and
element to prevent dirt intrusion. cause rapid wear of the piston rings and cylinder.
13.Align the groove (10) of the air cleaner
assembly with the “∆” mark (4) of the air 14.Reinstall the seat (page 29), making sure it is
cleaner housing by rotating the air cleaner securely attached.
assembly clockwise. Install and tighten the
retaining bolt (1) securely.
(10) (1)
(2) (4)

(3)
(1) air cleaner retaining bolt
(2) two access top tabs
(3) air cleaner assembly
(4) “∆” mark
(10) groove

44 Servicing Your Honda

 Crankcase Breather
Refer to Safety Precautions on page 19.

Service more frequently if your CRF is ridden in

the rain or often at full throttle.
Service the breather if you can see deposits in the
transparent section of the drain tube.

Draining

1. Remove the crankcase breather tube plug (1)

from the tube (2) and drain deposits into a
suitable container.
2. Reinstall the crankcase breather tube plug.

(1)

(2)

(1) crankcase breather tube plug

(2) tube

Servicing Your Honda 45

Throttle
Refer to Safety Precautions on page 19. 1. Pull the dust cover (2) back. Lower Adjustment
2. Loosen the upper lock nut (3). The lower adjuster is used for major freeplay
3. Turn the upper adjuster (4). adjustment, such as after replacing the throttle
Throttle Freeplay Turning the adjuster in direction (–) will cables or removing the carburetor. It is also used
decrease freeplay and turning it in direction if you can not get the proper adjustment with the
(1) (+) will increase freeplay. upper adjuster.
4. Tighten the lock nut. Return the dust cover to
its normal position.
5. After adjustment, check for smooth rotation of
the throttle grip from fully closed to fully
open in all steering positions. (–)
If the adjuster is threaded out near its limit or
the correct freeplay cannot be reached, turn
the adjuster all the way in and back out one
(1) freeplay turn. Tighten the lock nut, install the dust (5)
cover and make the adjustment with the
Inspection (+) (6)
lower adjuster.
Check freeplay (1).
Freeplay: 1/8 - 3/16 in (3 - 5 mm)
If necessary, adjust to the specified range. (5) lock nut (+) increase
(6) adjuster (–) decrease
Upper Adjustment
1. Remove the fuel tank (page 30).
Minor adjustments are generally made with the
2. loosen the lock nut (5).
upper adjuster.
3. Turn the adjuster (6) in direction (–) to
decrease freeplay, and in direction (+) to
(2) (3) increase freeplay.
(+) 4. Tighten the lock nut.
5. Operate the throttle grip to ensure that it
functions smoothly and returns completely.
6. Install the fuel tank (page 31).

If you can’t get the freeplay within the specified

(–) range, contact your Honda dealer.

(4)

(2) dust cover (+) increase

(3) lock nut (–) decrease
(4) upper adjuster

46 Servicing Your Honda

 Throttle
Throttle Inspection

(1)

(1) throttle

1. Check that the throttle assembly is positioned

properly and the securing bolts are tight.
2. Check for smooth rotation of the throttle (1)
from fully open to fully closed in all steering
positions. If there is a problem, see your
Honda dealer.
3. Inspect the condition of the throttle cables
from the throttle grip down to the carburetor.
If the cable is kinked or chafed, have it
replaced.
4. Check the cables for tension or stress in all
steering positions.
5. Lubricate the cables with a commercially-
available cable lubricant to prevent premature
rust and corrosion.

Servicing Your Honda 47

Engine Idle Speed
Refer to Safety Precautions on page 19.
Idle Speed Adjustment
The best way to assure proper carburetion is to
see your Honda dealer for regularly scheduled 1. Turn the pilot screw (1) in until it is lightly
servicing, including carburetor adjustment. seated and record the number of turns. Turn
the pilot screw out the same number of turns.
Remember, idle speed adjustment is not a 2. If the engine is cold, start it and warm it up
“cure-all” for other problems in your engine’s three minutes and then shut it off.
fuel-delivery system. Adjusting the idle will not 3. Connect a tachometer to the engine.
compensate for a fault elsewhere. 4. Shift into neutral and start the engine.
5. Keep the motorcycle in an upright position.
The engine must be at normal operating 6. Adjust idle speed with the throttle stop screw
temperature for accurate idle speed adjustment. (2).
Idle speed:
For information about high altitude carburetor 1,700 ± 100 rpm
adjustment, see page 145.
(2)

(1)

(1) pilot screw

(2) throttle stop screw

48 Servicing Your Honda

 Clutch System
Refer to Safety Precautions on page 19. 4. Turn the cable end adjuster (3) in direction (+)
until it seats lightly and then turn it out 5 Clutch Lever Freeplay
turns.
Clutch Lever Adjustment (1)

The distance between the tip of the clutch lever (–)

and grip may be adjusted.

Make sure to adjust the clutch lever freeplay after

the clutch lever position adjustment or clutch
cable disconnected. (+)
(3)

(1) (1) clutch lever

(3) cable end adjuster
(+) increase freeplay Inspection
(–) decrease freeplay
Check freeplay.
5. Loosen the lock nut (4) and turn the integral Freeplay: 3/8 – 13/16 in (10 – 20 mm)
cable adjuster (5) to adjust the clutch lever
freeplay 3/8 – 13/16 in (10-20 mm) at the tip If necessary, adjust to the specified range.
(2) of lever. Tighten the lock nut. Improper freeplay adjustment can cause
premature clutch wear.
(1) lock nut (2) adjuster
(5)
1. Loosen the lock nut (1). (–)
2. To position the clutch lever farther away from
the handgrip, turn the adjuster (2)
counterclockwise. To position the brake lever
closer to the handgrip, turn the adjuster (+)
clockwise. (4)
3. Tighten the lock nut.
(4) lock nut
(5) integral cable adjuster
(+) increase freeplay
(–) decrease freeplay

6. Adjust the cable end adjuster for minor

adjustement.

(cont’d)

Servicing Your Honda 49

Clutch System
Cable End Adjustment Integral Cable Adjustment
Minor adjustments are generally made with the The integral cable adjuster is used if the cable Other Inspections & Lubrication
clutch cable end adjuster. end adjuster is threaded out near its limit — or
the correct freeplay cannot be obtained. • Check that the clutch lever assembly is
(–)
positioned properly and the securing bolts are
(4) tight.
(–)
• Check the clutch cable for kinks or signs of
wear. If necessary, have it replaced.
• Lubricate the clutch cable with a
commercially-available cable lubricant to
(2) (+) prevent premature wear and corrosion.
(+)
(3)
(2) cable end adjuster
(3) lock nut (+) increase
Clutch Operation
(+) increase freeplay
(–) decrease freeplay (4) integral cable adjuster (–) decrease
1. Check for smooth clutch lever operation. If
Turning the cable end adjuster (2) in direction (+) 1. Turn the cable end adjuster in direction (+) necessary, lubricate the clutch lever pivot or
will increase freeplay and turning it in direction seats lightly and then turn it out 5 turns. clutch cable.
(–) will decrease freeplay. 2. Loosen the lock nut (3). 2. Check the clutch cable for deterioration,
3. Turn the integral cable adjuster (4) to obtain kinks, or damage.
If the adjuster is threaded out near its limit or the the specified freeplay.
correct freeplay cannot be reached, turn the 4. Tighten the lock nut. Check the adjustment.
adjuster all the way in direction (+) and back out 5. Start the engine, pull the clutch lever in, and
one turn in direction (–) and make the adjustment shift into gear. Make sure the engine does not
with the integral cable adjuster. stall and the motorcycle does not creep.
Gradually release the clutch lever and open
the throttle. Your CRF should move smoothly
and accelerate gradually.

If you can’t get proper adjustment, or the clutch

does not work properly, the cable may be kinked
or worn, or the clutch discs may be worn. See
your Honda dealer or refer to the Honda Service
Manual (page 154).

50 Servicing Your Honda

 Clutch System
5. Remove the clutch pressure plate (8).
Clutch Cover/Disc/Plate Removal Clutch Disc/Plate Inspection
(8)
1. Drain the transmission oil (page 40). Replace the clutch discs (1) if they show signs of
2. Remove the rear brake pedal (1) by removing scoring or discoloration.
its pivot bolt (2), washer (3) and dust seals (4). Measure the thickness of each clutch disc.
Service Limit: 0.112 in (2.85 mm)
(4) (3)
Replace the clutch discs and clutch plates as an
assembly.
(7)
(1)

(7) clutch spring bolts/springs

(8) clutch pressure plate

(2) 6. Remove the clutch lifter (9) and clutch lifter

(1) rod (10).
(1) rear brake pedal (3) washer 7. Remove the eight clutch discs and seven (1) clutch disc
(2) pivot bolt (4) dust seals clutch plates (11).
Turn the lifter bearing plate of the clutch lifter Check the clutch plate (2) for excessive warpage
3. Remove the five clutch cover bolts (5) and bearing with your finger. The bearing plate or discoloration. Check the plate warpage on a
clutch cover (6). should turn smoothly and quietly. Discard the surface plate using a feeler gauge.
clutch lifter if the bearing plate does not turn Measure the thickness of the clutch plates.
smoothly. Service Limit: 0.004 in (0.10 mm)
(6)

(11)
Replace the clutch discs and plates as a set.
(9)

(2)

(5)

(5) clutch cover bolts (6) clutch cover (10)

4. Remove the five clutch spring bolts and clutch (9) clutch lifter (11) clutch discs and plates
springs (7). (10) clutch lifter rod (2) clutch plate
Loosen the bolts in a crisscross pattern in 2 or 3
progressive steps. (cont’d)

Servicing Your Honda 51

Clutch System
7. Install the clutch pressure plate (5).
Clutch Spring Inspection Clutch Disc/Plate Installation 8. Install the five clutch springs and bolts (6).
9. Tighten the bolts in a crisscross pattern in 2 or
1. Coat the clutch discs (1) and clutch plates (2) 3 steps, to the specified torque:
with clean transmission oil. 9 lbf·ft (12 N·m, 1.2 kgf·m)
2. Install the eight clutch discs and seven clutch
(1) plates alternately, starting with a clutch disc. (5)

(1) clutch spring

(1) (2)
Measure the free length of each spring. (6)
Service Limit: 1.46 in (37.2 mm)

If one or more springs are beyond the service

(5) clutch pressure plate
limit, replace the springs as a set. (6) clutch spring bolts/springs

Replace the clutch discs, clutch plates and clutch 10. Apply transmission oil to a new O-ring (7)
springs as a set if the clutch plates have been and install in the groove of the clutch cover
(1) clutch discs (2) clutch plates
burnt/heat discolored. (8).
3. Apply grease to the clutch lifter rod (3). 11. Install the cover by tightening the five cover
4. Insert the clutch lifter rod into the mainshaft. bolts to the specified torque:
5. Apply engine oil to the needle bearing of the 7 lbf·ft (10 N·m, 1.0 kgf·m)
clutch lifter.
6. Install the clutch lifter (4) onto the rod. (7)
(8)

(3)

(4) (7) O-ring (8) clutch cover

(3) clutch lifter rod (4) clutch lifter

52 Servicing Your Honda

 Clutch System
12. Lubricate the dust seals (9), rear brake pedal
(10) pivot and pivot bolt (11) with Honda
Lithium Grease or equivalent.
13. Install the dust seals, washer (12) and pivot
bolt and tighten the pivot bolt to the specified
torque:
27 lbf·ft (36 N·m, 3.7 kgf·m)

Connect the brake pedal return spring (13) if

it was removed.

(9) (12)

(11)
(13) (10)

(9) dust seals (12) washer

(10) rear brake pedal (13) return spring
(11) pivot bolt

14. Fill the crankcase with transmission oil (page

40).

Servicing Your Honda 53

Hot Start Lever
Refer to Safety Precautions on page 19. Adjustment
Adjustments can be made with the cable end
adjuster.
Hot Start Lever Freeplay
Loosen the lock nut (3) and turn the adjuster (4).
Turning the adjuster clockwise (+) will increase
freeplay and turning it counterclockwise (–) will
decrease freeplay. After adjustment, tighten the
lock nut.

(3)

(1) (2)
(+)
(1) hot start lever
(2) hot start lever freeplay

(–)
Inspection (4)
Check freeplay:
1/16 – 1/8 in (2 – 3 mm) (3) lock nut (+) increase
If necessary, adjust to the specified range. (4) adjuster (–) decrease

54 Servicing Your Honda

 Spark Plug
Refer to Safety Precautions on page 19. 7. To obtain accurate spark plug readings,
Spark Plug Replacement & Inspection accelerate up to speed on a straightaway. Push
the engine stop button and disengage the
Spark Plug Recommendation 1. Remove the seat and fuel tank (pages 29,30). clutch by pulling the lever in.
2. Disconnect the direct ignition coil (1). Coast to a stop, then remove and inspect the
The recommended standard spark plug is 3. Clean any dirt from around the spark plug bases. spark plug. The porcelain insulator around the
satisfactory for most racing conditions. 4. Remove the spark plug (2). center electrode should appear tan or medium
gray.
Standard R0409B-8 (NGK)
(2) If you're using a new plug, ride for at least ten
Optional R0409B-9 (NGK) minutes before taking a plug reading; a brand-new
plug will not appers color initially.

Use only the recommended type of spark plugs in If the electrodes appear burnt, or the insulator is
the recommended heat range. white or light gray (lean) or the electrodes and
insulator are black or fouled (rich), there is a
NOTICE problem elsewhere (page 128).
Check the carburetor, fuel system and ignition
Using a spark plug with an improper heat range (1) timing.
or incorrect reach can cause engine damage.
(1) direct ignition coil
Using a non-resistor spark plug may cause (2) spark plug 8. With the sealing gasket attached. Thread the
ignition problems. spark plug in by hand to prevent cross-
5. Check the electrode for wear or deposits, the threading.
This motorcycle uses a spark plug that has an sealing gasket (3) for damage, and the 9. Tighten the spark plug:
iridium tip in the center electrode and a platinum insulator for cracks. Replace if you detect • If the old plug is good:
tip in the side the electrode . them. 1/8 turn after it seats.
Be sure to observe the following when servicing 6. Check the spark plug gap (4), using a wire-type • If installing a new plug, tighten it twice to
the spark plug. feeler gauge. If the gap is out of specifications, prevent loosening:
• Do not clean the spark plug. If an electrode is replace the plug with a new one. a) First, tighten the plug:
contaminated with accumulated objects or The recommended spark plug gap is: NGK: 1/2 turn after it seats.
dirt, replace the spark plug with a new one. 0.024 – 0.028 in (0.6 – 0.7 mm) b) Then loosen the plug.
• Use only a “wire-type feeler gauge” to check c) Next, tighten the plug again:
the spark plug if necessary. To prevent (4) 1/8 turn after it seats.
damaging the iridium tip of the center 10. Connect the direct ignition coil.
electrode and platinum tip of the side 11. Install the fuel tank and seat (page 31).
electrode, never use a “leaf-type feeler (3)
gauge’’.
• Do not adjust the spark plug gap. If the gap is
out of specification, replace the spark plug
with a new one.
(3) sealing gasket
(4) spark plug gap

Servicing Your Honda 55

Valve Clearance
Refer to Safety Precautions on page 19.
Cylinder Head Cover Removal Positioning At Top Dead Center On The
Excessive valve clearance will cause noise and Compression Stroke
eventual engine damage. Little or no clearance Before inspection, clean the engine thoroughly to
will prevent the valve from closing and cause keep dirt from entering the engine. 1. Remove the crankshaft hole cap (1).
valve damage and power loss. Check the valve
clearance when the engine is cold at the intervals 1. Remove the seat and fuel tank (page 29).
specified in the Maintenance Schedule. 2. Disconnect the breather tube (1) and direct
ignition coil (2).
The checking or adjusting of the clearance should
be performed while the engine is cold. (2)
The valve clearance will change as engine
temperature rises.

(1)

(1) crankshaft hole cap

(1) 2. Remove the spark plug (page 55).

(1) breather tube (2) direct ignition coil

3. Remove the cylinder head cover bolts (3), and

cylinder head cover (4).

(3)
(4)

(3) cylinder head cover bolts

(4) cylinder head cover

4. Remove the plug hole packing.

56 Servicing Your Honda

 Valve Clearance
3. Rotate the crankshaft by turning the primary 2. Measure the exhaust valve clearance by
drive gear bolt (3) (crankshaft) clockwise until Valve Clearance Inspection inserting a feeler gauge (1) between the
aligning the “punch” mark (4) on the primary exhaust rocker arm (4) and shim (5).
drive gear with the index mark (5) on the right 1. Measure the intake valve clearance by
crankcase cover. In this position, the piston may inserting a feeler gauge (1) between the valve
either be on the compression or exhaust stroke. (4)
lifters (2) and intake cam lobe (3). (5)
If the crankshaft passed the “punch” mark,
rotate the primary drive gear bolt clockwise (1)
again and align the “punch” mark with the
index mark.
The inspection must be made when the piston
is at the top of the compression stroke when
both the intake and exhaust valves are closed.
(2)
This condition can be determined by moving
the exhaust rocker arm (6). If it is free, it is an
indication that the valves are closed and that (1)
the piston is on the compression stroke. If it is
tight and the valves are open, rotate the (1) feeler gauge
primary drive gear lock bolt 360° and realign (3)
(4) exhaust rocker arm
the “punch” mark to the index mark. (5) exhaust valve shim
(1) feeler gauge
(5) (2) valve lifters Valve Clearances:
(3) IN: 0.005 ± 0.001 in (0.12 ± 0.03 mm)
(3) intake cam lobe
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm)

If intake valve clearance and exhaust valve

clearance need adjustment, see Camshaft
Removal (page 58) and select the correct shim for
each valve.
(4)
(3) primary drive gear lock bolt (5) index mark
(4) “punch” mark

(6)

(6) exhaust rocker arm

Servicing Your Honda 57

Valve Clearance
2. Remove the cam chain tensioner lifter cover Use the tensioner stopper tool.
Camshaft Removal bolt (1) and sealing washer (2). • Tensioner stopper 070MG-0010100

1. Record the intake valve clearance and exhaust 3. Turn the tensioner shaft clockwise with the
valve clearance. (1)
stopper tool (3) until it stops, in order to
retract the tensioner fully.
Then insert the stopper tool fully to hold the
stopper in the fully retracted position.

(3)

(2)

(1) cam chain tensioner lifter cover bolt

(2) sealing washer

(3)

(3) stopper tool

58 Servicing Your Honda

 Valve Clearance
4. Remove the camshaft holder bolts (4) and 6. Remove the valve lifters (7). 7. Remove the shims (8).
camshaft holders (5).
Loosen the camshaft holder bolts in a Position the removed intake valve lifters and
crisscross pattern in 2 or 3 steps. shims to indicate their location such as intake or (8)
exhaust, right or left.
5. Remove the camshaft (6), and then attach a
piece of wire to the cam chain to prevent it NOTICE
from falling into the crankcase.
Do not let the valve lifters and shims fall into the
Be careful to not let the set rings of the camshaft crankcase.
holders fall into the crankcase.
(4) (5)

(7) (8) shims

(6)

(4)
(7) valve lifters
(4) camshaft holder bolts (6) camshaft
(5) camshaft holders

Servicing Your Honda 59

Valve Clearance
3. Calculate the new shim thickness using the
Shim Selection equation below.

1. Clean the valve shim contact area in the valve A = (B – C) + D

lifter (1) with compressed air.
A: New shim thickness
B: Recorded valve clearance
(1) C: Specified valve clearance
D: Old shim thickness

• Make sure of the correct shim thickness by

measuring the shim with the micrometer.
• Reface the intake valve seat if carbon deposits
result in a calculated dimension of over 2.450
mm.
Reface the exhaust valve seat if carbon
deposits result in a calculated dimension of
over 2.900 mm.
(1) valve lifter

2. Measure the shim thickness and record it.

Sixty-nine different thickness shims (2) are
available from the thinnest (1.200 mm
thickness) shim to the thickest (2.900 mm
thickness) in intervals of 0.025 mm.

(2)

(2) shim

60 Servicing Your Honda

 Valve Clearance
2. Apply molybdenum disulfide oil (a mixture of 5. Place the cam sprocket (7) and align the
Camshaft Installation 1/2 engine oil and 1/2 molybdenum disulfide timing mark (8) on the cam sprocket with the
grease (containing more than 3% surface of the cylinder head (9).
1. Install the newly selected shims (1) on the molybdenum disulfide additive)) to the Install the cam chain (10) over the sprocket
valve retainers (2). surface of the cam and outer surface of the without rotating the sprocket.
each the valve lifters (3).
NOTICE 3. Install the valve lifters and camshaft into the
(10) (7)
cylinder head.
Do not let the shims fall into the crankcase.

(8)
(1)
(3) (9)

(2)

(2) (7) cam sprocket

(8) timing mark
(9) surface of the cylinder head
(3) valve lifters (10) cam chain

(1) shims (2) valve retainers 4. Rotate the primary drive gear lock bolt (4)
(crankshaft) clockwise and align the “punch”
mark (5) with the index mark (6).

