Contents

MOTORCYCLE SAFETY............................. 1 SERVICING YOUR HONDA ......................21 Chassis

Important Safety Information ........................... 2 Before You Service Your Honda Suspension ...................................................... 86
Important Safety Precautions ........................ 2 The Importance of Maintenance .....................22 Brakes ............................................................. 88
Accessories & Modifications ........................... 3 Maintenance Safety .........................................23 Wheels ............................................................ 92
Safety Labels .................................................... 4 Important Safety Precautions.......................23 Tires & Tubes ................................................. 93
Maintenance Schedule ....................................24 Drive Chain .................................................... 95
INSTRUMENTS & CONTROLS.................. 5 General Competition Maintenance .................26 Exhaust Pipe/Muffler ...................................... 98
Operation Component Locations ...................... 6 Before & After Competition Maintenance .....30 Steering Damper ........................................... 102
MIL (Malfunction Indicator Lamp) ................. 7 Between Motos & Practice Maintenance.....30 Additional Maintenance Procedures ............. 105
MIL Blink Pattern ......................................... 7 After Competition Maintenance ..................31
Current DTC/Freeze DTC............................. 7 Appearance Care .......................................... 107
Circuit Inspection .......................................... 8 Service Preparations
DTC Index..................................................... 9 Maintenance Component Locations ...............32
Mode Indicator ................................................ 10 Seat ..................................................................33
Fuel Tank ........................................................34
BEFORE RIDING......................................... 11 Subframe .........................................................37
Are You Ready to Ride? ................................ 12
Is Your Motorcycle Ready to Ride? ............... 13 Service Procedures
Pre-ride Inspection ...................................... 13 Fluids & Filters
Fuel System .....................................................39
BASIC OPERATING INSTRUCTIONS .... 15 Engine Oil .......................................................48
Safe Riding Precautions .............................. 16 Transmission Oil .............................................51
Starting & Stopping the Engine ...................... 17 Coolant ............................................................53
Fast Idle Knob ............................................. 17 Air Cleaner ......................................................55
Preparation .................................................. 17 Crankcase Breather .........................................57
Starting Procedure ....................................... 17
How to Stop the Engine .............................. 18 Engine
Break-in Guidelines ........................................ 19 Throttle ............................................................58
Engine Idle Speed ...........................................60
Clutch System .................................................61
Spark Plug .......................................................66
Valve Clearance ..............................................67
Piston/Piston Rings/Piston Pin ........................76

Contents
 Contents
ADJUSTMENTS FOR COMPETITION ... 109 TIPS...............................................................141 INDEX .......................................................... 164
Engine Mode Select Button........................... 110 Transporting Your Motorcycle .....................142
Current Mode ............................................ 110 Storing Your Honda ......................................143 QUICK REFERENCE
Mode Selection.......................................... 110 Preparation for Storage ..............................143
Front Suspension Adjustments...................... 111 Removal from Storage ...............................143
Front Suspension Damping ....................... 111 You & the Environment ................................144
Fork Springs .............................................. 113 Troubleshooting ............................................145
Front Suspension Disassembly.................. 114
Front Suspension Assembly ...................... 118 TECHNICAL INFORMATION.................147
Rear Suspension Adjustments ...................... 126 Vehicle Identification ....................................148
Rear Suspension Spring Pre-Load............. 126 Serial Numbers ..........................................149
Rear Suspension Damping ........................ 127 Specifications ................................................149
Rear Suspension Race Sag ........................ 128 Torque Specifications ...................................150
Suspension Adjustments for Track Nuts, Bolts, Fasteners ................................150
Conditions .................................................... 130 Oxygenated Fuels ..........................................153
Suspension Adjustment Guidelines .............. 131 Competition Logbook ...................................154
Tuning Tips .................................................. 134 Optional Parts List ........................................156
Spark Plug Reading................................... 134 Spare Parts & Equipment ..............................157
Steering Damper Adjustment ....................... 135 Spare Parts .................................................157
Steering Damper Damping........................ 135 General Tools.............................................157
Steering Damper Adjustment Guidelines ..... 136 Honda Special Tools..................................157
Chassis Adjustments ..................................... 137 Chemical Products .....................................157
Rear End.................................................... 137 Other Products ...........................................157
Fork Height/Angle..................................... 137 Wiring Diagram ............................................158
Wheelbase ................................................. 137
Gearing ......................................................... 138 CONSUMER INFORMATION .................159
Tire Selection for Track Conditions ............. 139 Authorized Manuals ......................................160
Personal Fit Adjustments .............................. 140 Contacting Honda .........................................161
Control Positioning ................................... 140 Your Honda Dealer .......................................162
Handlebar Position, Width & Shape ......... 140 The Honda Rider's Club (USA only) ............163

Contents
2015
Honda CRF450R
OWNER’S MANUAL & COMPETITION HANDBOOK
Introduction

Introduction
Congratulations on choosing your Honda CRF As you read this manual, you will find information ABBREVIATION
motocross motorcycle. that is preceded by a symbol. This Throughout this manual, the following
information is intended to help you avoid damage abbreviations are used to identify the respective
When you own a Honda, you’re part of a to your CRF, other property, or the environment. parts or system.
worldwide family of satisfied customers – people
who appreciate Honda’s reputation for building Unless you are mechanically qualified and have Abbrev. term Full term
quality into every product. the proper tools, you should see your dealer for the CKP sensor Crankshaft Position sensor
service and adjustment procedures discussed in
Your CRF is a high performance racing this manual. DLC Data Link Connector
motorcycle that utilizes the latest motocross DTC Diagnostic Trouble Code
technology and is intended for competition use in An official Honda Service Manual for your CRF is ECM Engine Control Module
sanctioned, closed-course events by experienced available (page 160). It is the same manual your
ECT sensor Engine Coolant Temperature
riders only. dealer uses. If you plan to do any service on your sensor
CRF beyond the standard maintenance procedures
Be aware that motocross is a physically demanding in this manual, you will find an official Honda
HPSD Honda Progressive Steering
Damper
sport that requires more than just a fine Service Manual a valuable reference.
motorcycle. To do well, you must be in excellent IAT sensor Intake Air Temperature sensor
physical condition and be a skillful rider. For the If you have any questions, or if you ever need a MAP sensor Manifold Absolute Pressure sensor
best results, work diligently on your physical special service or repairs, remember that your MIL Malfunction Indicator Lamp
conditioning and practice frequently. Honda dealer knows your CRF best and is PGM-FI Programmed Fuel Injection
dedicated to your complete satisfaction.
Before riding, take time to get acquainted with PSF Pneumatic Spring Fork
your CRF and how it works. To protect your Please report any change of address or ownership TDC Top Dead Center
investment, we urge you to take responsibility for to your dealer so we will be able to contact you TP sensor Throttle Position sensor
keeping your CRF well maintained. Scheduled concerning important product information.
service is a must, of course. But it’s just as
important to observe the break-in guidelines, and You may also want to visit our website at
perform all the pre-ride and other periodic checks USA: www.powersports.honda.com.
detailed in this manual. Canada: www.honda.ca.

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 California Proposition 65 Warning
use, the manual contains a table of contents, a WARNING: This product contains or emits
detailed list of topics at the beginning of each chemicals known to the State of California to cause
section, and an index at the back of the book. cancer and birth defects or other reproductive
harm.

Introduction
A Few Words About Safety

A Few Words About Safety

Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.

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

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
judgment.

Safety Messages
Motorcycle Safety

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

Motorcycle Safety 1
Important Safety Information

Important Safety Information

Don’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 with
you take responsibility for your own safety and every additional drink. So don’t drink and ride, and
understand the challenges you can meet in don’t let your friends drink and ride either.
competitive racing.
Keep your Honda in Safe Condition.
As an experienced rider, you know there is much Maintaining your CRF properly is critical to your
you can do to protect yourself when you ride. safety. A loose bolt, for example, can cause a
The following are a few precautions we consider to breakdown in which you can be seriously injured.
be most important.

Never Carry a Passenger.

Your CRF is designed for one operator only.
Carrying 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 abilities 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

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 these labels carefully and don’t remove them.

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

(For Canada)

NEVER OPEN WHEN HOT.

Hot coolant w i l l scald you.
N ' OUVREZ PAS OUAND CHAUD.
NICHT BEI HEISSEM MOTOR ÖFFNEN.

4 Motorcycle Safety
Instruments & Controls

Instruments & Controls

Read this section carefully before you ride. It Operation Component Locations .......................6
presents the location of the basic controls on your MIL (Malfunction Indicator Lamp) ...................7
CRF. MIL Blink Pattern..........................................7
Current DTC/Freeze DTC .............................7
Circuit Inspection...........................................8
DTC Index .....................................................9
Mode Indicator.................................................10

Instruments & Controls 5

Operation Component Locations

clutch lever front brake lever

MIL
throttle grip

engine stop button engine mode select button/

mode indicator

fast idle knob (engine idle speed)

kickstarter

shift lever rear brake pedal

6 Instruments & Controls

MIL (Malfunction Indicator Lamp)

MIL (Malfunction Indicator Lamp)