(4) (5) (6)

(4) primary drive gear lock bolt

(5) “punch” mark
(6) index mark
(cont’d)

Servicing Your Honda 61

Valve Clearance
6. Apply grease to the set rings (11) and install it 8. Remove the stopper tool (15) from the cam 10. Rotate the camshaft by rotating the crankshaft
onto the camshaft holders (12). chain tensioner lifter. clockwise several times.
11. Insert the feeler gauge (18) between the intake
(15) valve lifter and cam lobe.
(12)
If the feeler gauge cannot be inserted, the
(11) shim is caught between the valve lifter and
the valve retainer. Remove the camshaft
holders, place the shim correctly, and reinstall
the camshaft holders.
Valve Clearances:
IN: 0.005 ± 0.001 in (0.12 ± 0.03 mm)
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm)

(18) (18)
(11) set ring
(12) camshaft holder (15) stopper tool

7. Install the camshaft holders onto the cylinder 9. Install the a sealing washer (16) and cam
head with the intake cam lobes (13) facing up chain tensioner lifter cover bolt (17).
as illustrated below.
Apply the oil to the camshaft holder bolt
threads and seating surface. (17)
Tighten the camshaft holder bolts (14) to the
specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
(18) feeler gauge
Tighten the camshaft holder bolts in a criss-cross
pattern in 2 or 3 steps.

(14) (12)
(16)

(16) sealing washer

(17) cam chain tensioner lifter cover bolt
(13)

(14)

(13) intake cam lobes

(14) camshaft holder bolts

62 Servicing Your Honda

 Valve Clearance
12.Install the spark plug (page 55). 3. Install the cylinder head cover (5) and tighten
13.Coat a new O-ring (19) with oil and install it Cylinder Head Cover Installation cylinder head cover bolts (6) to the specified
onto the crankshaft hole cap (20). torque:
Apply grease to the crankshaft hole cap 1. Check the spark plug hole packing (1) is in 7 lbf·ft (10 N·m, 1.0 kgf·m)
threads. good condition, replace it if necessary.
Install and tighten the crankshaft hole cap to Install the spark plug hole packing to the (6)
the specified torque: spark plug hole (2). (5)
11 lbf·ft (15 N·m, 1.5 kgf·m)
(19)
(1)

(5) cylinder head cover

(6) cylinder head cover bolts
(2)
(20)
4. Connect the direct ignition coil (7) and
(1) spark plug hole packing breather tube (8).
(19) O-ring (2) spark plug hole
(20) crankshaft hole cap
2. Inspect the cylinder head cover packing (3)
for damage or deterioration, replace it if (7)
necessary.
Install the cylinder head cover packing into
the groove of the cylinder head cover (4).

(3)

(8)

(7) direct ignition coil

(8) breather tube

(4) 5. Install the fuel tank and the seat (page 31).

(3) cylinder head cover packing

(4) cylinder head cover

Servicing Your Honda 63

Piston/Piston Rings/Piston Pin
8. Disconnect the spark plug (page 55). 12.Remove the engine hanger nuts (3) and engine
Cylinder Head Removal 9. Remove the cylinder head cover (page 56). hanger plates (4).
10. Position the piston at top dead center on the
1. Clean the area above the engine before compression stroke (page 56). (4)
disassembly to prevent dirt falling into the Remove the camshaft (page 58).
(3)
engine. 11. Loosen the water hose clamp (1) and
2. Drain the engine oil (page 37). disconnect the water hose (2).
3. Drain the radiator coolant after cooling the
motorcycle (page 42).
4. Remove the seat and fuel tank (page 30).
5. Remove the subframe (page 32).
6. Remove the carburetor (page 119).
7. Remove the exhaust pipe (page 90).

(3) engine hanger nuts

(2)
(4) engine hanger plates

(1)

(1) water hose clamp

(2) water hose

64 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
13.Remove the cylinder head bolts (5). 15.Remove the cylinder head nuts/washers (7) 16.Remove the dowel pins (9), cylinder head
14.Loosen the cylinder bolt (6). and cylinder head (8). gasket (10) and cam chain guide (11).
Loosen the nuts in a crisscross pattern in 2 or
(5) 3 steps. NOTICE
NOTICE Do not let the dowel pins and cam chain fall into
the crankcase.
Do not let the nuts, washers, valve lifters, shims,
and cam chain fall into the crankcase.
(9) (10)

(6)

(5) cylinder head bolts

(6) cylinder bolt

(11)
(7) (8)
(9) dowel pins (11) cam chain guide
(10) cylinder head gasket
(7) cylinder head nuts/washers
(8) cylinder head

Servicing Your Honda 65

Piston/Piston Rings/Piston Pin
Cylinder Removal Piston Removal Piston Ring Removal

1. Remove the cylinder bolt (1) and cylinder (2). 1. Place clean shop towels in the crankcase to Spread each piston ring (1) and remove by lifting
keep the piston pin clips, or other parts, from it up at a point just opposite the gap.
falling into the crankcase.
NOTICE 2. Remove the piston pin clips (1) using a pair of NOTICE
needle-nose pliers.
Do not let the cam chain fall into the crankcase. 3. Press the piston pin (2) out of the piston (3),
Do not pry on or strike the cylinder. Do not damage the piston ring by spreading the
and remove the piston. ends too far.
Under racing conditions, the piston and rings
(2) should be replaced after 15.0 hours of running.
Replace the piston pin after 15.0 hours of running. (1)

(3) (4)

(1)
(1) cylinder bolt
(2) cylinder

2. Remove the dowel pins (3) and cylinder (1) piston ring
gasket (4).
(2) (1)

NOTICE (1) piston pin clip (3) piston

(2) piston pin (4) piston rings
Do not let the dowel pins fall into the crankcase.
(3)

(4)
(3) dowel pins
(4) cylinder gasket

66 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
Piston/Piston Pin/Piston Ring Piston Ring Installation top ring
Inspection
1. Clean the piston ring thoroughly.
oil ring
We recommend you consult the Service Manual 2. Apply engine oil to piston rings and install
or your authorized Honda dealer for correct them.
Service Limit measurements.
NOTICE

Do not damage the piston ring by spreading the

ends too far.
Do not damage the piston during piston ring
installation.

• To install the oil ring, install the spacer first,

then install the side rails. mark
• Install the top ring on the piston with the
marking side facing up.
top ring
3. After installing the rings they should rotate
freely, without sticking. side rail
Space the ring end gaps 180 degrees apart oil
between top ring and upper side rail. spacer
ring
Space the ring end gaps 90 degrees apart
between upper side rail, spacer and lower side side rail
rail.

Servicing Your Honda 67

Piston/Piston Rings/Piston Pin
(1) (2)
Piston Installation Cylinder Installation

1. Place clean shop towels over the crankcase 1. Place clean shop towels over the crankcase
opening to keep the piston pin clips from opening to prevent dust or dirt from entire the
falling into the crankcase. engine.
2. Apply molybdenum disulfide oil (a mixture of 2. Clean off any gasket material from the gasket
1/2 engine oil and 1/2 molybdenum disulfide surface of the crankcase.
grease (containing more than 3% 3. Remove the shop towel. Do not let any gasket
molybdenum disulfide additive)) to the inner debris fall into the crankcase.
surface of the connecting rod small end. (3) 4. Install the dowel pins (1) and a new cylinder
3. Install the piston (1) with the “IN” mark (2) gasket (2).
and/or the large valve recesses (3) facing the (1) (2)
intake side of the engine. NOTICE
4. Apply flesh engine oil to the piston pin (4)
and inner surface of the piston pin hole. Do not let the dowel pins fall into the crankcase.
Install the piston pin and new piston pin clips
(5). (1)

NOTICE

Use new piston pin clips. Never reuse old piston

pin clips. (4) (5)
Do not let the piston pin clips fall into the
crankcase.
Do not align the piston pin clip end gap with the
piston cut-out.
(2)

(5) (1) dowel pins

(2) cylinder gasket

(6) 5. Clean the any gasket material off the cylinder.

(1) piston (4) piston pin

(2) “IN” mark (5) piston pin clip
(3) large valve recesses (6) cut-out

68 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
6. Apply clean engine oil to the cylinder wall, 7. Install the cam chain guide (6) and fit the cam
piston outer surface and piston rings. chain guide tabs (7) in the cylinder cut-outs Cylinder Head Installation
Route the cam chain (3) through the cylinder (8).
(4). Push the guide until it bottoms in the 1. Install the dowel pins (1) and new cylinder
Install the cylinder over the piston rings by crankcase guide hole. head gasket (2).
hand while compressing the piston rings (5).
NOTICE
NOTICE (6)
Do not let the dowel pins fall into the crankcase.
Do not damage the piston rings and cylinder
walls. (7)
(1)

(3)
(2)

(8)

(6) cam chain guide

(7) cam chain guide tabs
(8) cylinder cut-outs

(5) (4) (1) dowel pins

(2) cylinder head gasket
(3) cam chain (4) cylinder
(5) piston rings

(cont’d)

Servicing Your Honda 69

Piston/Piston Rings/Piston Pin
2. Route the cam chain through the cylinder 4. Install the cylinder bolt (5) and cylinder head 5. Install the engine hanger plates (7), engine
head (3). bolts (6) and tighten them to the specified hanger nuts/bolts (8) of the frame side and
Install the cylinder head. torque: engine hanger nut/bolt (9) of the engine side.
7 lbf·ft (10 N·m, 1.0 kgf·m) Tighten the engine hanger nut to the specified
NOTICE torque:
(6) frame side: 25 lbf·ft (34 N·m, 3.5 kgf·m)
Do not damage mating surfaces when installing engine side: 40 lbf·ft (54 N·m, 5.5 kgf·m)
the cylinder head.
(7)
3. Apply engine oil to all cylinder head nut
threads.
Install the washers and cylinder head nuts (4).
Tighten the cylinder head nuts in a crisscross
pattern in 2 – 3 steps. to the specified torque:
29 lbf·ft (39 N·m, 4.0 kgf·m) (5)

NOTICE (5) cylinder bolt

(6) cylinder head bolts (9)
Do not let the washers and nuts fall into the (8)
crankcase.
(7) engine hanger plates
(8) engine hanger nuts/bolts of the frame side
(9) engine hanger nut/bolt of the engine side

(3)
(4)

(3) cylinder head

(4) cylinder head nuts/washers

70 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
6. Connect the radiator hose (9) to the cylinder 9. Install the crankshaft hole cap (page 63). 15. Pour a fresh recommended coolant mixture
head and tighten the radiator hose clamp (10) 10. Install the cylinder head cover (page 63). (page 41).
securely. 11. Install the exhaust pipe (page 90).
12. Install the carburetor (page 123) . Check for the following:
13. Install the subframe (page 33). – compression leaks
14. Install the fuel tank (page 31) and the seat – abnormal engine noise
(page 29). – secondary air leaks
– coolant leaks

(9)

(10)

(9) radiator hose

(10) radiator hose clamp

7. Install the shims, valve lifters and camshaft

(page 61).
8. Install the spark plug (page 55).

Servicing Your Honda 71

Suspension
Refer to Safety Precautions on page 19 • Refer to Suspension Adjustment Guidelines (4)
(page 114). Make all rebound and
Loose, worn, or damaged suspension components compression damping adjustments in one-click
may adversely affect the handling and stability of increments. (Adjusting two or more clicks at
your CRF. If any suspension components appear a time may cause you to pass over the best
worn or damaged, see your Honda dealer for adjustment.) Test ride after each adjustment.
further inspection. Your dealer is qualified to • If you become confused about adjustment
determine whether or not replacement parts or settings, return to the standard position and
repairs are needed. start over.
• If the fork is still too stiff/soft after adjusting (3) (3)
compression damping, determine which
Front Suspension Inspection portion of the travel is still too stiff/soft. This (3) wear ring (4) outer tube
is an important step that will help you solve
• When your CRF is new, break it in for suspension problems.
approximately one hour to ensure that the
suspension has worked in (page 15). 1. Make sure that the fork protectors (1) and dust
• After break-in, test run your CRF with the seals (2) are clean and not packed with mud
front suspension at the standard setting before and dirt.
attempting any adjustments. 2. Check for signs of oil leakage. Damaged or
• For optimum fork performance, we leaking fork seals should be replaced before
recommend that you disassemble and clean your CRF is ridden.
the fork after riding your CRF for 3 hours.
See page 97 for fork disassembly.
(3)
• Replace the fork oil every 3 races or 7.5 hours
of running. See page 74 for oil level
adjustment after changing the fork oil. (1) (3) wear rings
• Replace the damper fork oil every 9 races or
22.5 hours of running. See page 100 for 4. Make a quick check of fork operation by
damper fork oil level adjustment after locking the front brake and pushing down on
changing the fork oil. the handlebar several times.
(2)
• Use Pro Honda HP Fork Oil 5W or an
equivalent which contains special additives to
assure maximum performance of your CRF's (1) fork protector (2) dust seal
front suspension.
• Periodically check and clean all front 3. Inspect the wear rings (3) for wear or damage.
suspension parts to assure top performance. Replace the wear ring if it is 0.06 in (1.5 mm)
Check the dust seals for dust, dirt, and foreign or flat with the outer tube (4).
materials. Check the oil for any When replacing the wear ring, remove the
contamination. fork leg (page 97).
Install the wear ring with its end gap facing
rearward.

72 Servicing Your Honda

 Suspension
1. Bounce the rear of the motorcycle up and down
Rear Suspension Inspection and check for smooth suspension action.

The swingarm is controlled by one hydraulic

shock absorber with an aluminum reservoir for
oil and nitrogen gas pressure. The gas pressure
in the reservoir is contained within a rubber
bladder.

The shock absorber’s spring preload and

damping adjustments (compression and rebound)
should be adjusted for the rider’s weight and
track conditions (page 113).

Do not attempt to disassemble, service, or

dispose of the damper; see your Honda dealer.
The instructions found in this owner’s manual are 2. Remove the subframe (page 32).
limited to adjustments of the shock assembly only. 3. Check for a broken or collapsed spring.
4. Check the rear shock absorber (1) for a bent
• When your CRF is new, break it in for shaft or oil leaks.
approximately one hour with the standard
suspension settings before attempting to
adjust the rear suspension.
• Make all compression and rebound damping (1)
adjustments in the specified increment or
turns described in page 110. (Adjusting two or
more increments or turns at a time may cause
you to pass over the best adjustment.) Test
ride after each adjustment.
• If the rear suspension is too stiff/soft, adjust it
by turning all the compression and rebound
adjusters according to the procedures
described in page 110. After adjusting the
adjusters simultaneously, suspension may be (1) rear shock absorber
fine-tuned by turning one of the compression
and rebound damping adjusters in one click or 5. Push the rear wheel sideways to check for
in 1/12 turn increments. worn or loose swingarm bearings. There
• If you have a problem finding an acceptable should be no movement. If there is, have the
adjustment, return to the standard position and bearings replaced by your Honda dealer.
begin again.

Servicing Your Honda 73

Suspension
NOTICE 4. Drain the fork oil by turning the outer tube (1)
Recommended Fork Oil upside down. (About 12 cc of fork oil will be
The outer tube can drop on the slider and left in the outer tube when it is left inverted
damage the fork dust seal and guide bushing for about 20 minutes at 20 °C/68°F.)
viscosity (weight) 5 W
when the fork damper is removed. To avoid
suggested oil Pro Honda HP Fork Oil or damage, hold both the outer tube and slider
equivalent when removing the fork damper. (1)

Fork Oil Change (5)

(6)
Refer to Suspension Removal on page 97.

1. Record the rebound damping adjuster position

and turn the adjuster counterclockwise until it
stops. (7) (1)
2. Hold the outer tube (1), then remove the fork
damper (2) from the outer tube using a lock (1) outer tube (6) guide bushing
(5) dust seal (7) slider (1) outer tube
nut wrench (3). Gently slide the outer tube
down onto the lower end of the slider (4).
3. Drain the fork oil from the outer tube (1). Amount of fork oil left in the fork
Drain the fork oil from the oil hole (9) of the (within damper and spring) unit: cc
minute
(2) (1) fork damper.
5 10 20 35 55 85 145
°C/°F

30/86 27 15.3 10.6 9.4 8.3 7.9 7.9

(1)
20/68 29.4 16.5 11.8 10.6 9.4 8.2 8.2
(9) 10/50 28.2 21.2 16.5 15.3 12.9 11.8 11.8
0/32 30.6 22.4 18.8 16.5 16.5 15.3 14.1
(1)
(3)

(4)

(1) outer tube (3) lock nut wrench

(2) fork damper (4) slider, lower end

(1) outer tube (9) oil hole

74 Servicing Your Honda

 Suspension
5. Pour the recommended fork oil into the outer Fork Oil Capacity: Optional Stiffer (0.47 kgf/mm) Fork Spring
tube (1). Standard (0.45 kgf/mm) Fork Spring
No mark
(factory products) 1 scribe mark and
or 3 scribe marks 75 degrees apart
1 scribe mark
(aftermarket parts)
(1) Standard oil 12.6 US oz
Standard oil 12.5 US oz
capacity (369 cm3) capacity (372 cm3)
Maximum oil 14.0 US oz Slightly stiffer as Maximum oil 14.1 US oz Slightly stiffer as
capacity (413 cm3) it nears full capacity (416 cm3) it nears full
compression. compression.
Minimum oil 10.7 US oz Slightly softer as Minimum oil 10.8 US oz Slightly softer as
capacity (317 cm3) it nears full capacity (320 cm3) it nears full
compression. compression.
(1) outer tube
Optional Softer (0.43 kgf/mm) Fork Spring Be sure the oil capacity is the same in both fork
legs.

3 scribe marks

Standard oil 12.4 US oz

capacity (366 cm3)
Maximum oil 13.9 US oz Slightly stiffer as
capacity (410 cm3) it nears full
compression.
Minimum oil 10.6 US oz Slightly softer as
capacity (314 cm3) it nears full
compression.

(cont’d)

Servicing Your Honda 75

Suspension
6. Check that the O-ring (10) on the fork damper
(2) is in good condition. Apply the
recommended fork oil to the O-ring.

(10)

(2)

(2) fork damper

(10) O-ring

7. Temporarily install the fork damper to the

outer tube.
After installing the fork leg (page 106) tighten
the fork damper to the specified torque:
25 lb·ft (34 N·m, 3.5 kgf·m)

76 Servicing Your Honda

 Brakes
Refer to Safety Precautions on page 19.
Front Brake Lever Adjustment Rear Brake Pedal Height
Both the front and rear brakes are the hydraulic
disc type. As the brake pads wear, the brake The brake pedal height should be approximately
fluid level will drop. A leak in the system will (1) level with the right footpeg.
also cause the level to drop.
1. Loosen the lock nut (1) and turn the adjusting
Frequently inspect the system to ensure there are bolt (2) in direction (+) to raise the pedal (3)
no fluid leaks. Periodically inspect the brake or in direction (–) to lower it.
fluid level and the brake pads for wear. 2. Tighten the lock nut at the desired pedal
(2)
height.
If the front brake lever or rear brake pedal
(3)
freeplay does not feel within the normal range
while riding, check the brake pads. If they are (3)
not worn beyond the recommended limit (page (1) lock nut (3) piston
80), there is probably air in the brake system. (2) adjuster (–)
Refer to the Honda Service Manual or see your
Honda dealer to have the air bled from the 1. Loosen the lock nut (1).
system. 2. To position the brake lever farther away from (+)
the handgrip, turn the adjuster (2) clockwise.
To position the brake lever closer to the (1)
handgrip, turn the adjuster counterclockwise. (2)
3. Tighten the lock nut.
4. Apply the brake, release it, then spin the
wheel and check that it rotates freely. Repeat (1) lock nut (+) raise the pedal height
this procedure several times. (2) adjusting bolt (–) lower the pedal height
5. Check freeplay by pulling in slowly on the (3) rear brake pedal
front brake lever until the brake starts to
engage.
Freeplay: 0.8 in (20 mm)
6. Apply grease to the contacting faces of the
adjuster and piston (3).

Servicing Your Honda 77

Brakes
Rear Brake Fluid Level Check
Fluid Level Inspection

Front Brake Fluid Level Check

(2)

(2) LOWER level mark

(1)
With the motorcycle in an upright position, check
the fluid level.
(1) LOWER level mark
It should be above the LOWER level mark (2). If
With the motorcycle in an upright position, check the level is at or below the LOWER level mark,
the fluid level. check the brake pads for wear (page 80).
It should be above the LOWER level mark (1). If Worn brake pads should be replaced. If the pads
the level is at or below the LOWER level mark, are not worn, have your brake system inspected
check the brake pads for wear (page 80). for leaks.
Worn brake pads should be replaced. If the pads If the brake pedal freeplay exceeds 0.8 in
are not worn, have your brake system inspected (20 mm), there is probably air in the brake
for leaks. system and it must be bled. Refer to the Honda
If the brake lever freeplay exceeds 0.8 in Service Manual or see your Honda dealer for
(20 mm), there is probably air in the brake brake bleeding.
system and it must be bled. Refer to the Honda
Service Manual or see your Honda dealer for
brake bleeding.

78 Servicing Your Honda

 Brakes
Adding Front Brake Fluid Adding Rear Brake Fluid
The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4
brake fluid or an equivalent. brake fluid or an equivalent.
When adding brake fluid be sure the reservoir is When adding brake fluid be sure the reservoir is
horizontal before the cap is removed or brake horizontal before the cap is removed or brake
fluid may spill out. fluid may spill out.
(6)
(1) (4) (9)
(5)

(2)

(8)

(7)

(3)

(1) screws (5) bolts (8) diaphragm

(2) reservoir cap (6) reservoir cap (9) upper level mark
(3) diaphragm (7) set plate
(4) upper level mark
1. Remove the bolts (5) reservoir cap (6), set
1. Remove the screws (1), reservoir cap (2) and plate (7) and diaphragm (8).
diaphragm (3). 2. Fill the reservoir with DOT 4 brake fluid to
2. Fill the reservoir with DOT 4 brake fluid to the upper level mark (9). Do not overfill.
the upper level mark (4). Do not overfill. 3. Set the diaphragm as shown.
3. Reinstall the diaphragm and reservoir cap. 4. Reinstall the set plate and reservoir cap.
4. Tighten the screws to the specified torque: 5. Tighten the bolts to the specified torque:
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m) 0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)

Servicing Your Honda 79

Brakes
Rear Brake Pads
Brake Pad Wear Inspect the brake pads (5) from the rear side of
the caliper to determine the pad wear. If either
Brake pad wear depends on the severity of usage pad is worn anywhere to a thickness of 0.04 in
and track conditions. (Generally, the pads will (1 mm), both pads must be replaced.
wear faster on wet and dirty tracks) Inspect the
pads at each regular maintenance interval (page (4)
(5) minimum thickness
21). indicator

Front Brake Pads 0.04 in

Inspect the brake pads (2) through the front (1 mm)
wheel to determine the pad wear. If either pad is
worn anywhere to a thickness of 0.04 in (1 mm), (6)
both pads must be replaced.

minimum thickness
indicator (5)
0.04 in
(1) (3) replace
(1 mm)

(4) rear brake caliper (6) brake disc

(5) brake pads

(2)
Other Inspections
replace
Check that the brake lever and pedal assemblies
wear indicator
grooves are positioned properly and the securing bolts are
0.04 in tight.
(1 mm)
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.

(2)

replace

(1) front brake caliper (3) brake disc

(2) brake pads

80 Servicing Your Honda

 Wheels
Refer to Safety Precautions on page 19. 2. Tighten, any loose spokes and rim locks (3) to
the specified torque:
Maintenance of spoke tension and wheel trueness Front Spoke :
(roundness) is critical to safe motorcycle 2.7 lbf·ft (3.68 N·m, 0.4 kgf·m)
operation. During the first few rides, spokes will Rear Spoke :
loosen more rapidly due to the initial seating of 2.7 lbf·ft (3.7 N·m, 0.4 kgf·m)
the parts. Excessively loose spokes may result in Rim Lock : 9 lbf·ft (12 N·m, 1.2 kgf·m)
instability at high speeds and the possible loss of 3. Check wheel rim runout. If runout is
control. It’s also important that the rim locks are noticeable, see the Honda Service Manual for
secure to prevent tire slippage. inspection instructions.

It is not necessary to remove the wheels to

perform the recommended service in the Axles & Wheel Bearings
Maintenance Schedule (page 21). However,
information for wheel removal is provided for See the Honda Service Manual for inspection
emergency situations. information:

1. Check the axle shaft for runout.

Wheel Rims & Spokes 2. Check the condition of the wheel bearings.

(1)

(2)

(3)

(1) wheel rim (3) rim lock

(2) spoke

1. Inspect the wheel rims (1) and spokes (2) for

damage.

Servicing Your Honda 81

Tires & Tubes
Refer to Safety Precautions on page 19. Always check air pressure when your tires are • Inspect carefully for bumps or bulges in the
“cold.” If you check air pressure when your tires side of the tire or the tread. Replace any tire
To safely operate your CRF the tires must be the are “warm” — even if your CRF has only been that has a bump or bulge.
proper type (off-road) and size, in good condition ridden for a few miles — the readings will be • Look closely for cuts, slits, or cracks in the
with adequate tread, and correctly inflated. higher. If you let air out of warm tires to match tires. Replace a tire if you can see fabric or
the recommended cold pressures, the tires will be cord.
WARNING underinflated. • Check for rocks or other objects embedded in
Using tires that are excessively worn or The correct “cold” tire pressures are: the tire or tread. Remove any objects.
improperly inflated can cause a crash in • Measure tread depth (1). Replace the tire
which you can be seriously hurt or killed. Front 15 psi (100 kPa, 1.0 kgf/cm2) before depth at the center reaches 0.12 in (3
mm), or any time you notice a reduction in
Rear 15 psi (100 kPa, 1.0 kgf/cm2) traction.
Follow all instructions in this owner’s
manual regarding tire inflation and • Check the position of both valve stems. A
If you decide to adjust tire pressures for a tilted valve stem indicates the tube is slipping
maintenance.
particular riding condition, make changes a little inside the tire or the tire is slipping on the
at a time. rim.
The following pages give detailed information on
how and when to check your air pressure, how to Inspection Tube Replacement
inspect your tires for wear and damage, and our
recommendations on tire repair and replacement. Take time to inspect your tires and wheels before If a tube is punctured or damaged, you should
you ride. replace it as soon as possible. A repaired tube
Air Pressure may not have the same reliability as a new one,
and it may fail while you are riding.
(1)
Properly inflated tires provide the best
Use a replacement tube equivalent to the original.
combination of handling, tread life, and riding
comfort. Generally, underinflated tires wear
unevenly, adversely affect handling, and are more
likely to fail from being overheated.
Underinflated tires can also cause wheel damage
on hard terrain. Overinflated tires make your
CRF ride harshly, are more prone to damage
from surface hazards, and wear unevenly.
(1) tire tread depth
Make sure the valve stem caps are secure. If
necessary, install a new cap.

82 Servicing Your Honda

 Tires & Tubes
Tire Replacement

The tires that came on your CRF were designed

to provide a good combination of
handling, braking, durability, and comfort across
a broad range of riding conditions.

WARNING
Installing improper tires on your
motorcycle can affect handling and
stability. This can cause a crash in which
you can be seriously hurt or killed.

Always use the size and type of tires

recommended in this owner’s manual.

80/100 – 21 51M
Front
DUNLOP D742F
100/90 – 19 57M
Rear
DUNLOP D756

Type bias-ply, tube

• Use a replacement tire equivalent to the

original.
• Replace the tube any time you replace a tire.
The old tube will probably be stretched and, if
installed in a new tire, could fail.

Servicing Your Honda 83

Drive Chain
Refer to Safety Precautions on page 19.
(3) Drive Chain Sliders
The service life of the chain depends on proper (1)
lubrication and adjustment. Poor maintenance 1. Check the chain slider (1) for wear.
can cause premature wear or damage to the drive If the wear is 3/16 in (5 mm) or more, replace
chain or sprockets. it.

When the motorcycle is ridden on unusually (1)

dusty or muddy tracks, more frequent
maintenance will be necessary.
(2)
Before servicing your drive chain, turn the (1) drive chain slack (3) driven sprocket
engine OFF, raise the rear wheel off the ground (2) drive sprocket
by placing the optional workstand or equivalent
support under the engine and check that your
transmission is in neutral. 3. Check drive chain slack at several points
along the chain. The slack should remain
It is not necessary to remove or replace the drive constant. If it isn’t, some links may be kinked
chain to perform the recommended service in the and binding. Lubricating the chain will often
Maintenance Schedule. eliminate binding and kinking.
(1) chain slider
Drive Chain Inspection NOTICE
2. Check the chain guide slider (2) for wear.
Excessive chain slack may allow the drive chain Replace the chain guide slider if it is worn to
1. Turn the engine off, raise the rear wheel off to damage the engine cases. the bottom of the wear limit (3).
the ground by placing the optional workstand
or equivalent support under the engine and 4. Inspect the drive chain for:
shift the transmission into neutral. • damaged rollers
2. Check slack (1) in the upper drive chain run • loose pins
midway between the sprockets (2)(3). Drive • dry or rusted links
chain slack should allow the following • kinked or binding links
vertical movement by hand: • excessive wear
1 – 1 3/8 in (25 – 35 mm)
Replace the drive chain (page 86) if it has
damaged rollers, loose pins, or kinks that cannot
be freed. Lubricate the drive chain (page 85) if it
appears dry or shows signs of rust. Lubricate (2) (3)
any kinked or binding links and work them free.
Adjust chain slack if needed.
(2) chain guide slider
(3) wear limit

84 Servicing Your Honda

 Drive Chain
Drive Chain Rollers Adjustment Lubrication

1. Check the upper drive chain roller (1) and 1. Loosen the rear axle nut (1). Commercially prepared drive chain lubricants
lower drive chain roller (2) for wear or 2. Loosen both the lock nuts (2) and turn the may be purchased at most motorcycle shops and
damage. adjusting bolts (3) counterclockwise to should be used in preference to motor oil. Pro
2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda Chain Lube or an equivalent, or SAE 80
rollers and replace them if below the service Align the index marks (4) of the axle plates or 90 gear oil is recommended.
limit. (5) with the same reference marks (6) on both
Service Limit: sides of the swingarm. Saturate each chain joint so that the lubricant
Upper roller: 1.5 in (39 mm) penetrates the space between adjacent surfaces of
Lower roller: 1.2 in (31 mm) the link plates and rollers.
(4) (2)
(5)
Replace the roller if necessary as follows.
Install the upper drive chain roller (Green) with
the “/” mark (3) facing toward the frame and
lower drive chain rollar (Black) as shown.
Tighten the drive chain roller bolt and nut to the (3)
specified torque: (6)
Upper roller bolt: 9 lbf·ft (12 N·m, 1.2 kgf·m) (1)
Lower roller nut: 9 lbf·ft (12 N·m, 1.2 kgf·m)

(3) (1) rear axle nut (4) index mark

(1)
(2) lock nut (5) axle plate
(3) adjusting bolt (6) reference mark

3. Tighten the rear axle nut to the specified

torque:
94 lbf·ft (128 N·m, 13.1 kgf·m)
4. Recheck chain slack and adjust as necessary.
5. Loosen the adjusting bolt counterclockwise
(2)
lightly until it touches the axle plate. Then,
while holding the adjusting bolt with a
(1) upper drive chain roller /” mark
(3) “/
(2) lower drive chain roller
wrench, tighten the lock nut to the specified
torque:
20 lbf·ft (27 N·m, 2.8 kgf·m)

Servicing Your Honda 85

Drive Chain
4. Inspect the sprocket teeth for wear or damage. Service limit: 10.2 in (259 mm)
Removal, Cleaning & Replacement We recommend replacing the sprocket
whenever a new chain is installed.
For maximum service life, the drive chain should Both chain and sprockets must be in good
be cleaned, lubricated, and adjusted before each condition, or the new replacement chain or
outing. sprocket(s) will wear rapidly.
Excessively worn sprocket teeth have a
1. Remove the master link retaining clip (1) with hooked, worn appearance. Replace any MEASURE A SPAN OF 17 PINS (16 PITCHES)
pliers. Do not bend or twist the clip. sprocket which is damaged or excessively
Remove the master link (2). Remove the worn.
drive chain. 6. Lubricate the drive chain.
7. Pass the chain over the sprockets and join the
ends of the chain with the master link. For
(1) ease of assembly, hold the chain ends against
adjacent rear sprocket teeth while inserting
the master link. Install the master link
retaining clip so that the closed end of the clip
will face the direction of forward wheel
rotation.
8. Recheck chain slack and adjust as necessary.

(2) More About Drive Chain

NOTICE • The master link is the most critical element of

(1) retaining clip (2) master link
drive chain security. Master links are
Use of a new chain with worn sprockets will reusable, as long as they remain in excellent
2. Clean the drive chain in high flash-point cause rapid chain wear.
solvent and allow it to dry. condition. We recommend installing a new
3. Inspect the drive chain for possible wear or master link retaining clip when the drive
5. Measure a section of the drive chain to chain is reassembled.
damage. Replace the drive chain if it has determine whether the chain is worn beyond
damaged rollers, loose fitting links, or • You may find it easier to install a new chain
its service limit. Put the transmission in gear, by connecting it to the old chain with a
otherwise appears unserviceable. and then turn the rear wheel forward until the
Replacement chain: D.I.D.520DMA2 master link and pulling the old chain to
lower section of the chain is pulled taut. With position the new chain on the sprockets.
the chain held taut and any kinked joints
straightened, measure the distance between a
span of 17 pins, from pin center to pin center.
If the measurement exceeds the service limit,
replace the chain. After the chain is
measured, shift the transmission into neutral
again before proceeding with inspection and
service.

86 Servicing Your Honda

 Exhaust Pipe/Muffler
2. Loosen the muffler clamp bolts (4).
Exhaust Pipe/Muffler Inspection 3. Remove the mufflers (5) by removing the
Check the mounting bolts and joint nuts for muffler mounting bolts (6) and washers (7).
tightness.
Check the exhaust pipe, exhaust joint pipe and (6)
mufflers for cracks or deformation. (7)
A damaged exhaust pipe, exhaust joint pipe and (4)
mufflers may reduce engine performance.

Muffler Removal (5)

1. Remove the seat mounting bolts (1), side

cover bolts (2) and side covers (3).

(4) muffler clamp bolt

(5) muffler
(1) (6) muffler mounting bolt
(7) washer

(3)
(2)

(1) seat mounting bolt (3) side cover

(2) side cover bolt

Servicing Your Honda 87

Exhaust Pipe/Muffler
5. Install each muffler mounting bolt (7) and 8. Install and tighten the side covers (10) and
Muffler Installation washer (8). side cover bolts (11).
6. Tighten each muffler clamp bolt (9) to the 9. Install the seat mounting bolts (12) and
1. Remove the old gasket. specified torque: tighten them to the specified torque:
2. Install the muffler clamp (1) by aligning the 15 lbf·ft (21 N·m, 2.1 kgf·m) 19 lbf·ft (26 N·m, 2.7 kgf·m)
tab (2) of the muffler clamp with the cut-out 7. Tighten each muffler mounting bolt (7) to the
(3) of each muffler (4). specified torque:
(12)
19 lbf·ft (26 N·m, 2.7 kgf·m)

(3) (1) (7)

(9)

(2)

(8) (10)
(11)
(4)
(10) side cover (12) seat mounting bolt
(11) side cover bolt
(1) muffler clamp (3) cut-out
(2) tab (4) muffler (7) muffler mounting bolt
(8) washer
3. Install the new gaskets (5) to the exhaust joint (9) muffler clamp bolt
pipe (6).
4. Install each muffler to the exhaust joint pipe.

(5)

(6)

(5) gasket
(6) exhaust joint pipe

88 Servicing Your Honda

 Exhaust Pipe/Muffler
5. Install the exhaust joint pipe mounting bolt.
Exhaust Joint Pipe Removal Exhaust Joint Pipe Installation 6. Install the muffler (page 88), but do not
tighten the bolt yet.
1. Remove the muffler (page 88). 1. Remove the old gasket. 7. Tighten the joint pipe clamp bolt to the
2. Remove the mud guard (1) by removing the 2. Install the joint pipe clamp (1) by aligning the specified torque:
screws (2). tab (2) of the joint clamp with the cut-out (3) 15 lbf·ft (21 N·m, 2.1 kgf·m)
of the exhaust joint pipe (4). 8. Tighten the exhaust joint pipe mounting bolt
to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
(3)
(1) 9. Tighten the muffler clamp bolts and muffler
(2)
(2) mounting bolts (page 88).
10. Installation can be done in the reverse order of
removal.
(1)

(4)

(1) mud guard (2) screws (1) joint pipe clamp (3) cut-out
(2) tab (4) exhaust joint pipe
3. Loosen the joint pipe clamp bolt (3).
4. Remove the exhaust joint pipe mounting bolt 3. Install a new gasket (5) to the exhaust pipe (6).
(4) and exhaust joint pipe (5). 4. Install the exhaust joint pipe to the exhaust
pipe, and temporarily install the joint pipe
clamp bolt and exhaust joint pipe mounting
(4) bolt.

(4)
(3) (5)
(6)

(5)

(3) joint pipe clamp bolt

(4) exhaust joint pipe mounting bolt
(5) exhaust joint pipe
(4) exhaust joint pipe
(5) gasket
(6) exhaust pipe

Servicing Your Honda 89

Exhaust Pipe/Muffler
Exhaust Pipe Removal Exhaust Pipe Installation

1. Remove the muffler (page 88). 1. Install a new exhaust pipe gasket (1) as
2. Remove the exhaust joint pipe (page 89). shown.
3. Remove the exhaust pipe joint nuts (1), 2. Install the exhaust pipe (2) and exhaust pipe
exhaust pipe (2) and old gasket (3). joint nuts (3)

(1) (3)

(2) (2)
(3) (1)

(1) exhaust pipe joint nuts (1) exhaust pipe gasket (new)
(2) exhaust pipe (2) exhaust pipe
(3) gasket (old) (3) exhaust pipe joint nuts

3. Install the exhaust joint pipe (page 89) but do

not tighten the bolt yet.
4. Install the muffler (page 88) but do not tighten
the bolt yet.
5. Tighten the exhaust pipe joint nuts to the
specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
6. Tighten the joint pipe clamp bolt and exhaust
joint pipe mounting bolt (page 89).
7. Tighten the muffler clamp bolts and muffler
mounting bolts (page 88).
8. Installation can be done in the reverse order
of removal.

90 Servicing Your Honda

 Additional Maintenance Procedures
Refer to Safety Precautions on page 19.
Handlebar Inspection
Steering Head Bearings Inspection 1. Remove the handlebar pad.
2. Check the handlebar (1) for bends or cracks.
1. With your CRF on a box or workstand (front 3. Check that the handlebar has not moved from
wheel elevated), turn the handlebar to the its proper position (by inspecting the paint
right and left to check for roughness in the mark).
steering head bearings. 4. Check the torque of the upper holder (2) bolts:
16 lbf·ft (22 N·m, 2.2 kgf·m)
Tighten the front bolts first.

(2)

2. Stand in front of your CRF, grab the fork (at (1)

the axle), look at the steering head, and push
the fork in and out (toward the engine) to
check for play in the steering head bearings.
(1) handlebar (2) handlebar upper holders
If any roughness or play is felt, but you do
not see any movement in the steering head,
the fork bushings may be worn. Refer to the Control Cables
Honda Service Manual for replacement or
adjustment procedures, or see your Honda Periodically, disconnect the throttle, clutch and
dealer. hot start cables at their upper ends. Thoroughly
lubricate the cable pivot points with a
commercially-available cable lubricant. Be
certain that the throttle cables have no kinks or
other damage.

Servicing Your Honda 91

Additional Maintenance Procedures
LEFT SIDE (9)
Nuts, Bolts, Fasteners
(7)
Check and tighten nuts, bolts, and fasteners
before every outing.

Torque
Item
lbf•ft N•m kgf•m
ENGINE
1 Cylinder head cover bolts 7 10 1.0
2 Exhaust pipe joint nuts 15 21 2.1
3 Water pump cover bolts 7 10 1.0
4 Crankshaft hole cap 11 15 1.5
5 Transmission oil check
bolt 7 10 1.0
6 Clutch cover bolts 7 10 1.0 (8)
7 Cylinder bolt 7 10 1.0
8 Oil filter cover bolts 9 12 1.2 (10)
9 Cylinder head bolts 7 10 1.0
10 Drive sprocket bolt 23 31 3.2
(7) cylinder bolt
(8) oil filter cover bolts
RIGHT SIDE (1) (9) cylinder head bolts
(10) drive sproket bolt

(2)

(3)

(5)
(6) (4)

(1) cylinder head cover bolts

(2) exhaust pipe joint nuts
(3) water pump cover bolts
(4) crankshaft hole cap
(5) transmission oil check bolt
(6) clutch cover bolts

92 Servicing Your Honda

 Appearance Care
Refer to Safety Precautions on page 19. If you use a high pressure washer, avoid spraying
the following areas: Washing Your Motorcycle with a Mild
Frequent cleaning and polishing will keep your wheel hubs Detergent
Honda looking newer longer. Frequent cleaning muffler outlet
also identifies you as an owner who values his under seat 1. Rinse your CRF thoroughly with cool water to
motorcycle. A clean CRF is also easier to inspect engine stop button remove loose dirt.
and service. brake master cylinders 2. Fill a bucket with cool water. Mix in a mild,
under fuel tank neutral detergent, such as dish washing
While you’re cleaning, be sure to look for drive chain liquid or a product made especially for
damage, wear, and gasoline or oil leaks. carburetor washing motorcycles or automobiles.
steering head bearings 3. Wash your CRF with a sponge or a
suspension pivot points soft towel. As you wash, check for heavy
General Recommendations grime. If necessary, use a mild
cleaner/degreaser to remove the grime.
• To clean your CRF you may use: (1)
– water Do not use steel wool to clean the frame as it
– a mild, neutral detergent and water could damage or discolor the frame surface.
– a mild spray and wipe cleaner/polisher Muffler stain remover is for removing stains on
– a mild spray and rinse cleaner/degreaser and the non-coated aluminum frame only.
water
• Avoid products that contain harsh detergents 4. After washing, rinse your CRF thoroughly
or chemical solvents that could damage the with plenty of clean water to remove any
metal, paint, and plastic on your CRF or (2) residue.
discolor the seat and decals. 5. Dry your CRF with a chamois or a
• If your CRF is still warm from recent (1) steering head bearings soft towel.
operation, give the engine and exhaust system (2) suspension pivot points 6. Lubricate the drive chain to prevent rusting.
time to cool off. 7. Start the engine and let it idle for several
• We recommend the use of a garden hose to NOTICE minutes. The engine heat will help dry moist
wash your CRF. High pressure washers, (like areas.
those at coin-operated car washes) can High pressure water (or air) can damage 8. As a precaution, ride at a slow speed and
damage certain parts of your CRF. The force certain parts of your CRF. apply the brakes several times. This will help
of water under extreme pressure can penetrate dry the brakes and restore normal braking
the dust seals of the suspension pivot points You may use Pro Honda Hondabrite, a performance.
and steering head bearings-driving dirt inside multi-surface cleaner/degreaser, to remove both
and needed lubrication out. dirt and petroleum-based grime from paint, alloy,
plastic, and rubber surfaces. Wet any heavy
deposits with water first. Then spray on the
Hondabrite and rinse with a garden hose at full
pressure. Stubborn deposits may require a quick
wipe with a sponge.