The MIL (1) on your CRF keeps you informed,
alerts you to possible problems, and makes your MIL Blink Pattern Current DTC/Freeze DTC
riding safer and more enjoyable. Refer to the MIL
frequently. The MIL will blink the appropriate DTC number if The DTC is indicated in two ways according to the
the ECM detects an active problem while the failure status.
(1)
engine is running at less than 4,000 rpm.
The MIL will stay on when engine speed is over – In the case that the ECM detects an active
4,000 rpm. problem, the MIL will come on and will start to
blink the DTC when the engine is started.
The MIL has two types of blinks: a long blink and – In the case that the ECM does not detect an
short blink. The long blinking lasts for 1.2 seconds, active problem but has recorded a previous
the short blinking lasts for 0.4 seconds. problem in its memory, the MIL will not come
One long blink is the equivalent of 10 short blinks. on. If it is necessary to retrieve any past
For example, when one long blink is followed by problems stored in the memory, refer to an
two short blinks, the MIL is 12 (one long blink = official Honda Service Manual.
(1) MIL 10 blinks, plus two short blinks).

The MIL flashes when there is any abnormality in When the ECM stores more than one DTC, the
the PGM-FI system. It should also light for a few MIL will indicate them by blinking in the order
seconds and then go off when the engine is started. from the lowest number to highest number.

If the MIL comes on at any other time, reduce

speed and refer to an official Honda Service
Manual available for purchase from your dealer
(page 160).

If the MIL does not come on when the engine is

started, have your dealer check it for problems.

Instruments & Controls 7

MIL (Malfunction Indicator Lamp)

Circuit Inspection
(1) (5) (6)
Always clean around the ECM and keep debris
away from the connectors before disconnecting (4)
them.

A faulty PGM-FI system is often related to poorly

connected or corroded connections. Check the
following connections.

(1) MAP sensor connector

(2) ECT sensor connector
(3) TP sensor connector
(4) IAT sensor connector
(5) Injector connector
(6) No.1/No.2 CKP sensor connector
(7) ECM connector

Remember, circuit inspection is not a “cure-all” for

other problems in your engine’s PGM-FI system.

(2)

(3)

(7)

8 Instruments & Controls

 MIL (Malfunction Indicator Lamp)

DTC Index
Refer to MIL Blink Pattern on page 7.
MIL blinks Function Failure Symptom/Fail-safe function
1 MAP sensor circuit malfunction Poor performance (driveability)
2 MAP sensor performance problem Poor performance (driveability)
7 ECT sensor circuit malfunction Hard start at a low temperature
8 TP sensor circuit malfunction Poor engine acceleration
9 IAT sensor circuit malfunction Engine operates normally
• Engine does not start
12 Injector circuit malfunction
• Injector, fuel pump and ignition shut down
• Engine does not start
19 No.1 CKP sensor circuit malfunction
• Injector, fuel pump and ignition shut down
• Engine does not start
69 No.2 CKP sensor circuit malfunction
• Injector, fuel pump and ignition shut down
Should be serviced by your dealer, unless the owner has proper tools and is technically qualified.
The series of 12, 19, and 69 MIL blinks cannot be checked because the engine cannot be started.
If the engine does not start, check all connector connections and/or refer to an official Honda Service
Manual (page 160) for troubleshooting of the PGM-FI symptom.

Instruments & Controls 9

Mode Indicator

Mode Indicator
The mode indicator (1) is located in the engine
mode select button (2). It should light for a few
seconds and then go off when the engine is started.

(2) (1)

(1) mode indicator

(2) engine mode select button

The mode indicator indicates a selected mode

when you operate the engine mode select button
(page 110).

If the mode indicator stays on or does not come on

when it should, have your dealer check it for
problems.

10 Instruments & Controls

Before Riding

Before Riding
Before each ride, you need to make sure you and Are You Ready to Ride? ..................................12
your CRF are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? ................13
prepared, this section discusses how to evaluate Pre-ride Inspection.......................................13
your riding readiness, and what items you should
check on your CRF.

For information about suspension, steering

damper, and other adjustments, see page 109.

Before Riding 11
Are You Ready to Ride?

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, steering when you ride.
damper, and other adjustments, see page 109.

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.