Servicing Your Honda 93

Appearance Care
Condensation Control Aluminum Frame Maintenance Exhaust Pipe Maintenance

Some condensation can form within the Aluminum corrodes when it comes in contact The exhaust pipe and exhaust joint pipe are
transmission cavity as well. This is natural and with dust, mud and road salt. stainless steel, but may became stained by oil or
just one more reason you should change the mud.
engine and transmission oil often. To remove stains, use Scotch Brite Hand Pad
#7447 (maroon) or an equivalent. Remove heat stains with a liquid kitchen
Wet the pad and polish the surface using strokes abrasive.
After Cleaning Lubrication parallel to the length of the frame.

There are some things you should do just after Clean the frame using a wet sponge and a mild
washing your CRF to help prevent rust and detergent, then rinse well with clean water. Dry
corrosion. the frame with a soft clean cloth, using strokes
parallel to the length of the frame.
Once your CRF is clean and dry, you should
protect any bare steel from rusting by applying a NOTICE
light coating of a rust-inhibitor. Lubricate the
drive chain and drive sprocket after removing Do not use steel wool to clean the frame as it
and thoroughly cleaning in solvent. Be sure the could damage or discolor the frame surface.
chain is wiped clean and is dry before applying Muffler stain remover (Scotch Brite Hand Pad
the chain lube. #7447-maroon) is for removing stains on the
non-coated aluminum frame only.
Follow the suggestions given in the pages of this
manual for lubricating items such as the brake
and clutch lever pivot points and footpeg pivot
pins.

94 Servicing Your Honda

 Adjustments for Competition
This section tells you how to fine tune your CRF Front Suspension Adjustments...........................96
for maximum competition performance. Rear Suspension Adjustments ..........................109
Suspension Adjustments for Track
Initial suspension adjustments should be Conditions ...................................................113
performed after a minimum of two hours of easy Suspension Adjustment Guidelines..................114
break-in time. Carburetor Adjustments & Tuning Tips ...........117
Chassis Adjustments.........................................129
Optional front and rear suspension springs are Gearing .............................................................130
available in both firmer and softer than standard Tire Selection for Track Conditions.................131
rates, in order to tailor your CRF specifically for Personal Fit Adjustments .................................132
your weight, riding style and course conditions.

Follow the instructions given in the rear

suspension sag setting section of Rear
Suspension Adjustments to determine if your
combined rider and sprung machine weight (rider
fully dressed for competition and machine
coolant, oil and fuel levels ready for competition)
requires an optional firmer or softer rear spring.
The need for either optional rear spring may need
to be balanced by installing the optional fork
springs of a similar rate.

Adjustments for Competition 95

Front Suspension Adjustments
The front suspension can be adjusted for the
rider’s weight and riding conditions by using one Front Suspension Air Pressure Front Suspension Damping
or more of the following methods:
Air is an unstable gas which builds up pressure Rebound Damping Adjustment
• Oil volume — The effects of higher or lower as it is worked (such as in a fork). Air pressure The fork rebound damping adjuster has 16
fork oil level are only felt during the final 3.9 acts as a progressive spring and affects the entire positions or more. Turning the rebound damping
in (100 mm) of fork travel. range of fork travel. This means the fork action adjuster screw (1) one full turn clockwise
• Compression damping — Turning the on your CRF will get stiffer during a race. For advances the adjuster four positions. To adjust
this reason, release built-up air pressure in the
compression damping screw adjusts how fork legs between motos. Be sure the fork is the rebound damping to the standard setting,
quickly the fork compresses. fully extended with the front tire off the ground proceed as follows:
• Rebound damping — Turning the rebound when you release the pressure. Turn the adjuster clockwise until it will no longer
damping screw adjusts how quickly the fork turn (lightly seats). This is the full hard position.
extends. The standard air pressure is 0 psi (0 kPa, 0 The adjuster is set in the standard position when
• Fork springs — Optional springs are kgf/cm2). You may relieve accumulated air the adjuster is turned counterclockwise 9 clicks.
available in softer and stiffer types than the pressure in the fork legs by using the pressure Make sure that both fork legs are adjusted to the
standard rate. (page 149) release screws. The front wheel should be off the same position.
ground before you release the pressure. The air
The inverted fork on your CRF features sealed pressure should be adjusted according to the Compression Damping Adjustment
damper cartridges with dual (separate air and oil) altitude and outside temperature. This adjustment affects how quickly the fork
chambers to prevent aeration. The design also compresses. The fork compression damping
isolates the oil in each fork tube/slider, which 1. Place a workstand under the engine, so that adjuster has 16 positions or more. Turning the
the front wheel is off the ground.
may contain air bubbles and/or metal particles, Do not adjust air pressure with the front wheel compression damping adjuster screw (2) one full
from the sealed cartridge to provide more on the ground as this will give false pressure turn changes the adjuster four positions. To adjust
consistent damping. readings. the adjuster to the standard position, proceed as
2. Remove the pressure release screw (1). follows:
(1) 3. Check that the O-ring (2) is in good condition. Turn the adjuster clockwise until it will no longer
4. Install and tighten the pressure release screw turn (lightly seats). This is the full hard position.
to the specified torque: The adjuster is set in the standard position when
0.9 lbf·ft (1.2 N·m, 0.1 kgf·m) the adjuster is turned counterclockwise 8 clicks.
Make sure that both fork legs are adjusted to the
same position.
(2)
(2)

(1)

(1) compression damping adjuster

(2) rebound damping adjuster

(1) pressure release screws (2) O-ring

96 Adjustments for Competition

 Front Suspension Adjustments
Both compression and rebound damping can be
increased by turning the adjuster clockwise. Fork Springs Front Suspension Disassembly

NOTICE The fork springs in CRF’s are about right for • If your CRF is brand-new, put enough part-
riders weighing between 150 and 160 lbs (less throttle break-in time (about one hour) on it to
Always start with full hard when adjusting riding gear). So if you're a heavier rider, you ensure that the suspension has worked in.
damping. have to go up on the oil level or get a stiffer • For optimum performance, and extended fork
Do not turn the adjuster screw more than the spring. Do not use less oil than the minimum life, the fork should be completely
given positions or the adjuster may be damaged. specified for each spring or there will be a loss of disassembled and cleaned after the first three
Be sure that the rebound and compression rebound damping control near full extension. If hours of riding. See the Service Manual or
adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service.
between positions. damping adjuster counterclockwise 1-turn and
lower the oil level in increments of 0.2 oz (5 cc) 1. Place your CRF on the workstand or
(2) in both fork legs until the desired performance is equivalent support with the front wheel off the
obtained. Do not, however, lower the oil level ground.
below the minimum oil level. 2. Remove the number plate bolt (1) and number
plate (2).
Minimum oil capacity: 3. Remove the handlebar pad (3).
Standard spring: 10.8 US oz (320 cm3)
Softer spring: 10.7 US oz (317 cm3) (3)
Stiffer spring: 10.6 US oz (314 cm3)
(1)
When adjusting oil levels, bear in mind that the
(1) air in the fork will increase in pressure while
riding; therefore, the higher the oil level, the
(1) rebound damping (2) compression higher the eventual pressure of any air in the
adjuster screw damping fork.
adjuster screw (2)

Oil capacity 14.0 US oz (413 cm3)

(MAX)
Force (N)

(1) number plate bolt (3) handle bar pad

Oil capacity 12.5 US oz (369 cm3) (2) number plate
(STANDARD)

Oil capacity 10.7 US oz (317 cm3)

(MIN)

Stroke (mm)

(cont’d)

Adjustments for Competition 97

Front Suspension Adjustments
4. Remove the washers/handlebar holder nuts (4), 7. Remove the disc cover (8) by removing the Do not support the brake caliper by the brake
mounting rubbers and handlebar (5). disc cover bolts (9). hose. Do not operate the brake lever after the
front wheel is removed. To do so will cause
NOTICE difficulty in fitting the brake disc between the
Keep the master cylinder upright to prevent air brake pads.
(8)
from entering system.
(15) (14)
(5)
(9)

(8) disc cover (9) disc cover bolts (16)

(13)
8. Remove the front axle nut (10) and loosen the
front axle pinch bolts (11) on both forks. (17)
Pull the front axle shaft (12) out of the wheel (13)
(4) hub and remove the front wheel. (13) fork protector bolts
(4) washers/houndlebar holder nuts (14) brake hose clamp bolts
(11) (11) (15) fork protectors
(5) handlebar
(16) brake caliper mounting bolts
5. Loosen the upper pinch bolts (6). (17) brake caliper
6. Loosen the fork damper (7), using the lock
nut wrench but do not remove them yet. 11.Loosen the fork leg lower pinch bolts (18),
then pull the fork legs down and out.
NOTICE
Do not use an adjustable wrench to loosen the
fork damper: it may damage them.

(12) (10)
(7)
(6)
(10) axle nut (12) front axle shaft (18)
(11) axle pinch bolts

9. Remove the fork protector bolts (13), brake

hose clamp bolts (14) and fork protectors
(15).
10. Remove the brake caliper mounting bolts (16)
and brake caliper (17). (18) lower pinch bolts

(6) upper pinch bolts (7) fork damper

98 Adjustments for Competition

 Front Suspension Adjustments
12.Clean the fork assembly, especially the sliding NOTICE 17.Temporarily install the fork damper to the
surface of the slider (19) and dust seal (20). outer tube.
13.Record the rebound damping adjuster position The outer tube can drop on the slider and 18.Set the axle holder (28) in a vise with a piece of
and turn the adjuster counterclockwise until it damage the fork dust seal and guide bushing wood or soft jaws to avoid damage.
stops. when the fork damper is removed. To avoid
14.Measure the length (21) between the axle damage hold both the outer tube and slider when NOTICE
holder and outer tube and record it before removing the fork cap.
disassembling the fork. Overtightening the vise can damage the axle holder.
Standard: 12.5 ± 0.08 in (317 ± 2 mm)
(20) 19.Loosen the center bolt (29).

(20) (19) (28)

(26)
(21) (20) fork dust seal (26) guide bushing
(29)
(19) slider (21) length 16.Drain the fork oil from the outer tube.
(20) dust seal Drain the fork oil from the oil hole (27) of the
fork damper.
15.Hold the outer tube (22), then remove the fork
(28) axle holder (29) center bolt
damper (23) from the outer tube using a lock
nut wrench (24). Gently slide the outer tube (27)
20.Push out the center bolt from the axle holder
down onto the lower end of the slider (25). of the slider by pushing the fork damper.
21.Make the mechanic's stopper tool out of a thin
piece of steel (1.0 mm thick) as shown if you
do not have the special tool.
(23)

(24)
(22) (25) (27) oil hole

33 mm
(22) outer tube (24) lock nut wrench
(23) fork damper (25) slider, lower end

(cont’d)

Adjustments for Competition 99

Front Suspension Adjustments
22.Apply pressure to the fork damper and insert a
special tool or mechanic’s stopper tool (30) Damper Oil Change
(see below) between the axle holder (28) and
lock nut (31) 1. Set the fork damper (1) in a vise with a piece
23.Hold the lock nut and remove the center bolt (32) of wood or soft jaws to avoid damage.
(29) from the fork damper. 2. Loosen the fork cap assembly (2) while
holding the fork damper using the lock nut
NOTICE wrench (3).
Do not remove the lock nut from the fork damper (31)
piston rod. If the lock nut is removed, the piston (1)
rod will fall in the fork damper and you can not
(2)
reassemble the fork damper. (31) lock nut (32) push rod

26.Remove the fork damper assembly (33) from

(30) (31) the fork assembly (34).
Remove the fork from the vise.
(28)
Remove the fork spring (35) from the fork.
(3)
(29)
(33)
(1) fork damper (3) lock nut wrench
(2) fork cap assembly

(28) axle holder (30) stopper tool (35)

(29) center bolt (31) lock nut

24.Remove the push rod (32) from the fork (34)

damper.
25.Remove the special tool or mechanic's stopper (33) fork damper assembly (35) fork spring
tool between the axle holder and lock nut (31) (34) fork assembly
while applying pressure to the fork damper.

NOTICE
Be careful not to damage the lock nut and fork
center bolt hole.

100 Adjustments for Competition

 Front Suspension Adjustments
3. Remove the fork cap assembly (2) from the 6. Extend the fork damper piston rod to maximum. 7. Extend the fork damper piston rod to
fork damper (1). Pour the recommended fork oil into the fork maximum. Adjust the oil level of the fork
damper. damper (1) as shown.
Be careful not to damage the fork cap bushing Recommended Oil: Oil Level: 1.65 – 1.85 in (42 – 47 mm)
(4). Pro Honda HP Fork Oil 5W or equivalent
Do not disassemble the fork cap assembly. Recommended Amount: (1)
Replace the fork cap as an assembly if it is 6.5 US oz (192 cm3)
damaged.

(2)
(1)
1.65 – 1.85 in
(42 – 47 mm)

(1) fork damper

(1)
8. Apply fork oil to the bushing (4) and new O-
(1) fork damper ring (6) on the fork cap assembly (2).
(4) Extend the fork damper piston rod to
7. Pump the fork damper piston rod (5) slowly maximum length, holding it, install the fork
several times to bleed the air from the fork cap assembly to the fork damper (1).
(1) fork damper (2) fork cap assembly damper (1).
(4) fork cap bushing Be careful not to damage the fork cap bushings.
4. Empty the fork oil from the fork damper (1) (1) If it is difficult to install the fork cap assembly,
by pumping the damper rod several times. the fork damper oil level might be higher than
standard oil level. Inspect the fork damper oil
level again.
(1)
(2)

(5) (4)

(1)
(1) fork damper (5) piston rod

(6)

(1) fork damper (1) fork damper (4) bushing

(2) fork cap assembly (6) O-ring
5. Clean the fork cap and fork damper threads. (cont’d)

Adjustments for Competition 101

Front Suspension Adjustments
9. Tighten the fork cap assembly (2) while 11.Screw in the lock nut (7) to the fork damper 13.Drain the extra oil from the fork damper oil
holding the fork damper (1) using the lock nut piston rod (5) fully. hole (9).
wrench (3) to the specified torque:
22 Ibf·ft (30 N·m, 3.1 kgf·m) (5) By doing this procedure, about 17 cm3 of fork
fluid will be drained from the damper spring
(7)
(1) chamber through the oil hole and cause 175 cm3
(2) of fork fluid to be left in the fork damper spring
chamber.

(9)

(5) piston rod (7) lock nut

(3)
Turn the rebound adjuster and compression
adjuster counterclockwise to the softest position.
(1) fork damper (3) lock nut wrench Check the fork damper piston rod sliding surface
(2) fork cap assembly for damage.
Apply fork oil to the fork damper piston rod
10.Hold the fork damper (1) in an upright sliding surface
position and pump the fork piston rod (5) to Cover the fork piston rod end with soft jaws to (9) oil hole
3.9 in (100 mm) slowly several times. prevent fork damage.
14.Blow out the oil from the fork damper spring
(1) NOTICE chamber using compressed air to the oil hole.
Wipe the oil completely off the fork damper.
Be careful not to bend or damage the fork 15.If you can not use compressed air, remove the
damper piston rod when the piston rod is stroked.
pressure release screw (10) on the fork cap.
12.Blow the extra oil off to the fork damper (1) Hold the fork damper up side down for 10
spring chamber (8) by pumping the fork minutes and drain the oil from the fork
(5) damper piston rod to full stroke. damper spring chamber.

(8)

(1) fork damper (5) piston rod (1)

(10)

(10) pressure release screw

(1) fork damper (8) spring chamber

102 Adjustments for Competition

 Front Suspension Adjustments
2. Tighten the lock nut (2) fully and measure the
Fork Assembly thread length (A) as shown.

1. Drain the fork oil from the outer tube/slider Standard: 0.43 – 0.51 in (11 – 13 mm)
(1) by placing it upside down.
(About 7 cc of fork oil will be left in the outer Wipe the oil completely off the fork damper.
tube/slider when it is left inverted for about 20
minutes at 20°C/68°F)

(2)
(1)

(A)

(2) lock nut (A) thread length

3. Blow out the oil completely off the fork

(1) outer tube/slider spring (3) using the compressed air.
Install the fork spring.
Install the fork damper assembly (4) to the
outer tube/slider (1).

(4)

(3)

(1)

(1) outer tube/slider (4) fork damper assembly

(3) fork spring

(cont’d)

Adjustments for Competition 103

Front Suspension Adjustments
4. Set the axle holder in a vise with a piece of 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the center bolt (8) O-ring.
wood or soft jaws to avoid to damage. center bolt (8) clearance. Remove the piston base or mechanic's stopper
Standard: 0.06 – 0.08 in (1.5 – 2.0 mm) tool while applying pressure to the fork
NOTICE damper.
If the clearance is out of specification, check the Install the center bolt to the axle holder and
Overtightening the vise can damage the axle lock nut and center bolt installation. tighten it to the specified torque:
holder.
51 Ibf·ft (69 N·m, 7.0 kgf·m)
5. Temporarily install the fork damper to the (2)
fork. (8)
Push out the fork damper piston rod from the
axle holder of the slider by pushing the fork
damper.
Apply pressure to the fork damper and insert
the special tool or mechanic's stopper tool (5)
between the axle holder and lock nut (2).
(8)
Measure the thread length again.
Standard: 0.43 – 0.51 in (11 – 13 mm)
6. Install the push rod (6) into the piston rod
until it stops.
Check the push rod installation by turning the (2) lock nut (8) center bolt
push rod right and left.
(8) center bolt
7. Install a new O-ring (7) to the center bolt (8). 9. Tighten the lock nut (2) to the fork center bolt
Install the center bolt to the fork damper (8) closely by hand. Tighten the lock nut to
piston rod aligning the center bolt adjusting 11.Measure the length between the axle holder
the specified torque: and outer tube, and record it.
rod (9) with the push rod. Tighten the center 16 Ibf·ft (22 N·m, 2.2 kgf·m)
bolt fully by hand. Standard: 12.5 ± 0.1 in (317 ± 2 mm)
12.Compare the length (10) at assembly and at
(2) disassembly. They should be the same length.
(5)

If the length at assembly is longer than at

disassembly, check the center bolt and lock nut
(9)
installation.
(7)

(8)
(2)

(6) (8)

(2) lock nut (7) O-ring (2) lock nut

(5) special tool (8) center bolt (8) fork center bolt
(6) push rod (9) adjusting rod (10)

(10) length

104 Adjustments for Competition

 Front Suspension Adjustments
13.Remove the fork damper from the fork. Fork Oil Capacity: Optional Stiffer (0.47 kgf/mm) Fork Spring
14.Pour the recommended fork oil (11) into the
Standard (0.45 kgf/mm) Fork Spring
outer tube/slider (1).

)( )
No mark

(
1 scribe mark and
(factory products)
Recommended Oil: or
3 scribe mark 75 degrees apart
Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark
(aftermarket parts)
Standard oil 12.6 US oz
(11) Standard oil 12.5 US oz capacity (372 cm3)
capacity (369 cm3)
Maximum oil 14.1 US oz Slightly stiffer as
Maximum oil 14.0 US oz Slightly stiffer as capacity (416 cm3) it nears full
capacity (413 cm3) it nears full compression.
compression.
Minimum oil 10.8 US oz Slightly softer as
(1) Minimum oil 10.7 US oz Slightly softer as capacity (320 cm3) it nears full
capacity (317 cm3) it nears full compression.
compression.

Optional Softer (0.43 kgf/mm) Fork Spring Be sure the oil capacity is the same in both fork
legs.

( )
(1) outer tube/slider (11) fork oil
3 scribe mark

Standard oil 12.4 US oz

capacity (366 cm3)
Maximum oil 13.9 US oz Slightly stiffer as
capacity (410 cm3) it nears full
compression.
Minimum oil 10.6 US oz Slightly softer as
capacity (314 cm3) it nears full
compression.

(cont’d)

Adjustments for Competition 105

Front Suspension Adjustments
15.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the
assembly (4) is in good condition. Apply the specified torque using the lock nut wrench
recommended fork oil to the O-ring. (14).
Pull up the outer tube (1) slowly and install Actual: 25 Ibf·ft (34 N·m, 3.5 kgf·m) (15)
the fork damper assembly (4) into the outer Torque wrench scale reading:
tube. 23 Ibf·ft (31 N·m, 3.2 kgf·m), using a 20 in
(50 cm) long torque wrench.

When using the lock nut wrench, use a 20-inches

long deflecting beam type torque wrench. The
(12) (4)
lock nut wrench increase the torque wrench’s
(16)
leverage, so the torque wrench reading will be
less than the torque actually applied to the fork (15) align (16) upper fork clamp
damper.
(1)
19.Tighten the fork lower pinch bolts (13) to the
specified torque:
15 Ibf·ft (20 N·m, 2.0 kgf·m)
(14)
20.Tighten the fork upper pinch bolts (17) to the
(4) specified torque:
(1) outer tube/slider (12) O-ring 16 Ibf·ft (22 N·m, 2.2 kgf·m)
(4) fork damper assembly

16.Insert both fork legs into the fork clamps. NOTICE

Tighten the fork lower pinch bolts (13) to the Over-tightening the pinch bolts can deform the
specified torque: outer tubes. Deformed outer tubes must be
15 Ibf·ft (20 N·m, 2.0 kgf·m) replaced.
(4) fork damper assembly (14) lock nut wrench
(13) (17)
18.For ease of releasing air pressure after the
forks are installed, loosen the lower pinch
bolts and position the outer tubes so that the
(13) pressure release screws are in front of the
rebound damping adjusters.
Align (15) the top surface of the upper fork
clamp (16) with the outer tube upper surface
as shown.