12 Before Riding
Is Your Motorcycle Ready to Ride?

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 right): Check the following before each ride:
• Engine oil level ........................................... 49
• Transmission oil level................................. 52
WARNING • Fuel line for condition ................................ 39
Improperly maintaining this motorcycle or • Coolant for proper level.............................. 53
failing to correct a problem before riding • Cooling system and hoses for condition ..... 54
can cause a crash in which you can be • Spark plug for proper heat range, carbon
seriously hurt or killed. fouling and spark plug wire terminal for
looseness ..................................................... 66
Always perform a pre-ride inspection • Air cleaner for condition and
before every ride and correct any contamination ............................................. 55
problems. • Clutch lever adjustment and freeplay ......... 61
• Breather drain for cleaning ......................... 57
• Steering head bearing and related parts for
condition ................................................... 105
• Steering damper operation ........................ 102
• Throttle operation ....................................... 59
• Tires for damage or improper inflation
pressure ....................................................... 93
• Spokes for looseness................................... 92
• Rim locks for looseness .............................. 92
• PSF air pressure ........................................ 113
• Front and rear suspension for proper
operation ............................................... 86, 87
• Front and rear brakes, check operation....... 88
• Drive chain for correct slack and adequate
lubrication ............................................. 95, 96
• Drive chain sliders and drive chain rollers
for damage or wear ............................... 95, 96
• Exhaust pipe/Muffler for looseness ............ 98
• Every possible part for looseness (such as
cylinder head bolts, engine mounting bolts/
nuts, axle nuts, handlebar holder bolts, fork
bridge pinch bolts, drive chain adjuster, drive
chain guide, wire harness connectors,
kickstarter mounting bolt).................. 150-152
• MIL operation ............................................... 7

Before Riding 13
Basic Operating Instructions

Basic Operating Instructions

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

Basic Operating Instructions 15

Basic Operating Instructions

Basic Operating Instructions

Safe Riding Precautions

Before riding your CRF for the first time, please
review the Important Safety Precautions
begininng on page 2 and the previous section,
titled Before Riding.

For your safety, avoid starting or operating the

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

16 Basic Operating Instructions

Starting & Stopping the Engine

Starting & Stopping the Engine

Always follow the proper starting procedure Warm Engine Starting
described below. Starting Procedure 1. Shift the transmission into neutral.
2. Kick-start the engine. (Do not open the
Your CRF can be kickstarted with the transmission Always follow the proper starting procedure throttle.)
in gear by pulling in the clutch lever before described as follows.
operating the kickstarter. If Difficult to Start After Stalling
Check the engine oil, transmission oil and coolant 1. Shift the transmission into neutral.
levels before starting the engine (pages 49, 52, 53). 2. With the throttle fully opened, repeat
Fast Idle Knob kickstarter operation approximately 10 times
Cold Engine Starting to discharge excessive fuel from the engine.
The fast idle knob has two functions: 1. Shift the transmission into neutral. 3. Kick-start the engine. (Do not open the
• When pulled out, the fast idle knob assists in 2. If the temperature is 95°F (35°C) or below, throttle.)
first-time start-up for cold weather starting. pull the fast idle knob (1) fully out.
• When pushed in, it acts like an idle adjustment Snapping the throttle or fast idling for more than
screw. Refer to Idle Speed Adjustment on (1)
about 5 minutes may cause exhaust pipe and
page 60. muffler discolorations.

Preparation
Make sure that the transmission is in neutral.

(1) fast idle knob

3. With the throttle closed, operate the kickstarter

starting from the top of the kickstarter stroke,
kick through to the bottom with a rapid,
continuous motion.
4. About a minute after the engine starts, push the
fast idle knob back all the way to fully OFF.
If idling is unstable, open the throttle slightly.

Basic Operating Instructions 17

Starting & Stopping the Engine

How to Stop the Engine

Normal Engine Stop

1. Shift the transmission into neutral.
2. Lightly open the throttle (1) two or three times,
and then close it.
3. Push and hold the engine stop button (2) until
the engine stops completely.

(1)

(2)

(1) throttle (2) engine stop button

Emergency Engine Stop

To stop the engine in an emergency, push and hold
the engine stop button.

18 Basic Operating Instructions

Break-in Guidelines

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

This same procedure should be followed each time

when:

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

Basic Operating Instructions 19

Servicing Your Honda

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 ......................22 Suspension....................................................... 86
protect your investment, get maximum Maintenance Safety..........................................23 Front Suspension Inspection ....................... 86
performance, avoid breakdowns, and have more Important Safety Precautions.......................23 Rear Suspension Inspection......................... 87
fun. Maintenance Schedule .....................................24 Recommended Fork Oil .............................. 87
General Competition Maintenance ..................26 Fork Oil Change .......................................... 87
To help keep your CRF in good shape, this section Before & After Competition Maintenance ......30 Brakes .............................................................. 88
includes a Maintenance Schedule for required Between Motos & Practice Maintenance.....30 Wheels ............................................................. 92
servicing and step-by-step instructions for specific After Competition Maintenance ..................31 Tires & Tubes .................................................. 93
maintenance tasks. You’ll also find important Drive Chain ..................................................... 95
safety precautions, information on oils, and tips for Service Preparations Exhaust Pipe/Muffler....................................... 98
keeping your CRF looking good. Maintenance Component Locations ................32 Steering Damper............................................ 102
Seat...................................................................33 Additional Maintenance Procedures.............. 105
An ECM system is used on this motorcycle; Fuel Tank .........................................................34
consequently, routine ignition timing adjustment is Subframe ..........................................................37 Appearance Care ........................................... 107
unnecessary. If you want to check the ignition
timing, refer to the Honda Service Manual Service Procedures
(page 160). Fluids & Filters
Fuel System......................................................39
An optional tool kit may be available. Check with
Engine Oil ........................................................48
your dealer’s parts department.
Transmission Oil..............................................51
Coolant.............................................................53
Air Cleaner.......................................................55
Crankcase Breather ..........................................57

Engine
Throttle.............................................................58
Engine Idle Speed ............................................60
Clutch System ..................................................61
Spark Plug........................................................66
Valve Clearance ...............................................67
Piston/Piston Rings/Piston Pin.........................76

Servicing Your Honda 21

The Importance of Maintenance

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.

22 Servicing Your Honda

Maintenance Safety

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 not over, park it on a firm, level surface, using an
you should perform a given task. optional workstand or a maintenance stand to
provide support.
WARNING • To reduce the possibility of a fire or explosion,
Failure to properly follow maintenance be careful when working around gasoline. Use
instructions and precautions can cause only a non-flammable (high flash point)
you to be seriously hurt or killed. solvent such as kerosene –not gasoline– to
clean parts. Keep cigarettes, sparks, and flames
Always follow the procedures and away from all fuel-related parts.
precautions in this owner’s manual.

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 23

Maintenance Schedule

Maintenance Schedule
To maintain the safety and reliability of your CRF, Perform the pre-ride inspection (page 13) at each
regular inspection and service is required as shown scheduled maintenance period.
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 moto for dusty riding
condition.
The Maintenance Schedule also includes items that 2. Replace every 2 years. Replacement requires
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.
dealer perform these tasks unless you have 5. Replace the transmission oil, if the clutch discs
advanced mechanical skills and the required tools. and plates are replaced.
Procedures for items in this schedule are provided 6. Replace every year.
in an official Honda Service Manual available for
purchase from your dealer (page 160). Maintenance Procedures:
I : inspect and clean, adjust, lubricate or replace if
Service intervals in the maintenance schedule are necessary
expressed in terms of races and riding hours. To C : clean
avoid overlooking required service, we urge you to A: adjust
develop a convenient way to record the number of L : lubricate
races and/or hours you ride. R : replace
If you do not feel capable of performing a given
task or need assistance, remember that your Honda
dealer knows your CRF best and is fully equipped
to maintain and repair it. If you decide to do your
own maintenance, use only Honda Genuine Parts
or their equivalents for repair or replacement to
ensure the best quality and reliability.

24 Servicing Your Honda

 Maintenance Schedule
Perform the Pre-ride Inspection (page 13) at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. A: Adjust. L: Lubricate. R: Replace.

FREQUENCY Each race or Every 3 races or Every 6 races or Every 9 races or Every 12 races
NOTE about about about about or about Ref. Page
ITEMS 2.5 hours 7.5 hours 15.0 hours 22.5 hours 30.0 hours
FUEL LINE (NOTE 6) I R 39
FUEL PUMP FILTER (NOTE 6) R 43 – 46
THROTTLE OPERATION I 59
AIR FILTER (NOTE 1) C 55 – 56
CRANKCASE BREATHER I 57
SPARK PLUG I 66
VALVE CLEARANCE (NOTE 4) I 67 – 75
ENGINE OIL (NOTE 3) I R 49
ENGINE OIL FILTER (NOTE 3) R 49 – 50
ENGINE IDLE SPEED I 60
PISTON AND PISTON RINGS R 76
PISTON PIN R 79 – 85
TRANSMISSION OIL (NOTE 5) I R 52
RADIATOR COOLANT (NOTE 2) I 53, 54
COOLING SYSTEM I 54
DRIVE CHAIN I, L R 95
DRIVE CHAIN SLIDER I 95
DRIVE CHAIN ROLLER I 96
DRIVE SPROCKET I 97
DRIVEN SPROCKET I 97
BRAKE FLUID (NOTE 2) I 89
BRAKE PADS WEAR I 91
BRAKE SYSTEM I 88
CLUTCH SYSTEM (NOTE 5) I 61 – 62
CONTROL CABLES I, L 105
EXHAUST PIPE/MUFFLER I 98
SUSPENSION I 86, 87
SWINGARM/SHOCK LINKAGE L 29, 87
FORK OIL (NOTE 3) R 87
NUTS, BOLTS, FASTENERS I 106, 150 – 152
WHEELS/TIRES I 92 – 94
STEERING HEAD BEARINGS I 105

WE RECOMMEND THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL.