(13) fork lower pinch bolts (13) lower pinch bolts (17) upper pinch bolts

106 Adjustments for Competition

 Front Suspension Adjustments
21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle Fit the brake caliper over the disc, taking care
(18) and axle holder thoroughly. clamps contact each other. not to damage the brake pads.
Apply locking agent to the bolt threads. Install the left and right side collars into the
Install the fork protectors (19), fork protector wheel hub. Insert the front axle shaft through
bolts and brake hose clamp bolts (20). the wheel hub from the right side. Make sure
Tighten the fork protector bolts to the the front axle shaft is seated firmly onto the
specified torque: left fork leg clamp inner surface.
5.2 Ibf·ft (7 N·m, 0.7 kgf·m) Tighten the axle nut (23) to the specified
22.Align the brake caliper (21) and hose with the torque:
left fork leg, making sure that the brake hose 65 Ibf·ft (88 N·m, 9.0 kgf·m)
is not twisted. An improperly routed brake Tighten the left axle pinch bolts (24) to the
hose may rupture and cause a loss of braking specified torque:
efficiency. 15 Ibf·ft (20 N·m, 2.0 kgf·m)
23.Clean the threads of the caliper mounting (21)
bolts (22) and brake caliper thoroughly.
Apply locking agent to the bolt threads. (24) (21) caliper
Install the brake caliper on the slider and
tighten the caliper mounting bolts to the
specified torque:
22 Ibf·ft (30 N·m, 3.1 kgf·m)

(19)

(20)
(23)

(23) axle nut

(24) left axle pinch bolts
(21)
(18)

(18)
(22)

(18) fork protector blots

(19) fork protectors
(20) brake hose clamp bolts
(21) brake caliper
(22) caliper mounting bolts

(cont’d)

Adjustments for Competition 107

Front Suspension Adjustments
25.Install the handlebar (25), mounting rubbers 27.Install and tighten the number plate bolt (31).
(26), washers and handlebar holder nuts (27) Install the handlebar pad (32). (33)
and tighten the handlebar holder nuts to the
(32)
specified torque:
32 Ibf·ft (44 N·m, 4.5 kgf·m)
(31)
(25) (26)

(33) axle pinch bolts

(31) number plate bolt NOTICE

(32) handlebar pad
(27) To avoid damage when torquing the axle pinch
28.With the front brake applied, pump the fork bolts, be sure the axle is seated firmly onto the
(25) handlebar
(26) mounting rubbers up and down several times to seat the axle and left fork leg clamp inner surface.
(27) washers/handlebar holder nuts check front brake operation.
30.Install the disc cover (34) and tighten the disc
26.Install the number plate (28) by aligning its cover bolts (35) to the specified torque:
hole (29) with the tab (30) on the steering 10 Ibf·ft (13 N·m, 1.3 kgf·m)
stem.

(28) (34)

(35)

29.While keeping the forks parallel, alternately

tighten the right axle pinch bolts (33) to the (34) disc cover (35) disc cover bolts
(29) (30) specified torque:
15 Ibf·ft (20 N·m, 2.0 kgf·m) 31.Turn the rebound damping adjusters back to
(28) number plate (30) tab their original settings.
(29) hole

108 Adjustments for Competition

 Rear Suspension Adjustments
The rear suspension can be adjusted for the 3. Check that the spring preload is adjusted to Pin spanners should be used for turning the lock
rider’s weight and riding conditions by changing the standard length. Adjust as necessary by nut and adjusting nut. See page 149 for optional
the spring pre-load and the rebound and loosening the lock nut (1) and turning the pin spanners.
compression damping. adjusting nut (2).
Each complete turn of the adjusting nut Spring pre-load length (Standard spring)
The rear shock absorber assembly includes a changes the spring length by 1/16 in (1.5 Standard: 10.2 in (259 mm)
damper unit that contains high pressure nitrogen mm). Min. : 9.88 in (251 mm)
gas. Do not attempt to disassemble, service, or
dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring)
The instructions found in this owner’s manual are (1) Min. (Softer, 5.1 kgf/mm): 9.92 in (252 mm)
limited to adjustments of the shock assembly (3) Min. (Stiffer, 5.5 kgf/mm): 9.80 in (249 mm)
(4)
only. Min. (Stiffer, 5.7 kgf/mm): 9.88 in (251 mm)

Puncture or exposure to flame may also result in

an explosion, causing serious injury.
Service or disposal should only be done by your
Honda dealer or a qualified mechanic, equipped
with the proper tools, safety equipment and the (2)
Honda Service Manual.
(1) lock nut (3) pin spanners
(2) adjusting nut (4) spring length
If your CRF is new, put enough part-throttle
break-in time (about one hour) on it to ensure To increase spring pre-load:
that the suspension has worked in. Loosen the lock nut with the optional pin
spanners (3) and turn the adjusting nut to shorten
Rear Suspension Spring Pre-Load the spring length (4). Do not shorten to less
than:
9.9 in (251 mm)
Pre-load should be adjusted when the engine is
cold because it is necessary to remove the To decrease spring pre-load:
muffler (page 87). Loosen the lock nut with the optional pin
An optional pin spanner is available for turning spanners (3) and turn the adjusting nut to
the lock nut and adjusting nut to adjust spring increase the spring length (4). Do not increase to
pre-load. more than:
10.2 in (260 mm)
1. Place a workstand under the engine to raise
the rear wheel off the ground. Each turn of the adjuster changes spring length
2. Loosen the connecting tube clamp screw and and spring pre-load. One turn equals: spring
remove the subframe’s three mounting bolts, length/spring pre-load:
then remove the subframe. See page 32. 0.06 in (1.5 mm)/17.5 lbs (7.95 kg)

Adjustments for Competition 109

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

The high speed damping adjuster (1) is effective To adjust to the standard position:
when damping adjustment is desired for high 1. Turn the adjuster clockwise until it will no
speed operation. The low speed damping adjuster longer turn (lightly seats). This is the full hard
(2) should be used when damping adjustment is setting.
desired at relatively low speeds. 2. Turn the adjuster counterclockwise 1-3/4—
2-1/4 turns and the punch marks are aligned.
(3) rebound damping adjuster
• Both the high and low speed damping can be
increased by turning the appropriate adjuster Low Speed Damping:
To adjust to the standard position:
clockwise. The low speed damping can be adjusted by
1. Turn the adjuster clockwise until it will no
• Adjust the high speed adjuster in 1/12 turn turning the center screw of the compression
longer turn (lightly seat). This is the full hard
increments. adjuster.
position.
2. Turn the adjuster counterclockwise 7–10
The low speed adjuster has 13 positions or more.
(1) clicks with the punch marks on the adjuster
Turning the adjuster one full turn clockwise
and the shock absorber aligned.
advances the adjuster 4 positions.

To adjust to the standard position:

(2)
1. Turn the adjuster clockwise until it will no
longer turn (lightly seat). This is the full hard
setting.
2. Turn the adjuster counterclockwise 9 clicks
and the punch marks are aligned.

Rebound Damping
The rebound damping adjuster (3) is located at
the lower end of the shock absorber.
(1) high speed damping adjuster
(2) low speed damping adjuster It has 17 positions or more. Turning the adjuster
one full turn advances the adjuster 4 positions.

• Rebound damping can be increased by turning

the adjuster clockwise.

110 Adjustments for Competition

 Rear Suspension Adjustments
REAR FENDER MOUNTING BOLT 4. Calculate the race sag dimension.
Rear Suspension Race Sag To do this, subtract the loaded with rider
dimension (step 3) from the unloaded
Setting the proper race sag (ride height) is very dimension (step 2).
UNLOADED MEASUREMENT
important for competition use. (without rider) Standard Race Sag: 3.9 in (100 mm)
EXAMPLE: 23.6 in (600 mm)
Race sag refers to the amount of rear wheel Adjust spring pre-load as necessary to obtain
travel used by your CRF at rest, ready to ride, the desired handling results.
with you on the seat. As a general rule of thumb, Decreasing the race sag dimension (example:
the race sag dimension should be about one-third 3.5 in, 90 mm) improves turning ability for
of the maximum travel. tight terrain at the cost of slightly reduced
CHAIN ADJUSTER LOCK NUT straight line stability.
On your CRF, ride height is changed by adjusting Increasing the race sag dimension (example:
3. Measure the loaded with rider dimension.
the rear suspension spring pre-load. 4.3 in, 110 mm) may improve stability on
Remove the workstand. With two helpers
faster terrain with less turns, but will reduce
available, sit as far forward as possible on
Spring Pre-load & Race Sag Adjustment turning performance slightly and may upset
your CRF’s seat, wearing your riding apparel.
The following adjustment procedure establishes the balance between the front and rear
Ask one helper to steady your CRF perfectly
the correct starting point for any suspension suspension, producing a harsher ride. This
upright so you can put both feet on the pegs.
tuning — the proper rear spring pre-load will happen if the adjustment shifts the
Bounce your weight on the seat a couple of
adjustment for your specific needs. effective wheel travel toward the more
times to help the suspension overcome any
Your CRF should be at normal racing weight, progressive end of its range.
situation and settle to a good reference point.
including fuel and transmission oil. You should 5. Measure the loaded without rider dimension.
be wearing all your normal protective apparel. Do this with your CRF set at the standard race
Ask the other helper to measure the loaded
You will need two helpers. sag.
with rider dimension.
To calculate the proper adjustment, it is necessary
to measure between two fixed points — from the REAR FENDER MOUNTING BOLT
center of the rear fender mounting bolt to the
center of the chain adjuster lock nut as illustrated
here — for three different situations: LOADED MEASUREMENT LOADED MEASUREMENT
(on ground, with rider) (on ground without rider)
EXAMPLE: 19.7 in (500 mm) EXAMPLE: 21.6 in (550 mm)
unloaded: motorcycle on optional workstand with
rear suspension fully extended, no rider.
loaded with rider: motorcycle on ground, with
rider.
loaded without rider: motorcycle on ground,
CHAIN ADJUSTER LOCK NUT Example:
without rider
Unloaded = 23.6 in (600 mm)
1. Support your CRF on a workstand with the Example: – Loaded = 21.6 in (550 mm)
rear wheel off the ground. Unloaded = 23.6 in (600 mm) Sag = 2.0 in (50 mm)
2. Measure the unloaded dimension. – Loaded = 19.7 in (500 mm) (Without Rider)
Race Sag = 3.9 in (100 mm)
(cont’d)

Adjustments for Competition 111

Rear Suspension Adjustments
6. Calculate the free sag dimension. Because of the great absorption quality of the
To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you
dimension (step 5) from the unloaded to notice when your CRF’s suspension is
dimension (step 2). bottoming. Some riders may think the damping
Free sag indicates the distance your rear or perhaps the leverage ratio is too harsh. In
suspension should sag from the weight of the reality, the problem is most likely insufficient
sprung portion of your CRF. spring pre-load or a spring that is too soft. Either
With the spring pre-load set to obtain the situation prevents utilizing the full travel.
proper race sag, the rear suspension should
sag: 0.39 to 0.98 in (10 to 25 mm) Keep in mind that a properly adjusted suspension
If the rear of your CRF sags more than 0.98 system may bottom slightly every few minutes at
in (25 mm) from its own weight, the spring is full speed. Adjusting the suspension to avoid this
too stiff for your weight. It is not compressed occasional bottoming may cost more in overall
enough, even though you have the proper race suspension performance than it is worth.
sag adjustment. As a result, the rear
suspension will not extend as far as it should. A spring that is too firm for your weight will not
allow the rear tire to hook up under acceleration
Spring Rates and will pass more bumps on to you.
If you are lighter or heavier than the average
rider and cannot set the proper ride height
without altering the correct spring pre-load,
consider an aftermarket shock absorber spring.

A spring that is too soft for your weight forces

you to add excessive spring pre-load to get the
right race sag and, as a result, the rear end of the
motorcycle is raised. This can cause the rear
wheel to unload too much in the air and top out
as travel rebounds. The rear end may top out
from light braking, or kick sideways over lips
and square-edged terrain. It may even top-out
when you dismount your CRF.

112 Adjustments for Competition

 Suspension Adjustments for Track Conditions
Soft Surface
On soft ground, sand, and especially mud,
consider increasing compression damping front
and rear.

Sand often requires a bit more rebound damping

to minimize rear end kick. Although sand bumps
are usually larger, there’s more distance between
them, giving the shock more time to recover.

You may want a little bit stiffer front suspension

for sand tracks to help keep the front end up and
improve straight-line stability.

In a muddy event, stiffer aftermarket springs

front and rear may help, especially if you are
heavier than the average rider. Your CRF may be
undersprung because of the added weight of the
clinging mud. This additional weight may
compress the suspension too much and affect
traction.

Hard Surface
For a fast, hard track with no large jumps, you
can probably run the same spring as normal, but
run softer damping both ways-compression and
rebound. If you run softer rebound damping, the
wheel will follow the rough ground and small
bumps much better, and you will hook up better.
With a lot of rebound damping, the wheel returns
very slowly and doesn’t contact the ground
quickly enough after each bump. The result is a
loss of traction and slower lap times.

Adjustments for Competition 113

Suspension Adjustment Guidelines
Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 96 - 110. Remember to make all adjustments in
one-click increments. Test ride after each adjustment.

Front Suspension Adjustment

Adjustments for Type of Track

Hard-surfaced track Begin with the standard setting. If the suspension is too stiff/soft, adjust according to the chart below.

Sand track Adjust to a stiffer position.

Example: – Turn the compression damping adjuster to a stiffer position.
– Install the optional stiff spring. (Adjust compression damping to a softer position and rebound damping to a harder position at
this time.)

Mud track Adjust to a stiffer position because mud build-up increases your CRF’s weight.
Example: – Turn the compression damping adjuster to a stiffer setting.
– Install the optional stiff spring.

Adjustments for Too Soft/Stiff Damping

Symptom Action
Soft Initial travel too soft: – Test stiffer compression damping adjustments in one-click increments.
suspension • Steering is too quick. – Test stiffer rebound damping in one-click increments.
• Front end darts while cornering or riding in a straight line.

Middle travel too soft: If suspension isn’t stiff in initial travel:

• Front end dives when cornering. – Test stiffer compression damping adjustments in one-click increments.
If initial travel becomes stiff because of the above adjustment:
– Reduce the rebound damping in one-click increments.
– Test softer compression damping adjustments in one-click increments.
If that doesn’t solve the problem, install the optional stiff spring.

Final travel too soft: If initial and middle travel aren’t stiff:
• Bottoms on landings. – Test stiffer compression damping adjustments in one-click increments.
• Bottoms on large bumps, especially downhill bumps. If initial and middle travel are stiff:
– Install the optional stiff spring.
If initial travel is stiff after installing the optional stiff spring:
– Test soft compression damping adjustments in one-click increments.
If initial travel is still soft after installing the optional stiff spring:
– Test stiffer compression damping adjustments in one-click increments.
If final travel is still soft after installing the optional stiff spring:
– Increase the fork oil level in increments of 0.2 oz (5 cc).

Entire travel too soft: – Install the optional stiff spring.

• Front end shakes. – Test stiffer compression damping adjustments in one-click increments.
• Fork bottoms over any type of terrain. – Increase rebound damping in one-click increments.

114 Adjustments for Competition

 Suspension Adjustment Guidelines
Symptom Action
Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments.
suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments.
• Stiff on small cornering bumps. – Check for dirt in the dust seals. Check the fork oil for any contamination.
• Front end wanders while riding at full throttle in a straight line. If the front end dives while cornering, reduce the rebound damping in one click
increments. If that doesn’t solve the problem, install the optional stiff spring.
If the stiff spring makes the suspension too stiff over the full range of travel:
test softer compression damping adjustments in one-click increments until the
desire compression damping for initial travel is obtained.

Middle travel too stiff: If initial travel isn’t stiff:

• Stiff on bumps when cornering. – Test stiffer compression damping adjustments in one-click increments. (This
• Front end wanders when cornering. should produce smooth fork action from initial to middle travel.)
• Stiff suspension on bumps, especially downhill bumps. If initial and middle travel is stiff:
• While braking, front end dives during initial travel, then feels stiff. – Test softer compression damping adjustments in one-click increments.
– Reduce the rebound damping in one-click increments.

Final travel too stiff: If initial and middle travel aren’t stiff:
• Doesn’t bottom on landings, but feels stiff. – Test stiffer compression damping adjustments in one-click increments. (This
• Stiff on large bumps, especially downhill bumps. should produce smooth fork action from initial to middle travel.)
• Stiff on large bumps when cornering. If final travel is still stiff after the above adjustment, or
If initial and middle travel becomes stiff:
– Install the optional soft spring.
– Test softer compression damping adjustments in one-click increments.
If the entire travel feels stiff after the above adjustment:
– Test softer compression damping adjustments in one-click increments until the
desired initial travel compression damping is obtained.
– Lower the oil level by 0.2 oz (5 cc).

Entire travel too stiff: – Test softer compression damping adjustments in one-click increments.
• Stiff suspension on any type of terrain. – Reduce the rebound damping in one-click increments.
– Lower the oil level by 0.2 oz (5 cc).

Adjustments for Competition 115

Suspension Adjustment Guidelines
Rear Suspension Adjustment
Adjustments for Type of Track

Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below.

Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring preload).
Example: – Turn the compression damping adjuster and, especially, rebound damping adjuster to a stiffer setting.
– Increase standard Race Sag (+0.2 to 0.4 in/5 to 10 mm).

Mud track Adjust to a stiffer position because mud build-up increases your CRF’s weight.
Example: – Adjust the compression and rebound damping adjusters to stiffer settings.
– Install the optional stiff spring.
– Reduce standard Race Sag (–0.2 to 0.4 in/5 to 10 mm).

Symptoms and Adjustment

• Always begin with the standard settings.
• Turn the low speed compression and rebound adjusters in one-click increments, and the high speed compression adjuster in 1/6 turn increments at a time. Adjusting two or
more clicks or turns at a time may cause you to pass over the best adjustment. Test ride after each adjustment.
• If, after setting, the suspension feels unusual, find the corresponding symptom in the table and test stiffer or softer compression and/or rebound damping adjustments until
the correct settings are obtained as described.

Symptom Action

Stiff suspension Suspension feels stiff on small 1. Test softer low speed compression adjustment.
bumps 2. If it still feels stiff, further test softer low and high speed compression adjustments simultaneously.

Suspension feels stiff on large 1. Test softer high speed compression adjustment.
bumps 2. If it still feels stiff, further test softer low and high speed compression adjustments simultaneously.

Entire travel too stiff 1. Test softer high and low speed compression adjustments and rebound adjustment simultaneously.
2. If it still feels stiff, replace the spring with a softer spring (optional) and begin with the standard settings to
softer settings.

Soft suspension Entire travel too soft 1. Test stiffer high and low speed compression adjustments simultaneously.
2. If it still feels soft, replace the spring with a harder spring (optional) and begin with the standard settings to
stiffer setting.

Rear end sways 1. Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings
simultaneously.

Suspension bottoms Suspension bottoms at landing 1. Test stiffer high speed compression adjustment.
after jumping 2. If it still bottoms, test stiffer high and low speed compression adjustments, and replace the spring with a
harder spring (optional) if necessary.

Suspension bottoms after landing 1. Test stiffer low speed compression adjustment.
2. If it still bottoms, test stiffer high and low speed compression adjustments, and replace the spring with a
harder spring (optional) if necessary.

Suspension bottoms after end of 1. Test softer rebound dumping adjustment.

continuous bumps 2. If it still bottoms, test stiffer high and low speed compression adjustments and softer rebound damping
adjustment, and replace the spring with a harder spring (optional) if necessary.

116 Adjustments for Competition

 Carburetor Adjustments & Tuning Tips
The carburetor used on your CRF should perform Hot Start Circuit
suitably with the standard recommended settings Carburetor Components A lean mixture must be delivered to the cylinder
under average load, climatic, and barometric when a hot engine is being started. When the hot
conditions. However, to fine tune the engine’s Cold Start Circuit start lever is pulled back, the hot start valve (1)
power output, the carburetor may require A very rich mixture must be delivered to the opens, allowing air to be supplied to the main
adjustments for specific competition needs. cylinder when cold engine is being started. When bore (2) through the hot start air passage (3). This
the choke knob (1) is pulled out, fuel is metered extra air enters the air-fuel mixture from the slow
Optional main jets and slow jets are available for by the starter jet (2) and is mixed with air from circuit resulting in a lean condition.
your CRF. See your Honda dealer. the air passage (3) (located above the throttle
valve (4)) to provide a rich mixture for starting.
Any engine or air cleaner housing modifications The mixture discharges through the orifice (5) (1)
or the use of an aftermarket exhaust system may into the cylinder.
require jetting changes.
(3)
3
(1) (3)

(2)

(1) hot start valve

(5) (2) main bore
(4) (3) hot start air passage

(2)

(1) choke knob (4) throttle valve

(2) starter jet (5) orifice
(3) air passage

(cont’d)

Adjustments for Competition 117

Carburetor Adjustments & Tuning Tips
Accelerator Pump Circuit Slow Circuit Main Circuit
The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2)
throttle is opened. As the throttle valve (1) opens, with air from the air passage (2). The mixture and needle jet (3). It is then mixed with air
the pump rod (2) depress the diaphragm (3). At enters the venturi through the bypass (3) and coming from the air jet (4) and enters the venturi
this time, the inlet check valve (4) is shut pilot outlet (4) that has been metered by the pilot past the needle jet.
resulting in a sharp increase in pressure in the screw (5).
pump chamber (5). The outlet check valve (6) Baffle Plates
then opens, supplying fuel to the main bore via The baffle plates (5) prevents foaming of fuel or
the accelerator nozzle (7). abnormal fuel level around the mainjet.

Float Bowl
The float (6) and float valve (7) operate to
(3) maintain a constant level of fuel in the float
bowl.