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

NOTE: 1. Clean after every moto for dusty riding condition.

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.
6. Replace every year.

Servicing Your Honda 25

General Competition Maintenance

General Competition Maintenance

Perform maintenance on firm, level ground using
an 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 Honda Genuine Parts or their equivalents

when servicing your CRF.

Clean parts in non-flammable (high flash point)

cleaning solvent (such as kerosene) when
disassembling. Lubricate any sliding surfaces,
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 on page 13.

26 Servicing Your Honda

 General Competition Maintenance
Spark Plug Spark Plug Cap Air Cleaner
Some non-resistor plugs may cause ignition problems. Refer Install a small plastic tie-wrap around the spark plug cap to Clean and oil your air cleaner regularly because the volume
to the recommendations elsewhere in this manual for specific reduce any possibility of it loosening or of water penetration. 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 25). deteriorated and allows dirt to pass. Inspect the air cleaner
closely each time it’s serviced for evidence of small tears or
seam separation. Keep a spare air 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. Pro Honda White Lithium
Grease, or an equivalent, is handy for this because any dirt
that penetrates this sealing area will show up clearly
(page 55).
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 49).

Transmission Oil Air Cleaner Housing Sealing

Drain and replace transmission oil often to ensure the greatest Remove and reseal the air cleaner connecting tube where it
service life of the transmission and clutch. Frequent changes connects to the air cleaner housing with Pro Honda Handgrip
will also assure consistent performance of both shifting and Cement or an equivalent if there is any doubt to its sealing
clutch action (page 52). integrity. Inspect the air cleaner and air intake tract regularly
for signs of deterioration or dirt penetration.

Servicing Your Honda 27

General Competition Maintenance
Handgrips Gaskets Fuel Line
Always use Pro Honda Handgrip Cement when replacing Always use new gaskets when reassembling components. Refer to Fuel Line Inspection on page 39.
handgrips. Check the fuel line for deterioration, damage, or leakage.
Refer to an official Honda Service Manual (page 160) for Cylinder head/Cylinder Replace the fuel line every year.
installation instructions. Put a little grease on the dowel pins of the cylinder head and
cylinder to prevent corrosion from dissimilar metals. The
Throttle Grip tolerances are quite tight, so it’s important to keep these
Right throttle grip: Align the index mark on the throttle grip dowels absolutely clean (pages 76, 78).
with the index mark of the throttle pipe.
Left handlebar grip: Align the index mark on the left
handlebar grip with the paint mark on the handlebar.

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.
For added security, you may choose to bind the handgrips to
It makes good racing sense.
the handlebar and throttle pipe with safety wires 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 handgrip 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 Pro Honda Dielectric Grease on all electrical
connections.

Throttle Control
Remove the throttle control every few rides, clean the inside
of the throttle pipe and handlebar thoroughly. Inspect the cable
carefully for kinks or other damage that may restrict throttle
control in anyway. Move the handlebar from lock to lock to be
Engine Mounting Bolts and Nuts
sure there is no cable interference. Make certain the throttle
Make sure the engine mounting bolts and nuts are tightened
operation is perfect after servicing and inspecting.
to the proper torque specification. For added peace of mind,
remove the nuts, clean the threads, and apply Pro Honda
Hondalock or an equivalent prior to torquing the nuts.

28 Servicing Your Honda

 General Competition Maintenance
Suspension Linkage Lubrication Brake Fluid Replacement PSF Air Pressure
Disassemble, clean, inspect and lubricate all suspension linkage Refer to Brake Pad Wear on page 91. Set the PSF air pressure within the specified range
pivot bearings with molybdenum disulfide grease (containing Brake Caliper Inspection: Be sure both the front and rear (page 113).
more than 3% molybdenum disulfide additive) after each 7.5 calipers are able to move freely on the caliper pin and caliper
hours of running time in order to maintain proper suspension bracket pins. Check pad thickness periodically and replace the Steering Head Bearings
pads when minimum thickness is reached. If the brakes fade Periodically clean, inspect and regrease the steering head
performance and minimize component wear.
when they are hot, inspect the pads for glazing or damage, and bearings — especially if wet, muddy or extremely dusty
replace if necessary. courses are encountered often.
Brake Fluid Replacement: Refer to an official Honda Service Use urea based multi-purpose grease designed for high
Manual (page 160) for brake fluid replacement instructions. temperature, high pressure performance (example:
Replace the brake fluid in the brake system every 2 years. EXCELITE EP2 manufactured by KYODO YUSHI, Japan
Replace the fluid more frequently if you subject your brakes to or equivalent).
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.