(4)
(1)

(7) (2) (2)

(6) (1)
(5)
(2)

(3) (1) slow jet (4) pilot outlet

(2) air passage (5) pilot screw
(4) (3) bypass
(4)
(5)
(7)

(1) throttle valve (5) pump chamber (6)

(2) pump rod (6) outlet check valve (3)
(3) diaphragm (7) accelerator nozzle
(4) inlet check valve (1)
(5)

(1) main jet (5) baffle plates

(2) jet needle (6) float
(3) needle jet (7) float valve
(4) air jet

118 Adjustments for Competition

 Carburetor Adjustments & Tuning Tips
Jet Needle
Carburetor Circuit Functions The jet needle controls fuel/air mixture over fully Carburetor Removal
closed to 3/4 throttle. The straight section (1)
The carburetor has several major circuits, each affects throttle response at smaller throttle 1. Turn the fuel valve OFF.
providing the fuel/air mixture over a given openings. By changing the position of the clip 2. Drain the remaining fuel in the float bowl by
portion of throttle valve opening. (2) in its groove, you can improve acceleration at loosening the drain screw (1).
medium low and medium speed.
These major circuits overlap as shown below. WARNING
Gasoline is highly flammable and
explosive. You can be burned or
(2)
seriously injured when handing fuel.

(1) • Stop the engine and keep heat, sparks

and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

(1) straight section (2) clip

(1)

Slow Jet and Pilot Screw

The slow jet and pilot screw affects fuel/air ratio
over fully closed to 1/4 throttle.
Adjust the pilot screw to obtain the best off-idle
performance.
• If the engine blubbers (rich) exiting a corner,
Main jet turn the pilot screw clockwise to lean the
The main jet affects fuel/air ratio from half (1/2) mixture.
to full throttle (4/4). The size should be reduced • If the engine surges (lean) exiting a corner, (1) drain screw
at higher altitudes. turn the pilot screw counterclockwise to
richen the mixture. 3. Tighten the drain screw.
Honda carburetor jet sizes are numbered in
increments of 2 or 3. When changing the main jet The minimum to maximum range of pilot screw
size, increase or decrease it gradually until the adjustment is 1 to 1 3/4 turns out from the lightly
desired jetting is obtained. Because Honda jet seated position.
size numbers do not correspond with other If you exceed 1 3/4 turns out, the next larger
carburetor manufacturer’s jet size numbers, use slow jet is needed.
only Honda jets. If you are under 1 turns out, the next smaller
slow jet is needed.
(cont’d)

Adjustments for Competition 119

Carburetor Adjustments & Tuning Tips
4. Remove the fuel tank (page 30). 9. Remove the hot start cable holder (4). 11.Remove the throttle drum cover bolt (7) and
5. Remove the sub-frame (page 32). throttle drum cover (8).
6. Loosen the insulator band screw (2).
(7)

(4)
(8)
(2) (4) hot start cable holder
(7) throttle drum cover bolt
(2) intake band screw 10.Disconnect the rear suspension (5) upper (8) throttle drum cover
mounting nut and bolt (6).
7. Disconnect the throttle sensor connector (3). 12.Loosen the lock nut (9), adjusters (10) and
8. Remove the carburetor. disconnect the throttle cables (11) from the
(6) throttle drum (12).

(5) (12) (10)

(3) (5) rear suspension

(6) upper mounting nut/bolt (11) (9)
(3) throttle sensor connector
(9) lock nut (11) throttle cables
(10) adjusters (12) throttle drum

120 Adjustments for Competition

 Carburetor Adjustments & Tuning Tips
3. Remove the link arm set screw (7). When installing the floating valve (10) onto
Carburetor Disassembly/Assembly When installing the link arm set screw, apply the throttle valve (8) make sure the floating
a locking agent to the link arm set screw valve’s flat side faces out and the hole (11)
1. Pull up the cable clamp (1) and remove the threads. faces down.
carburetor top bolts (2). 4. Remove the throttle valve (8), throttle valve
Then remove the carburetor top (3). roller (9) and floating valve (10). (8)

(3) (7) (8)

(10)

(11)

(1)
(2)

(1) cable clamp (8) throttle valve

(2) carburetor top bolts (10) floating valve
(3) carburetor top (9) (11) hole

2. Remove the jet needle holder (4) and jet

needle (5) from the throttle valve (6).
(10)

(8)
(5)

(4) (7) link arm set screw (9) throttle valve roller
(8) throttle valve (10) floating valve
(6)

(4) jet needle holder

(5) jet needle
(6) throttle valve

(cont’d)

Adjustments for Competition 121

Carburetor Adjustments & Tuning Tips
5. Remove the accelerator pump cover screws 7. Remove the holder screw (19), throttle stop 9. Measure the float level (26) with the float
(12) and accelerator pump cover (13). screw holder (20), float bowl screws (21), level gauge (27) during float tab just
tube guides (22) and float bowl (18). contacting the float valve and the carburetor
intake (28) facing up. The float level should
(21) (19) (20) be 0.24 in (6.0 mm).
(13) If the float level is out of specification adjust
(21)
it by bending the float tab carefully.
(18)

(26)
(22)
(12)
(21)
(21) (22)
(12) accelerator pump cover screws
(13) accelerator pump cover (18) float bowl
(19) holder screw
6. Remove the D-ring (14), O-ring (15) spring (20) throttle stop screw holder (28) (27)
(16) and diaphragm (17). (21) float bowl screws
(22) tube guides
Clean the diaphragm. (26) float level
When installing the D-ring into the accelerator 8. Remove the pump rod (23). (27) float level gauge
pump cover (13) make sure the D-rings Clean the pump rod and rod passage (24).
(28) carburetor intake
flatside faces down, away from the float bowl Install the pump rod into the link lever (25).
(18). 10.Remove the leak jet (29) from the float bowl
Push the rod forcibly into the link lever until
(18). Clean the leak jet.
it snaps into place.
(13) (14)

(24) (29)
(18) (18)
(16) (15)

(14)

(13)

(17)
(23)
(25)
(13) accelerator pump cover (16) spring (23) (25)
(14) D-ring (17) diaphragm
(15) O-ring (18) float bowl (23) pump rod (25) link lever (18) float bowl (29) leak jet
(24) rod passage

122 Adjustments for Competition

 Carburetor Adjustments & Tuning Tips
To assemble, reverse the disassembly procedures.
To install the carburetor, reverse the removal
procedures.

• Route the throttle cables (1), hot start cable

(2) and throttle sensor wire correctly.
• After installing the carburetor, adjust the
throttle grip free play and hot start lever free
play.
• After installing the carburetor, check the (4)
throttle sensor connector (3) for correct (4)
routing as necessary.
• After installing the carburetor, check the air
vent hoses (4) and overflow hose (5) for (5)
kinking or pinching and correct routing as
necessary.

(1)

(4)
(2) (3)

(5)

(4) air vent hoses

(5) overflow hose
(1) throttle cables
(2) hot start cable
(3) throttle sensor

Adjustments for Competition 123

Carburetor Adjustments & Tuning Tips
Standard Tuning Recommendations

For the following recommendations to be

accurate, you must use the standard settings as a
baseline. Also, don’t change any of the settings
until you’ve determined what changes are
necessary.

Adjustment Standard settings

Pilot screw opening 1–3/4 turns out
Slow jet #40
Jet needle NHFS
Needle clip position 3rd groove
Main jet #172
Float level 0.24 in (6.0 mm)
Identification number FCR01C

Adjustments for Altitude & Temperature

All jetting recommendations are based on

standard jetting with an unmodified engine. The
following conditions can affect the fuel mixture.

124 Adjustments for Competition

 Carburetor Adjustments & Tuning Tips
Once you’ve adjusted the carburetor for
Special Tuning Conditions temperature and altitude, it shouldn’t need major Pre-Adjustment Checks
readjustment unless race conditions change
There are some unique atmospheric conditions or drastically. However, there are some unique Before adjusting carburetor settings, check the
situations that may require additional atmospheric conditions or race day situations that following:
adjustments. may require additional adjustments. They are as • air cleaner
follows. • air leaks
It should not be necessary to go more than one • float level
jet size richer or leaner to fine tune your CRF. If To prevent engine damage, always adjust the • clogged carburetor jets
larger jetting changes are necessary, check for air main jet before adjusting the jet needle. Always • spark plug fouling (improper heat range or
leaks, blocked or restricted exhaust or fuel choose the next richer jet if there is any doubt so other cause)
systems, or a dirty air cleaner. there is a margin for safety. • freshness of fuel
• owner modifications (such as exhaust system,
Main Jet • Go richer on the main jet, by one holes in the air cleaner housing, etc.)
Condition Main Jet Adjustment number, when: the track has a very • ignition timing
long straights next larger long straightaway or uphill section, • compression
a high percentage of sand, or the
uphill sections track is muddy. If the above check out, then, adjust the carburetor
sand • Go leaner on the main jet, by one for your specific racing conditions. Engine
number, when: it is very humid or response and appearance of the firing end of a
mud raining, or it is hotter than 113 spark plug are highly indicative of the engine
high humidity next smaller degrees F. condition.
raining After using the chart, and making any Refer to the list on page 149 for the optional
hotter than 113 °F (59 °C) adjustments for special conditions, it shouldn’t be carburetor parts.
necessary to go more than one jet size richer or
leaner to fine tune your CRF. If larger jetting To prevent engine damage, always adjust the
changes are necessary, check for worn crankshaft main jet before adjusting the jet needle. If there
seals, air leaks, blocked or restricted exhaust or is any doubt — always choose the next richer jet
fuel systems, or a dirty air cleaner. so there is a margin for safety.

Adjustments for Competition 125

Carburetor Adjustments & Tuning Tips
6. Adjust the pilot screw as required.
Carburetor Minor Adjustments
WARNING
The standard carburetor settings are ideal for the Gasoline is highly flammable and
following conditions: sea level altitude, and 20°C explosive. You can be burned or
(68 °F) air temperature. If your conditions are (1) seriously injured when handing fuel.
different, you may need to adjust the carburetor
settings, using the tuning information on page • Stop the engine and keep heat, sparks
124 and 125. Confirm your settings are correct and flame away.
before proceeding. • Handle fuel only outdoors.
• Wipe up spills immediately.
Minor Adjustments
1. Adjust the carburetor setting using the tuning (1) pilot screw 7. If you’ve determined that the main and slow
information on page 124 and 125.
jets must be changed, you must rotate the
2. When the engine is warm enough to run Adjustment Procedure carburetor and remove the float bowl plug.
without the choke, push the choke knob down 1. Turn the pilot screw in until it is lightly seated 8. Turn the fuel valve OFF, and disconnect the
to its off position. and record the number of turns. Turn the pilot fuel line from the fuel valve.
3. Adjust the pilot screw (1) to obtain the best screw out the same number of turns. 9. Drain the remaining fuel in the float bowl by
off-idle performance. 2. Warm up the engine. loosening the drain screw (2). Then tighten
– If the engine blubbers (rich) exiting a 3. Adjust the engine idle speed (page 48). the drain screw after draining the fuel.
corner, turn the pilot screw clockwise to 4. Make 2 – 3 laps of a course with the standard 10. Loosen the connecting and insulator band
lean the mixture. setting or corrected jetting (page 124). and screws. Rotate the carburetor.
– If the engine surges (lean) exiting a corner, spark plug. Note engine acceleration and 11. Remove the float bowl plug (3).
turn the pilot screw counter clockwise to other engine conditions in relation to throttle
richen the mixture. opening. Verify carburetion by removing the
spark plug and reading its firing end (page
The minimum to maximum range of pilot screw 55). It may take more than two or three laps (2)
adjustments is 1 to 1 3/4 turns out from the to get a good spark plug reading with a new
lightly seated position. If you exceed 1 3/4 turns spark plug.
out, the next larger slow jet is needed. If you are 5. Change carburetor settings or select suitable
under 1 turn out, the next smaller slow jet is carburetor jets, taking into consideration the
needed. engine conditions and factors for temperature
and altitude (page 124).

(3)

(2) drain screw (3) float bowl plug

126 Adjustments for Competition

 Carburetor Adjustments & Tuning Tips
12.Change the main jet (4) and slow jet (5) as 15.Remove the fuel tank (page 30). 19.Reinstall the jet needle, jet needle holder
required. 16.Rotate the carburetor to the left and remove the carburetor top and carburetor top bolts.
carburetor top bolts (6) and carburetor top (7). 20.Rotate the carburetor and align the lug (12) on
the carburetor with the slot (13) on the intake
(5) (4)
tube.

(7) (12)

(6)
(4) main jet (5) slow jet
(6) carburetor top bolts
(7) carburetor top (13)
13. Reinstall the float bowl plug.
14.If you’ve determined that the jet needle or clip 17.Remove the jet needle holder (8), insert the (12) lug (13) slot
position of jet needle must be changed, you carburetor maintenance tool (9) to the jet
must remove the carburetor top. needle (10) from the throttle valve (11), and 21.Tighten the connecting and intake tube band
remove it. screws.
22.Install the fuel tank (page 31).
23.Start the engine.
If the engine idle speed is too high or too low
or engine is not idling, adjust the engine idle
(9)
speed (page 48).
24.Repeat steps 4 – 23 until the engine gives
maximum power with the correct spark plug
(10) reading. It is always better to jet a little rich
than a little lean. It is advisable to record the
settings, course conditions, lap times, and
climatic and barometric conditions for future
(8) reference.
(11)

(8) jet needle holder

(9) carburetor maintenance tool
(10) jet needle
(11) throttle valve

18.Change the clip position of jet needle or jet

needle as required.

Adjustments for Competition 127

Carburetor Adjustments & Tuning Tips
Spark Plug Reading NOTICE NOTICE
Using spark plugs with an improper heat range An improperly tightened spark plug can damage
Refer to Spark Plug on page 55. or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may
be damaged. If a plug is too tight, the threads
Check any jetting change by reading the spark Before removing the spark plug, clean the spark may be damaged.
plug. The following procedure is recommended. plug area thoroughly to prevent dirt from
You may not get an accurate reading if you entering the cylinder.
simply turn off the engine and pull the plug for (2)
inspection. Ride for 10 - 15 minutes before taking a plug
reading. A new plug will not color immediately.
Use a new spark plug. Inspect the plug before (3)
installing it. To obtain an accurate reading of a new spark
plug: (1)
1. Accelerate at full-throttle on a straight.
2. Push the engine stop button and pull the (1) insulator (3) side electrode
clutch lever in to release the clutch. (2) center electrode
3. Coast to a stop.
4. Remove the spark plug. Spark Plug Coloring Guidelines
5. Use a magnifying glass to inspect the spark
plug. The porcelain insulator (1) around the Condition Spark Plug Appearance Mixture
center electrode (2) should appear clean and Normal Dark brown to light tan correct
colorless with a gray ring around the center color with dry electrode
electrode where it exits the porcelain.
Metallic specks indicate lean jetting that is Overheating Light gray or white color lean
(Lean)
removing metal from the piston. Black sooty
streaks on the porcelain indicate rich jetting. Wet Wet or sooty rich
(Rich)

Remember that in addition to improper jetting:

• A lean condition can be caused by air leaks in
the inlet tract or exhaust system, the passage
of too much air because of the use of the
wrong air cleaner, use of a less-restrictive
aftermarket exhaust system, or a hole or holes
(deliberate or unintentional) in the air box.
• A rich condition can be caused by a plugged
or dirty air cleaner, use of a more-restrictive
aftermarket exhaust system, a clogged spark
arrester, or excessive oil on the air cleaner.
Excessive smoking will occur.

128 Adjustments for Competition

 Chassis Adjustments
The following suggestions may improve a
specific concern. Subtle changes in overall Fork Height/Angle Wheelbase
handling may also be noted.
The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle
not adjustable. Align the groove in the outer tube changes in overall handling. You may adjust
Rear End with the top surface of the upper fork clamp. wheelbase by adding or removing links on the
drive chain. If you change the wheelbase, be
If you have a problem with rear wheel traction, Standard Position sure to re-check race sag and adjust, if necessary.
raise the rear end of your CRF by increasing the
rear spring pre-load. Instead of running 3.9 in The standard position (1) align the top of the In the past, a general rule was lengthen the
(100 mm) of sag, you can run 3.5 in (90 mm) so outer tube (2) (not the top of the fork cap) with wheelbase to add straight line stability, shorten
the rear of the bike will sit a little higher. This the top surface of the upper clamp (3). the wheelbase to improve turning. However, we
should produce more traction because of the (1) standard position
suggest you do not lengthen the wheelbase of
change to the swingarm and the location of your (2) your CRF unless you are racing on a track with
0 in (0 mm)
motorcycle’s center of gravity. (2) top of outer tube more fast sections than normal.
(1) (3) upper fork clamp
If you have a problem with the steering head As a general recommendation, keep the
shaking when you use the front brake hard or if wheelbase as short as possible. This positions
your CRF wants to turn too quickly, lower the the wheels closer together, improves turning
rear of the motorcycle by reducing the rear spring (3) response, increases weighting (traction) on the
pre-load. This will increase fork rake and trail rear wheel, and lightens weighting on the front
and should improve stability in a straight line. wheel.
The effective suspension travel will be
transferred toward the firmer end of wheel travel. With your CRF, you will probably find that the
standard setting or a shorter wheelbase will offer
Keep the race sag adjustment (page 111) in the more overall benefits.
3.5 - 3.9 in (90 – 100 mm) range.

Adjustments for Competition 129

Gearing
You can “adjust” the power delivery of the Lower Gearing (more driven sprocket teeth) A gearing change may help for riding in sand,
standard engine to suit track conditions by • decrease top speed in each gear where you want to keep the front end light so it
changing gearing. This allows you to utilize a • increases frequency of shifting (narrower gear can float from the peak of one sand whoop to the
different portion of the engine’s power range at a ratios) next. Generally, with higher gearing, it is easier
given throttle setting. New gearing may provide • increases engine rpm at a given throttle to maintain that perfect attitude (maximum rear
the change you are looking for without the need setting or ground speed (which may provide wheel traction and a light front end) because you
to consider further modifications. more power-to-the-ground on good traction remain in the powerband longer in each gear.
surfaces) The higher gearing allows you to steer more
The portion of your engine’s power range you efficiently with throttle control and body English.
use can be adjusted by changing the final drive However:
ratio with different sized rear sprockets. Gearing • spacing between gears may be too narrow If you are riding a track with sections where you
changes allow you to more closely match the • engine rpm may be too high choose to over-rev the engine temporarily rather
type of terrain and the available traction. than shifting up, higher gearing might help.
Normally, a change of one tooth on the rear Some tracks may be watered heavily prior to the
sprocket will be sufficient. first race, then lightly or not at all during the day. Sometimes you have to sacrifice performance on
This results in a track surface that is slippery one section of the track to gain a better overall
There is a choice of both higher and lower final during the first few races, then changes from time. Your goal is the fastest overall lap time,
drive ratios with two optional aluminum driven good to great and back to good and possibly ends even if the cost is some sections where the
sprockets. For muddy or sandy courses, there is the day with a slick rock-hard consistency. gearing feels wrong.
a more durable steel driven sprocket with the Ideally, your gearing should be adjusted to suit
standard number of teeth. Like the optional all these conditions. If you decide to try a gearing change, have
springs, these sprockets are listed in the Optional someone check your times with a stopwatch
Parts List section of this manual. • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate
higher gear (less teeth) to keep engine rpm appraisal of the gearing change. “Seat-of-the-
Unless you have the required mechanical down, and avoid unwanted wheelspin. The pants” feelings can’t be trusted. Eliminating
knowhow, tools, and Honda Service Manual, engine may bog in certain corners so you’ll wheelspin with a gearing change can make you
sprocket changing should be done by your Honda need to slip the clutch to compensate; feel like you’re going slower when, in reality,
dealer. downshifting may be too drastic a change in you’ve decreased your time by increasing your
speed. speed with better traction.
Higher Gearing (less driven sprocket teeth) • Average conditions: use the standard sprocket.
• increases top speed in each gear (provided the • Hard (but not slippery) track conditions: use These gearing recommendations should be
engine will pull the higher gearing) lower gearing (more teeth) to keep the engine evaluated by considering your ability, your riding
• reduces frequency of shifting (wider gear rpm high where the engine produces the most style, and the track.
ratios) power. This may require an extra upshift on
• reduces engine rpm at a given throttle setting certain sections or perhaps you can just rev it
or ground speed (which may allow better rear out a bit longer.
wheel traction on slippery or loose terrain)
For tight tracks, consider lower gearing to avoid
However: having to slip the clutch frequently. Repeated
• the engine may not pull the higher gearing fanning or pulling of the clutch lever in a turn to
• the spacing between gears may be too wide raise engine rpm may eventually damage the
• engine rpm may be too low clutch system.

130 Adjustments for Competition

 Tire Selection for Track Conditions
Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for
compound can affect your placing in competition. added traction, remember that it may transfer
The tires on your CRF offer a “happy medium” additional loads to the transmission because it
for the variety of soil conditions the majority of grips so well, especially when riding in situations
riders are likely to encounter. that normally place unusual demands on the
transmission.
Experienced competitors often switch to tires
developed for specific terrain conditions. If you Complete consumer information can be obtained
do switch, stay with the factory recommended from the various tire manufacturer
sizes. Other tires may affect handling or representatives and dealers.
acceleration.
Some general recommendations for specific
Be aware that tire sizes (width and aspect ratio) terrain follow:
do vary from manufacturer to manufacturer or
even among tires made by the same Hard, Slick Soil
manufacturer. Variations in tires, especially the Use tires with many relatively short knobs that
sidewall profile, can change the attitude of your are close together in order to obtain the largest
CRF and its handling. Tire variations that raise possible contact patch on the surface. The rubber
or lower the rear of your CRF have a more compound needs to be softer for hard ground in
significant effect on handling than variations in order to hook up, but not so soft that the knobs
front tires which, generally, don’t vary as much. roll over easily and affect holding a straight line.
Often, you can see or feel the change in tire size. These tires tend to wear more quickly than
Another way to check is to measure the rolling standard tires because of the combination of soft
circumference of the old and new tires. A higher rubber and hard terrain.
profile tire will have a larger rolling
circumference. Muddy Soil
Use a more open tread pattern to avoid clogging.
If you do switch to tires designed for special For these conditions, the relatively long knobs
terrain use, remember they will be less will probably be made from a harder rubber
acceptable in other circumstances. For example, compound to reduce any tendency to bend back
an aggressive mud tire will give excellent grip on under acceleration or wear quickly.
wet, loamy terrain, but less impressive grip on a
hard surface. Loose, Sandy Soil
Use a tire that is similar in construction to those
needed for tacky soil and mud, but with a few
more knobs.