Swingarm Pivot Lubrication

Clean, inspect and lubricate the swingarm and suspension
linkage pivots with molybdenum disulfide grease (containing
more than 3% molybdenum disulfide additive). Be sure all of
the dust seals are in good condition. Fork Oil/Performance
Disassemble, clean and inspect the fork and replace the oil
regularly. Contamination due to the tiny metal particles
produced from the normal action of the fork, as well as
normal oil breakdown, will deteriorate the performance of
the suspension. Refer to an official Honda Service Manual
(page 160). Use only KHL15-11 (KYB) which contains
special additives to assure maximum performance of your
CRF’s front suspension.
Swingarm
Do not attempt to weld or otherwise repair a damaged
swingarm. Welding will weaken the swingarm.

Spokes
Footpegs Check spoke tension frequently between the first few rides.
Worn footpeg teeth can be repaired by filing the grooves As the spokes, spoke nuts and rim contact points seat-in,
between the teeth with a triangular shaped file. the spokes may need to be retightened. Once past this initial
Be aware that filing them too sharp will reduce boot sole Bleed Hole seating-in period, the spokes should hold their tension.
lifespan. Sharpen only the points of the teeth. Filing the After every race, check the bleed hole below the water pump Still, be sure your race maintenance program includes
grooves deeper will weaken the footpegs. Be sure the pegs cover for leakage. Clean away any clogged dirt or sand, if checking spoke tension and overall wheel condition on a
are free to pivot freely and that the pivot pin retaining cotter necessary. Check for signs of seal leakage. If water leaks regular basis (page 92).
pins are in good condition. through the bleed hole, replace the mechanical seal. If oil leaks
through the bleed hole, replace the oil seal. Make sure Nuts, Bolts, Etc
that there is no continuous coolant leakage from the bleed hole Application of a thread locking agent to essential fasteners
while operating the engine. A small amount of coolant offers added assurance and security. Remove the nuts,
weeping from the bleed hole is normal. See an official Honda clean the threads of both the nuts and bolts, apply Pro
Service Manual or consult your dealer for replacing the Honda Hondalock or an equivalent and tighten to the
mechanical seal or oil seal. Both seals should be replaced at specified torque.
the same time.

Servicing Your Honda 29

Before & After Competition Maintenance

Before & After Competition Maintenance

Do not adjust the PSF air pressure to less than the
Between Motos & Practice Maintenance minimum calculated value or more than the
maximum calculated value.
After practice or between motos you have a chance
to make additional checks and adjustments.

• Clean accumulated dirt from under the fenders (1)

and off the wheels, suspension components,
handgrips, controls, and footpegs. A stiff,
nylon parts cleaning brush works well.
• Check tire air pressure.
• Check spoke tension, and make sure the rim
locks are secure.
(1) chain adjuster index marks

• After riding, the temperature and pressure inside

the front fork is high.
When adjusting the PSF air pressure after riding,
use the pressure adjustment value for “Before
riding” as a reference.
For details on PSF air pressure adjustment when
front fork is cold, refer to page 113.
Pressure adjustment range:
D = PSF air pressure increase
• Check to make sure the sprocket bolts and nuts
are secure. D= (PSF air pressure measurement after riding) -
• Clean the sides of the drive chain with a stiff, (PSF air pressure measurement before riding)
nylon parts-cleaning brush. Lubricate and
adjust the chain as necessary. psi
(kPa, kgf/cm2)
Do not perform maintenance while engine is Before riding After riding
running. Injury to your fingers or hands may result. (when front
fork is cold)
• After adjustment, check that the chain adjuster 31 D + 31
soft (minimum)
(220, 2.2) (220, 2.2)
index marks (1) are in the same position on
each side. This will ensure that the rear wheel medium - soft 33 D + 33
(230, 2.3) (230, 2.3)
is in proper alignment and allow maximum
35 D + 35
performance from the rear disc brake. standard
(240, 2.4) (240, 2.4)
Maintaining proper wheel alignment will also 36 D + 36
extend brake pad wear. medium - stiff
(250, 2.5) (250, 2.5)
stiff (maximum) 37 D + 37
(260, 2.6) (260, 2.6)