Adjustments for Competition 131

Personal Fit Adjustments
The following suggestions may make your ride • Position the shift lever and brake pedal so • Handlebar width can be trimmed with a
both more comfortable and more responsive to they are close to your boot for rapid access, hacksaw to better suit your particular shoulder
your control input. but not so close that either is depressed when width and riding preference. Think this
sitting or standing comfortably on your CRF. through carefully and cut off just a small
amount at a time from both sides equally. It is
Control Positioning obviously much easier to make the handlebar
narrower than it is to add material.
• Position the control levers so that you can use
them comfortably when seated and standing.
• Adjust the mounting bolt torque of the clutch
and brake lever assemblies so that they can
rotate on the handlebar in a fall. If an
assembly does not rotate, it may bend or
break a control lever. Make sure that the
bolts are torqued securely enough to prevent
slippage during normal operation.

Apply Honda Thread Lock or an equivalent to

the threads of these bolts prior to adjustment to Handlebar Position, Width & Shape
help ensure the correct torque is retained.
Tighten the top bolts first. • Chamfer the edges to remove burrs and other
• Position the handlebar so that both gripping irregularities or roughness after sawing the
the bar and operating the controls is handlebar.
comfortable while both seated and standing, • An alternate handlebar shape, through varying
while riding straight ahead and turning. rise or rearward sweep dimensions, will
Tighten the forward bolts first. provide further adjustment to riding position
• The handlebar position may be moved and may better suit your particular body size
rearward either 3 mm (using optional or riding style. Each of the ergonomic
handlebar lower holders) or 6 mm (by rotating dimensions of the machine were determined
(1) (1) the standard holders 180 degrees). Refer to to suit the greatest possible number of riders
the Service Manual for installation based on an average size rider.
instructions. Be sure to check control cable
and wiring harness routing after the
adjustment.

(1) control lever mounting bolts

As an alternative, consider wrapping the

handlebar area under the control assemblies with
teflon tape. Then tighten the assemblies to their
normal torque. Upon impact, the fully-tightened
assemblies should rotate on the teflon tape.

132 Adjustments for Competition

 Tips
Here’s helpful advice on how to transport and
store your Honda, as well as two troubleshooting
flow charts.

Transporting Your Motorcycle .........................134

Storing Your Honda..........................................135
You & the Environment ...................................136
Troubleshooting................................................137

Tips 133
Transporting Your Motorcycle
If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel
transport your Honda, we recommend that you against the front of the truck bed or trailer rail.
follow these guidelines: Attach the lower ends of two straps to the tie-down
• Use a loading ramp. hooks on your CRF. Attach the upper ends of the
• Make sure the fuel valve is off. straps to the handlebar (one on the right side, the
• Secure the motorcycle in an upright position, other on the left), close to the fork.
using motorcycle tie-down straps. Avoid
using rope, which can loosen and allow the Check that the tie-down straps do not contact any
motorcycle to fall over. control cables or electrical wiring.

Tighten both straps until the front suspension is

compressed about half-way. Too much pressure
is unnecessary and could damage the fork seals.

Use another tie-down strap to keep the rear of the

motorcycle from moving.

We recommend that you do not transport your

CRF on its side. This can damage the
motorcycle, and leaking gasoline could be a
hazard.

134 Tips
 Storing Your Honda
If you won’t be riding for an extended period, 5. Remove the radiator cap and coolant drain
such as during the winter, thoroughly inspect bolt/sealing washer (1) at the water pump (2) to Removal from Storage
your Honda and correct any problem before drain coolant.
storing it. That way, needed repairs won’t be After the coolant has been completely 1. Uncover and clean your CRF.
forgotten and it will be easier to get your CRF drained, ensure that the drain bolt sealing Change the engine and transmission oil if
running again. washer is in good condition and reinstall the more than 4 months have passed since the
drain bolt/sealing washer and radiator cap. start of storage.
To reduce or prevent deterioration that can occur 2. Uncover the end of the muffler and remove
during storage, also follow the following (2) the rag from the muffler outlet.
procedures. 3. Fill the fuel tank with recommended fuel
(page 34).
4. Pour a fresh recommended coolant mixture
Preparation for Storage (page 41) slowly into the radiator filler hole
up to the filler neck.
1. Completely clean all parts of your CRF. If Capacity:
your CRF has been exposed to sea air or salt 1.06 US qt (1.00R)
water, wash it down with fresh water and at disassembly
wipe dry. 0.98 US qt (0.93R)
(1)
2. Change the engine oil and filter (page 37). at draining
3. Replace the transmission oil (page 40). (1) drain bolt/sealing washer (2) water pump
4. Drain the fuel tank and carburetor into an Lean your CRF slightly right and left several
approved gasoline container. 6. Lubricate the drive chain. times to bleed trapped air in the cooling
Turn the fuel valve OFF and loosen the 7. Inflate the tires to their recommended system.
carburetor drain screw. Drain gasoline into an pressures. If the coolant level lowers, add coolant and
approved container. Tighten the drain screw. 8. Place your CRF on the work-stand or repeat the above procedure.
equivalent to raise both tires off the ground. Install the radiator cap securely.
WARNING 9. Stuff a rag into the muffler outlet. Then tie a
Gasoline is highly flammable and plastic bag over the end of the muffler to 5. Perform all maintenance checks (page 21).
explosive. You can be burned or prevent moisture from entering.
seriously injured when handling fuel. 10. Store your CRF in an unheated area, free of
dampness, away from sunlight, with a
• Stop the engine and keep heat, sparks minimum of daily temperature variation.
and flame away. 11. Cover your CRF with a porous material.
• Handle fuel only outdoors. Avoid using plastic or similar non-breathing,
• Wipe up spills immediately. coated materials that restrict air flow and
allow heat and moisture to accumulate.

Tips 135
You & the Environment
Owning and riding a motorcycle can be NOTICE
enjoyable, but you must do your part to protect
nature. When you show respect for the land, Improper disposal of drained fluids is harmful to
wildlife, and other people, you also help preserve the environment.
the sport of off-road riding.

Following are tips on how you can be an

environmentally-responsible motorcycle owner.

• Choose Sensible Cleaners. Use a

biodegradable detergent when you wash your
CRF. Avoid aerosol spray cleaners that
contain chloroflur carbons (CFCs) which
damage the atmosphere’s protective ozone
layer. Don’t throw cleaning solvents away;
see the following guidelines for proper
disposal.

• Recycle Wastes. It’s illegal and thoughtless to

put used engine oil in the trash, down a drain,
or on the ground. Used oil, gasoline, and
cleaning solvents contain poisons that can hurt
refuse workers and contaminate our drinking
water, lakes, rivers, and oceans.
Before changing your oil, make sure you have
the proper containers. Put oil and other toxic
wastes in separate sealed containers and take
them to a recycling center. Call your local or
state office of public works or environmental
services to find a recycling center in your area
and get instructions on how to dispose of
nonrecyclable wastes.

136 Tips
 Troubleshooting
The items that are serviceable using this Manual POOR PERFORMANCE AT HIGH SPEED
are followed by the page number reference in CHECK POSSIBLE CAUSES
parenthesis. The items that require use of the 1. Disconnect fuel FUEL FLOW • Lack of fuel in tank
Honda Service Manual are followed by an line at carburetor RESTRICTED (P-34)
and check for • Clogged fuel line
asterisk. clogging (P-34) (P-34)
• Clogged fuel fill
UNRESTRICTED
cap breather tube
POOR PERFORMANCE AT LOW AND UNSTABLE FUEL FLOW
(P-34)
IDLE SPEED • Clogged fuel valve
(P-34)
CHECK POSSIBLE CAUSES • Clogged fuel filter
1. Check if air INCORRECT • Over-oiled air cleaner. (P-35)
cleaner is over-
oiled (P-43) 2. Remove air DIRTY • Not cleaned
cleaner (P-43) frequently enough
CORRECT (P-43)
AIR FILTER
NOT DIRTY
2. Check if the intake LEAKING • Loose insulator clamp
tube is leaking • Damaged insulator
3. Install a larger CONDITION • Jet size wrong, rejet
NOT LEAKING carburetor main WORSE in the opposite
jet (P-126) direction (P-126)
CORRECT
3. Check carbureator INCORRECT • Fuel-air mixture too
pilot screw lean (Turn the pilot
adjustment (P-126) screw out) (P-126)
• Fuel-air mixture too rich 4. Check carbureator CLOGGED • Contaminants in
CORRECT (Turn the pilot screw in) jets for clogging the fuel
(P-126) NOT CLOGGED

4. Check carburetor CLOGGED • Contaminants in the

jets and accelerator fuel 5. Check valve INCORRECT • Cam sprocket not
pump for clogs • Not cleaned frequently timing installed properly
enough (P-119)
NOT CLOGGED
CORRECT

5. Try spark test WAKE OR • Faulty, carbon or wet

6. Try spark test WEAK OR • Faulty, carbon or wet
INTERMITTENT fouled spark pulg (P-55)
GOOD SPARK INTERMITTENT fouled spark pulg
SPARK • Faulty ignition control GOOD SPARK
SPARK (P-55)
module*
• Faulty ignition control
• Faulty alternator*
module*
• Faulty ignition coil*
• Faulty alternator*
• Broken or shorted
• Faulty ignition coil*
spark plug wire.
• Broken or shorted
• Faulty ignition pulse
spark plug wire.
generator*.
• Faulty ignition pulse
generator*.
6. Check for LOW • Ring worn
7. Check for LOW • Ring worn
low compression. • Cylinder worn or
low compression. • Cylinder worn or
damaged
CORRECT damaged
• Piston worn or CORRECT • Piston worn or
damaged
damaged
• Head gasket not
• Head gasket not
sealing
sealing

Tips 137
138 Tips
 Technical Information
This section contains dimensions, capacities, and Vehicle Identification .......................................140
other technical data. Specifications ...................................................141
Torque Specifications.......................................142
High Altitude Carburetor Adjustment ..............145
Oxygenated Fuels.............................................146
Competition Logbook ......................................147
Optional Parts List ...........................................149
Spare Parts & Equipment.................................150
Wiring Diagram................................................151

Technical Information 139

Vehicle Identification
The frame number (2) is stamped on the right
Serial Numbers side of the steering head.

The frame, VIN, and engine serial numbers are RIGHT SIDE
required when you register your CRF. They may
also be required when ordering replacement
parts. You may record these numbers in the
Quick Reference section at the rear of the
manual.
(2)
The VIN (vehicle identification number) (1)
appears on the Safety Certification Label
attached to the left side of the frame.

LEFT SIDE
(2) frame number
(1)
The engine number (3) is stamped on the left
crankcase.

LEFT SIDE

(1) vehicle identification number

(3)

(3) engine number

140 Technical Information

 Specifications
Item English Metric Item English Metric Item English Metric
Dimension Engine Drive train
Overall length 85.5 in 2,172 mm Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type
Overall width 32.6 in 827 mm Single 10˚ inclined from Transmission 5-speed, constant mesh
Cylinder arrangement
Overall height 50.3 in 1,277 mm vertical Primary reduction 3.166
Wheelbase 58.2 in 1,479 mm Bore and stroke 3.07 x 2.06 in 78.0 x 52.2 Gear ratio I 2.142
mm
Seat height 38.0 in 965 mm Gear ratio II 1.750
Displacement 15.2 cu-in 249.4 cm3
Footpeg height 17.6 in 446 mm Gear ratio III 1.450
Compression ratio 12.9 : 1
Ground clearance 14.2 in 361 mm Gear ratio IV 1.227
Valve clearance Intake: 0.005 ± 0.001 in
Frame (0.12 ± 0.03 mm) Gear ratio V 1.041
Type Twin tube Exhaust: 0.011 ± 0.001 in Final reduction 3.923
Telescopic fork (0.28 ± 0.03 mm)
Gear shift pattern Left foot-operated return
F. suspension travel 11.0 in (279 mm) Engine oil capacity system 1-N-2-3-4-5
stroke 12.4 in (315 mm) After draining 0.70 US qt 660 cm3 Electrical
Pro-link After draining and Ignition ICM
R. suspension
travel 12.3 in (313 mm) oil filter change 0.73 US qt 690 cm3
Starting system Kickstarter
80/100 – 21 51M After disassembly 0.90 US qt 850 cm3
Front tire Spark plug :
DUNLOP D742F Transmission oil Standard NGK R0409B-8
100/90 – 19 57M capacity
Rear tire For extended high
After draining 0.63 US qt 600 cm3 speed riding NGK R0409B-9
DUNLOP D756
3
After disassembly 0.74 US qt 700 cm
Tire pressure, front (cold) 15 (100, 1.0) Spark plug gap 0.024 – 0.028 in
Carburetor (0.6 – 0.7 mm)
Tire pressure, rear (cold) 15 (100, 1.0)
Single disc brake Type Piston valve
F. brake, swept area
51.8 in2 (334.5 cm2) Identification number FCR01C
Single disc brake Main jet (standard) # 172
R. brake, swept area
60.6 in2 (391.1 cm2) Jet needle (standard) NHFS
Fuel capacity 1.9 US gal 7.3 liter
Needle clip position
3rd groove
Caster angle 27.50˚ (standard)
Trail length 4.8 in 123 mm Slow jet (standard) # 40
Fork oil capacity Pilot screw opening 1–3/4 turns out
(except fork damper 12.5 US oz 369 cm3
Float level 0.24 in 6.0 mm
per leg)
Idle speed 1,700 ± 100 rpm

Technical Information 141

Torque Specifications
Nuts, Bolts, Fasteners Torque
Item Remarks
lbf•ft N•m kgf•m
Check and tighten nuts, bolts, and fasteners before every outing. ENGINE
1 Cylinder head cover bolts 7 10 1.0
Engine (1)
2 Exhaust pipe joint nuts 15 21 2.1
RIGHT SIDE
3 Water pump cover bolts 7 10 1.0
4 Crankshaft hole cap 11 15 1.5
5 Transmission oil check
bolt 7 10 1.0
(2) 6 Clutch cover bolts 7 10 1.0
7 Cylinder bolt 7 10 1.0
8 Oil filter cover bolts 9 12 1.2
(3) 9 Cylinder head bolts 7 10 1.0
10 Drive sprocket bolt 23 31 3.2

(5)
(6) (4)

(9)
LEFT SIDE
(7)

(8)
(10)

142 Technical Information

 Torque Specifications
Frame Torque
Item Remarks
lbf•ft N•m kgf•m
(4) FRAME
1 Steering stem nut 80 108 11.0
(2)
2 Fork bridge upper pinch
(1) (13) bolts 16 22 2.2
(12)
3 Fork bridge lower pinch
(3) bolts 15 20 2.0
4 Handlebar upper
holder bolts 16 22 2.2
5 Handlebar holder nuts 32 44 4.5
6 Front axle nut 65 88 9.0
7 Front axle pinch bolts 15 20 2.0
(6)
8 Rear axle nut 94 128 13.1 NOTE 1
9 Chain adjuster lock nuts 20 27 2.8 NOTE 2
10 Front engine hanger
bracket nut 47 64 6.5
11
(10) 11 Mid engine hanger
(14) bracket nut 47 64 6.5
(13) 12 Upper engine hanger
(9) plate nuts
(engine side) 40 54 5.5
(frame side) 25 34 3.5
13 Shock absorber (upper) 32 44 4.5 NOTE 1
(lower) 32 44 4.5 NOTE 1
(15)
(18) 14 Swingarm pivot nut 65 88 9.0 NOTE 1
(5) 15 Fork (fork damper) 25 34 3.5
(fork cap) 22 30 3.1
16 Rear shock arm nuts
(swingarm side) 39 53 5.4 NOTE 1, 3
(shock link side) 39 53 5.4 NOTE 1, 3
17 Rear shock link nuts
(7) (frame side) 39 53 54 NOTE 1, 3
18 Shock spring lock nut 32 44 4.5
19 Kickstarter arm bolt 28 38 3.9

NOTES: 1. U-nut.
(19) 2. UBS nut.
(11) 3. Apply oil to the threads and flange surface.
(16) (17) 4. Alock bolt.

(9)
(8)

Technical Information 143

Torque Specifications
Frame
Torque
Item Remarks
lbf•ft N•m kgf•m
(38)
(34) FRAME
(28) (33) 20 Front brake master
cylinder holder bolts 7 9.9 1.0
21 Brake hose bolts 25 34 3.5
22 Caliper mounting bolts 22 30 3.1 NOTE 4
23 Front brake disc nuts 12 16 1.6 NOTE 1
(37) 24 Rear brake disc nuts 12 16 1.6 NOTE 1
25 Brake pedal pivot bolt 27 36 3.7
(23)
26 Spoke (front) 2.7 3.68 0.4
(rear) 2.7 3.7 0.4
27 Rim locks 9 12 1.2
28 Subframe bolts (upper) 22 30 3.1
(Iower) 36 49 5.0
29 Fork center bolt 51 69 7.0
30 Fork center lock nut 16 22 2.2
(31) 31 Disc cover bolts 10 13 1.3
(22) 32 Fork protector bolts 5.2 7 0.7 NOTE 4
33 Muffler mounting bolts
(20) (39) (right) 19 26 2.7
(21)
(left) 19 26 2.7
(35) 34 Muffler clamp bolt
(38) (41)
(33) (36) (right) 15 21 2.1
(left) 15 21 2.1
(28)
35 Exhaust joint pipe
mounting bolt 19 26 2.7
(34)
36 Exhaust joint pipe
(32)
(21) clamp bolt 15 21 2.1
(27) 37 Driven sprocket nuts 24 32 3.3 NOTE 1
(24) 38 Seat mounting bolts 19 26 2.7
39 Front brake reservoir
cap screws 0.7 1.0 0.1
40 Rear brake reservoir
cap bolts 0.7 1.0 0.1
(25) (26)
(21) 41 Fork air pressure release
(40)
screw 0.9 1.2 0.1

(29) (30) NOTES: 1. U-nut.

(27) (26) 2. UBS nut.
3. Apply oil to the threads and flange surface.
4. Alock bolt.

144 Technical Information

 High Altitude Carburetor Adjustment
When operating this motorcycle at high altitude,
the air-fuel mixture becomes overly rich.

Above 6,500 feet (2,000 m), driveability and

performance may be reduced and fuel
consumption increased. The carburetor can be
modified to compensate for this high altitude
richness.

However, the carburetor must be returned to

standard factory specifications when lower
altitude riding is desired. See your Honda dealer
for high altitude modification.

NOTICE
Sustained operation at altitudes below 5,000 feet
(1,500 m) with high altitude carburetor
modifications may cause engine overheating and
damage.

Technical Information 145

Oxygenated Fuels
Some conventional gasolines are being blended If you notice any undesirable operating
with alcohol or an ether compound. These symptoms, try another service station or switch
gasolines are collectively referred to as to another brand of gasoline.
oxygenated fuels. To meet clean air standards,
some areas of the United States and Canada use Fuel system damage or performance problems
oxygenated fuels to help reduce emissions. resulting from the use of an oxygenated fuel
containing more than the percentages of
If you use an oxygenated fuel, be sure it is oxygenates mentioned above are not covered
unleaded and meets the minimum octane rating under warranty.
requirement.
Oxygenated fuels can damage paint and plastic.
Before using an oxygenated fuel, try to confirm Be careful not to spill fuel when filling the fuel
the fuel’s contents. Some states/provinces tank. Wipe up any spills immediately.
require this information to be posted on the
pump.
NOTICE
The following are the EPA-approved percentages Oxygenated fuels can damage paint and plastic.
of oxygenates:

ETHANOL (ethyl or grain alcohol) 10% by

Volume
You may use gasoline containing up to 10%
ethanol by volume. Gasoline containing ethanol
may be marketed under the name “Gasohol”.

MTBE (Methyl Tertiary Butyl Ether) 15% by

Volume
You may use gasoline containing up to 15%
MTBE by volume.

METHANOL (methyl or wood alcohol) 5% by

Volume
You may use gasoline containing methanol
containing up to 15% methanol by volume as
long as it contains cosolvents and corrosion
inhibitors to protect the fuel system. Gasoline
containing more than 5% methanol by volume
may cause starting and/or performance problems.
It may also damage metal, rubber, and plastic
parts of your fuel system.

146 Technical Information

 Competition Logbook
Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records
the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of
previous racing events. The best way to organize worked best at a particular location. These items your logbook may include:
the many bits of information is to record them in include: • Your placing in each moto and overall
a logbook. • basic track conditions, altitude, and finishing position.
temperature • Thoughts on what you could do to improve
Your logbook can include such information as • carburetion changes your performance next time.
suspension adjustments, carburetor adjustments, • suspension settings • Notes on any patterns noted in choice of
gearing, and tire selection. This detailed • chassis adjustments tested and selected starting gate positions or in riding portions of
information, along with your comments, can • gearing the course as the day progressed that may
prove valuable when you compete at the same • tire selection prove helpful in future events.
track or on similar terrain. • air pressure • Any places on the course where you chose the
wrong line and were passed too easily.
Your logbook can also tell you when Competition Records • Notes on strategy used by your competition or
maintenance was performed and when it will be • your placings by riders in another event that are worth
necessary again. Your logbook also lets you • thoughts to improve performance next time: remembering.
record any repairs and lets you keep track of the both yours and your CRF
running time on the engine and suspension • strategy notes Maintenance Records
components. Regular maintenance items you’ll want to record
Maintenance Records in your logbook should include:
If you choose to sell your CRF, the accurate • regular interval maintenance • Dates and results of cylinder, piston and ring
maintenance records in your logbook might be • repairs examinations
the deciding deal-maker for a potential buyer. • running time on engine • Patterns for frequency of need for
• running time on suspension components decarbonization with a particular oil
Consider using different color pens or pencils to • When you last performed shock linkage and
record important information on specific Timekeeping swingarm pivot bearing maintenance
subjects. For example, record results in black, This Manual lists maintenance intervals for • Engine, transmission, and suspension oil
jetting changes in red, suspension/chassis settings every-so-many races or every-so-many hours of changes
in blue, and gearing selections in green. Color running. • chain, sprocket, chain guide and slider
codes will help you identify the information you replacements
want with a glance. Because all races are not the same, the most • coolant changes and related component
effective way to schedule maintenance is by the replacements
hours you have run your CRF. • Spark plug, brake pad and control cable
replacements
An official “guesstimate” is close enough for our
timekeeping purposes. You may choose to record In addition, you should record any irregularities
your time the same way aircraft operators do (but noted in component wear so you’ll remember to
without the benefit of an electrical hourmeter). keep a close eye on these areas in the future.
All running time is broken down into hours and
tenths of an hour (each six minutes represents
one tenth of an hour).

Technical Information 147

Competition Logbook
Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance
Time Performed, etc.)

(Make several photocopies of this page for future use)

148 Technical Information

 Optional Parts List
These parts and tools may be ordered from your FRAME Remarks FRAME Remarks
authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 296.8 lbf/in (5.30 kgf/mm)
Standard 51 Teeth, Aluminum. Standard
CARBURETOR Remarks
<114> No mark
Main jet #162 – #182 (in increments of Optional 50 Teeth, Aluminum (factory products)
(Standard: #172) 2 or 3) <114> Blue
52 Teeth, Aluminum or Red
172 paint
<114>
(aftermarket parts)
Size Handlebar
Slow jet #35 – #45 lower holder Optional 285.6 lbf/in (5.10 kgf/mm)
(Standard: #40) (in increments of 2 or 3) Standard 3 mm offset Softer White
Jet Needles Optional no offset
Standard needle: NHFS Stiffer 308.0 lbf/in (5.50 kgf/mm)
Straight diameter: Ø2.765 mm TOOLS Remarks Red
Jetneedle number
Pin spanner A To adjust spring preload.
(two spanners required) 319.2 lbf/in (5.70 kgf/mm)
Pink
Straight diameter (2.765 mm) Workstand For maintenance

Jet needle number Jet needle number

(standard series) (1/2 clip position Fork spring 25.2 lbf/in (0.45 kgf/mm)
leaner than Standard
standard series,
leaner only at 1/8
to 3/4 throttle)
1 scribe mark
(aftermarket parts)

58.51 mm 58.96 mm
Optional 24.1 lbf/in (0.43 kgf/mm)
NHFQ NHGQ 3 scribe mark
Softer
Ø2.745 mm Ø2.745 mm
General flow characteristics
Richer
(at 1/16 to 1/4 throttle)

NHFR NHGR
Ø2.755 mm Ø2.755 mm Stiffer 26.3 lbf/in (0.47 kgf/mm)
(standard needle) 1 scribe mark and
NHFS NHGS 3 scribe mark 75
Ø2.765 mm Ø2.765 mm degrees apark
Leaner

NHFT NHGT The standard fork spring and shock spring

Ø2.775 mm Ø2.775 mm mounted on the motorcycle when it leaves the
NHFU NHGU factory are not marked. Before replacing the
Ø2.785 mm Ø2.785 mm springs, be sure to mark them so they can be
distinguished from other optional springs.

Technical Information 149

Spare Parts & Equipment
There are numerous spare parts you can take to ignition components
an event to help ensure you get in a full day of top end-complete Chemical Products
riding. In addition to the usual nuts and bolts, radiator hoses
consider the following: radiator shrouds (L & R) Pro Honda GN4, HP4 (without molybdenum
brake hoses (front & rear) additives) or HP4M (with molybdenum
additives) 4-stroke Oil (Engine Oil)
Spare Parts Pro Honda HP Trans Oil or Pro Honda GN4 or
General Tools HP4 (without molybdenum additives only)
spark plugs 4-stroke Oil (Transmission Oil)
air cleaner (clean & oiled, sealed in a plastic bag) sockets (3/8 in drive) Honda Thread Lock
optional carburetor jets/needles screwdrivers: blade & Phillips No. 1, 2, 3 Pro Honda HP Fork Oil 5W
chain & masterlinks wrench, large adjustable Honda Brake Fluid
chain guide slider wrenches: open end & box Pro Honda Chain Lube
chain guide wrenches: hex (Allen) Pro Honda Foam Filter Oil
chain rollers wrench, spoke Honda Brite Cleaner
inner tubes (front & rear) torque wrench (metric scale, click-stop style) Honda Contact Cleaner
fenders pliers: standard, needle-nose, channel-lock set Honda Dielectric Compound
footpegs hammer, plastic head Honda Hand Grip Cement
front & side number plates syringe with adjustable stop Honda Hondalock
handlebar tire pressure gauge Honda Moly 60 Paste (U.S.A. only) or
grips tire irons Molybdenum Disulfide Paste (containing more
levers (brake, clutch & hot start) tire pump or air tank than 40% molybdenum disulfide additive)
clutch lever handlebar mount feeler gauge set White Lithium Grease
clutch cable vernier caliper (metric) Wheel Bearing Grease
hot start cable pressure/vacuum testing equipment (USA only) Silicone Sealer
throttle assembly High-temperature Grease
throttle cable Pro Honda HP Coolant
shift lever Honda Special Tools
brake pedal
spokes (front & rear, each side) Any special tools for your motorcycle purchased Other Products
sprockets (larger & smaller than standard, for from your Honda dealer.
gearing changes & collision damage • Lock Nut Wrench 07WMA-KZ30100 pliers-safety wire
replacement) • Spoke Wrench 07JMA-MR60100 safety wire
assorted nuts, bolts, washers, screws, cotter pins • Spoke Wrench 070MA-KZ30100 mechanic’s wire
• Stopper tool 070MG-0010100 duct tape
Additional Spares • Piston base 07958-2500001 plastic tie-wraps
front brake assembly hose clamps
rear brake assembly drop light
wheels & tires (front & rear, mounted) electrical tape
clutch disc and plates
engine & transmission oil
seat

150 Technical Information

 Wiring Diagram

SPARK THROTTLE POSITION

PLUG SENSOR

Technical Information 151

152 Technical Information
 Consumer Information
This section contains information about Authorized Manuals .........................................154
contacting Honda and how to get an official Contacting Honda.............................................155
Honda service manual. Your Honda Dealer...........................................156
The Honda Rider’s Club (USA only) ..............157

Consumer Information 153

Authorized Manuals
The Service Manual used by your authorized Honda dealer is available from NOTE: Dealers and Companies, please provide dealer or company name, and also
Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals) the name of the person to whose attention the shipment should be sent. For
purchases outside U.S.A., please write to the address shown below for a quotation.

Also available but not necessary to service your model is the Honda Common
Service Manual which explains theory of operation and basic service S
information for various systems common to all Honda motorcycles, motor H Customer Name
scooters and ATVs. I
Attention
These Honda manuals are written for the professional technician, but most P
mechanically-capable owners should find them helpful if they have the proper Street Address-No P.O. Box Number Apt. #
T
tools and skills. Special Honda tools are necessary for some procedures.
O City State Zip Code
Publication Item No. Description Price Each*
61KRN02 2006 CRF250R Service Manual $48.00 Daytime Telephone Number ( )
61CM002 Common Service Manual $48.00
31KRN620 2006 CRF250R Owner’s Manual $16.00
*Prices are subject to change without notice and without incurring obligation.

Order On-Line: www.helminc.com

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By completing this form you can order the materials desired. You can pay by Y
check or money order, or charge to your credit card. Mail to Helm, M Account Number
Incorporated, at the address shown on this order form. (USA only) E
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154 Consumer Information

 Contacting Honda
Your owner’s manual was written to cover most
of the questions you might ask about your
Honda. Any questions not answered in the
owner’s manual can be answered by your Honda
dealer. If he doesn’t have the answer right away,
he will get it for you.

If you have a difference of opinion with your

dealer, please remember that each dealership is
independently owned and operated. That’s why
it’s important to work to resolve any differences
at the dealership level.

If you wish to comment on your experiences with

your Honda or with your dealer, please send your
comments to the following address (USA only):

Motorcycle Division, American Honda Motor

Co., Inc., P.O. Box 2220, Torrance CA 90509-
2220, mailstop: 100-4W-5B,
telephone: (866) 784-1870.

Canada: Refer to the warrantly booklet that was

supplied with your vehicle.

Please include the following information in your

letter:

• name, address, and telephone number

• product model, year, and frame/VIN serial
number
• date of purchase
• dealer name and address

We will likely ask your Honda dealer to respond,

or possibly acknowledge your comments directly.

Consumer Information 155

Your Honda Dealer
Once you purchase your new Honda, get familiar Your dealer can inform you about competition
with the organization of your Honda dealer so events in your area. You’ll also find that your
you can utilize the full range of services dealer is a source of information (USA only) the
available. Honda Rider’s Club of America.

The service department is there to perform We’re sure you’ll be as pleased with the service
regular maintenance and unexpected repairs. It your Honda dealer continues to provide after the
has the latest available service information from sale as you are with the quality and dependability
Honda. of your Honda.

The parts department offers Genuine Honda

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

156 Consumer Information

 The Honda Rider’s Club (USA only)
One of the best ways to get the most enjoyment
from owning and riding your Honda is through
the Honda Rider’s Club of America. Your
purchase of a new motorcycle, scooter, ATV or
PWC from a participating U.S. Honda dealer
entitles you to a complimentary one-year
membership in the Club. There are handreds of
HRCA Chapter sponsoring dealers across the
USA with events and activities almost every
weekend. Membership benefits include:
• 24-hour, toll-free roadside assistance for your
new Honda (includes roadside assistance for
your transport vehicle as long as your Honda
is aboard or in tow).
• Vehicle transport to the nearest Honda dealer
or service center, if necessary.
• An exclusive HRCA website complete with
access to the official Honda Common Service
Manual, contests, insider information and
more.
• Reimbursement (up to $75) for Motorcycle
Safety Foundation training. Separate free
training from the Specialty Vehicle Institute of
America for ATV owners.
• One full year of the Honda Red Rider
magazine or Honda Red Rider ATV (for ATV
purchasers).
• Discounts from HRCA partners for
experienced rider courses.
• Discounted vehicle insurance from the
HRCA’s insurance partner.
• Racing contingency programs and assistance
at selected dual-sport, off-road, and motocross
events.

Contact your Honda dealer for more information

or call: 1 800-847-HRCA or log on to
www.hrca.honda.com.

Consumer Information 157

Table of Contents
The following presents the contents of each Service Preparations ADJUSTMENTS FOR COMPETITION .....95
section of your owner’s manual. Maintenance Component Locations..................28 Front Suspension Adjustments..........................96
Seat Removal ....................................................29 Rear Suspension Adjustments.........................109
MOTORCYCLE SAFETY...............................1 Fuel Tank Removal ...........................................30 Suspension Adjustments for Track
Important Safety Information..............................2 Subframe Removal............................................32 Conditions ...................................................113
Important Safety Precautions..........................2 Suspension Adjustment Guidelines.................114
Accessories & Modifications ..............................3 Service Procedures Carburetor Adjustments & Tuning Tips ..........117
Safety Labels.......................................................4 Fluids & Filters Chassis Adjustments........................................129
Fuel System.......................................................34 Gearing ............................................................130
OPERATING CONTROLS .............................5 Engine Oil .........................................................36 Tire Selection for Track Conditions................131
Operation Component Locations ........................6 Transmission Oil ...............................................39 Personal Fit Adjustments ................................132
Coolant ..............................................................41
BEFORE RIDING ............................................7 Air Cleaner ........................................................43 TIPS ................................................................133
Are You Ready to Ride? .....................................8 Crankcase Breather ...........................................45 Transporting Your Motorcycle ........................134
Is Your Motorcycle Ready to Ride?....................9 Storing Your Honda.........................................135
Pre-ride Inspection..........................................9 Engine You & the Environment ..................................136
Throttle ..............................................................46 Troubleshooting...............................................137
BASIC OPERATING INSTRUCTIONS ......11 Engine Idle Speed .............................................48
Safe Riding Precautions................................12 Clutch System ...................................................49 TECHNICAL INFORMATION ..................139
Starting & Stopping the Engine ........................13 Hot Start Lever..................................................54 Vehicle Identification ......................................140
Preparation ....................................................13 Spark Plug .........................................................55 Specifications ..................................................141
Starting Procedure ........................................13 Valve Clearance.................................................56 Torque Specifications......................................142
Flooded Engine .............................................13 Piston/Piston Rings/Piston Pin..........................64 High Altitude Carburetor Adjustment .............145
How to Stop the Engine................................14 Oxygenated Fuels............................................146
Break-in Guidelines ..........................................15 Chassis Competition Logbook .....................................147
Suspension.........................................................72 Optional Parts List ..........................................149
SERVICING YOUR HONDA........................17 Front Suspension Inspection.........................72 Spare Parts & Equipment................................150
Before You Service Your Honda Rear Suspension Inspection..........................73 Wiring Diagram...............................................151
The Importance of Maintenance .......................18 Fork Oil Change ...........................................74
Maintenance Safety...........................................19 Brakes................................................................77 CONSUMER INFORMATION ...................153
Important Safety Precautions........................19 Wheels...............................................................81 Authorized Manuals ........................................154
Maintenance Schedule ......................................20 Tires & Tubes ....................................................82 Contacting Honda............................................155
General Competition Maintenance ...................22 Drive Chain .......................................................84 Your Honda Dealer..........................................156
Before & After Competition Maintenance........26 Exhaust Pipe/Muffler ........................................87 The Honda Rider’s Club (USA only) .............157
Between Motos & Practice Maintenance .....26 Additional Maintenance Procedures .................91
After Competition Maintenance ...................26 TABLE OF CONTENTS ..............................158
Appearance Care ...............................................93
INDEX ............................................................159

QUICK REFERENCE

158 Table of contents

 Index
A C E
accessories...........................................................3 capacity, fuel .....................................................34 engine,
adjustments, carburetor, flooded .........................................................13
altitude and temperature.............................124 adjustment ..................................................117 idle speed......................................................48
carburetor ...................................................117 circuit functions..........................................119 number .......................................................140
chassis ........................................................129 components.................................................117 oil .................................................................36
control freeplay .......................................46,49 disassembly/assembly ................................121 pinging .........................................................34
engine idle speed..........................................48 high altitude adjustment.............................145 starting..........................................................13
for competition.............................................95 idle speed......................................................48 stop button....................................................14
gearing........................................................130 minor adjustments ......................................126 stopping ........................................................14
high altitude carburetor ..............................145 care, appearance ................................................93 won’t start ....................................................13
personal fit..................................................132 chain drive.........................................................84 environment, protecting ..................................136
suspension, front ..........................................96 chassis adjustment for track conditions ..........129
suspension, rear..........................................109 choke knob ........................................................13 F
suspension, track conditions ......................113 cleaner, air .........................................................43
tire selection ...............................................131 cleaning, appearance care .................................93 filter,
after competition maintenance ..........................26 clutch system, adjustment .................................49 air .................................................................43
air cleaner ..........................................................43 consumer information .....................................153 oil .................................................................37
air pressure, controls, operating...............................................5 flooded engine, starting.....................................13
front suspension ...........................................96 competition logbook........................................147 fork,
tires...............................................................82 contacting Honda ............................................155 front suspension adjustment.........................96
appearance care .................................................93 controls, operating...............................................5 front suspension inspection..........................72
authorized manuals..........................................154 coolant ...............................................................41 oil recommendation......................................74
customer service..............................................155 frame number ..................................................140
B cylinder system..................................................64 front brake lever adjustment .............................77
front suspension maintenance ...........................72
basic operation...................................................11 D fuel,
before riding ........................................................7 line................................................................34
between motos & practice maintenance ...........26 damping adjustments, filter ..............................................................35
brakes, front ..............................................................96 recommendation...........................................34
fluid level .....................................................78 rear..............................................................110 refueling .......................................................34
lever, front adjustment .................................77 dealer, your Honda ..........................................156 system...........................................................34
pad wear .......................................................80 diagram, wiring ...............................................151 oxygenated .................................................146
pedal height ..................................................77 drive chain.........................................................84 tank capacity ................................................34
break-in guidelines ............................................15 valve .............................................................13

Index 159
Index
G M R
gap, spark plug ..................................................55 maintenance, rear suspension maintenance.............................72
gasohol ............................................................146 additional procedures ...................................91 Rider’s Club Honda.........................................157
gasoline..............................................................34 after competition ..........................................26 riding,
gearing.............................................................130 before & after competition...........................26 basic operation .............................................11
guidelines, suspension adjustment ..................114 between motos & practice............................26 before..............................................................7
component locations ....................................28 important safety information..........................2
H general competition......................................22 safety precautions.........................................19
importance....................................................18
handlebar inspection..........................................91 safety ............................................................19 S
high altitude carburetor adjustment ................145 schedule........................................................20
Honda, manual, service................................................154 safety,
contacting ...................................................155 modifications.......................................................3 a few words about ..................Safety Message
Rider’s Club ...............................................157 important information ....................................2
Service Manual ..........................................154 O important precautions.....................................2
your dealer..................................................156 labels ..............................................................4
oil, maintenance..................................................19
I engine ...........................................................36 riding precautions...........................................2
fork ...............................................................74 schedule, maintenance.......................................20
identification, vehicle......................................140 transmission .................................................39 serial numbers .................................................140
idle speed, engine ..............................................48 operating, service,
inspection, pre-ride..............................................9 controls...........................................................5 customer .....................................................155
instructions ...................................................11 manuals ......................................................154
L operation component locations ...........................6 spare parts........................................................150
optional, spark knock .......................................................34
labels, safety........................................................4 parts list ......................................................149 spark plug
logbook, competition.......................................147 sprockets.....................................................130 maintenance..................................................55
oxygenated fuels..............................................146 reading........................................................128
specifications...................................................141
P spring pre-load, rear suspension .....................109
starting,
pads, brake.........................................................80 engine ...........................................................13
parts, optional..................................................149 troubleshooting...........................................137
personal fit adjustments ..................................132 steering stem inspection ....................................91
pinging, engine..................................................34 stopping engine .................................................14
plug, spark .........................................................55 storage .............................................................135
pre-load, rear suspension.................................109 subframe ............................................................32
pre-ride inspection...............................................9
protective apparel ................................................2

160 Index
 Index
suspension,
front .........................................................72,96
rear.........................................................73,109
suspension adjustment,
front ..............................................................96
rear..............................................................109
for track conditions ....................................113
guidelines ...................................................114

T
transmission oil .................................................39
tuning tips ........................................................117
throttle,
freeplay.........................................................46
inspection .....................................................47
tires,
air pressure ...................................................82
flat ................................................................82
selection........................................................83
tools ...............................................................150
torque specifications........................................142
transporting......................................................134
troubleshooting................................................137
tubes, replacing .................................................82

V
valve, fuel..........................................................34
vehicle identification.......................................140

W
washing your motorcycle ..................................93
wheels................................................................81
wiring diagram ................................................151

Index 161
162 Memo
Memo 163
Quick Reference
The following is a brief, but important collection Record important information here:
of information you need to know about your Frame No.
Honda. You’ll also find space to record
Engine No.
important notes.
Owner’s:
Name
How To Avoid Costly Repairs Address
City/State
The engine of your Honda can be the most Phone
expensive component to repair. Proper
Dealer’s:
maintenance, especially the use of the
recommended fluids and filters, prevents Name
premature wear and damage. Address
City/State
Frequent causes of costly engine repairs are: Phone
• Transmission oil & engine oil: insufficient Service Mgr.
quantity, improper oil.
• Air cleaner: dirty, leaking because of
improper installation (poor seal). Maintenance The maintenance schedule (page 21) lists service frequencies for:
each race or about 2.5 hours,
every 3 races or about 7.5 hours, and
every 9 races or about 22.5 hours
every 12 races or about 30.0 hours
Pre-ride Inspection Check the items listed on the Pre-Ride inspection checklist each time before you ride
(page 9):
Fuel/Capacity unleaded gasoline, pump octane number of 91 or higher
tank: 1.9 US gal (7.3R)
Engine oil Pro Honda GN4 or HP4 (without molybdenum additives) or HP4M (with molybdenum
additives) 4-stroke oil, or an equivalent.
Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdem additives) 4-stroke
oil, or an equivalent.
Tires 80/100 – 21 51M 100/90 – 19 57M
Front Rear
DUNLOP D742F DUNLOP D756
Type bias-ply, tube
Tire Pressure (cold) Front: 15 psi (100 kPa, 1.0kgf/cm2)
Rear: 15 psi (100 kPa, 1.0kgf/cm2)
Spark Plug standard: R0409B-8 (NGK)
optional: R0409B-9 (NGK)
Coolant ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50 solution with
Pro Honda HP Coolant or equivalent distilled water.
Drive Chain D.I.D.520DMA2

Quick Reference