30 Servicing Your Honda

 Before & After Competition Maintenance
Routine Cleaning
After Competition Maintenance If your CRF is only slightly dirty, it is best to clean
it by hand with the aid of a stiff bristled nylon
It is important to the long term performance of brush and some clean rags.
your CRF to practice a consistent maintenance
program. Right after the event is a good time to Take care to prevent catching your fingers between
begin your next maintenance cycle. the chain and sprocket.
After Race Lubrication A variety of reasonably priced cleaning brushes
Apply a light coating of rust-inhibiting oil to the are available from variety, drug, food, and
drive sprocket and any steel portions of the chassis hardware stores. Some of these brushes are
or engine where the paint has worn away. extremely useful in removing dirt from the many
This will prevent rusting of the exposed metal. tight contours of the metal pieces of your CRF.
Apply rust-inhibiting oil more heavily if the event Avoid using stiff, abrasive brushes on the plastic or
was particularly wet or muddy. Take care to avoid rubber parts.
spraying any oil near the brake pads or the brake
discs. If your CRF was exposed to sea air or salt water,
rinse it as soon as possible after the event, dry it,
Take care to prevent catching your fingers between and apply a spray lubricant to all metal parts.
the chain and sprocket.
If you decide to wash your CRF or use cleaners,
Remove the drive chain, clean and lubricate it refer to Appearance Care (page 107).
(pages 96, 97). Be sure the chain is wiped clean
and is dry before lubricating the chain.

Servicing Your Honda 31

Maintenance Component Locations
front brake fluid reservoir
clutch lever front brake lever

throttle grip
air bleed bolt

radiator cap

fuel fill cap

• front suspension high speed • front suspension high speed

compression damping adjuster rebound damping adjuster
fast idle knob • rear suspension high speed • front suspension low speed
• front suspension low speed
(engine idle speed) compression damping rear suspension rebound damping adjuster
compression damping adjuster
spark plug adjuster rebound damping
engine oil rear suspension
• rear suspension low speed adjuster PSF air valve
fill cap spring pre-load
compression damping (both left and right)
adjuster
air cleaner adjuster
front brake steering damper
caliper adjuster
crankcase
breather
tubes

rear brake engine oil

pedal drain bolt
transmission drive chain rear brake fluid transmission transmission
engine oil filter oil drain bolt rear brake
caliper reservoir oil fill cap oil check bolt

32 Servicing Your Honda

Seat

Seat
Refer to Important Safety Precautions on page 23. Installation
1. Install the seat while aligning the seat front
Removal prong (1) with the front seat bracket (2) and
1. Remove the seat mounting bolts (1). seat rear prong (3) with the seat stopper plate
2. Remove the seat (2) by sliding it backward. (4).
2. Install and tighten the seat mounting bolts to
(2) the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)

(1) (3)

(2)

(1)

(1) seat mounting bolts (2) seat

(4)

(1) seat front prong (3) seat rear prong

(2) front seat bracket (4) seat stopper plate

Servicing Your Honda 33

Fuel Tank

Fuel Tank
Refer to Important Safety Precautions on page 23. (6) (5) 10. Remove the fuel tank bolt and collar (11).

Removal (8)
1. Remove the seat (page 33).
(11)
2. Remove the shroud A bolts and collars (1). (10)
3. Remove the shroud B bolts (2).
4. Slide the shrouds (3) toward the front to (9)
separate them from the air cleaner housing
covers (4).

(3)

(2) (8) breather tube

(9) fuel tank band
(5) hooks (6) recesses (10) air cleaner rubber
(11) fuel tank bolt and collar
(4)
7. Install a hose clamp (7) to the breather tube (8)
and shut the hose clamp securely. 11. Unhook the fuel feed hose (12) from the clamp
(13).

(1) (8)

(1) shroud A bolts and collars

(2) shroud B bolts
(3) shrouds (12)
(4) air cleaner housing covers (7)

5. Slide the shrouds toward the rear until their

hooks (5) are aligned with the recesses (6) of
the fuel tank.
(13)
6. Turn the shrouds as shown in the figure, and
then remove them. (7) hose clamp (8) breather tube
(12) fuel feed hose (13) clamp
8. Pull the breather tube (8) out of steering stem
nut.
9. Unhook the fuel tank band (9) and air cleaner
rubber (10).

34 Servicing Your Honda

 Fuel Tank
12. Pull the fuel tank (14) out of the frame and 13. Check for interference between the frame and Installation
hang it to the left of the frame. tank and adjust the cushion rubbers (16) if 1. Install the fuel feed hose (1) to the clamp (2).
Check the fuel tank stopper cable (15) for necessary.
deterioration, kinks or other damage.

Do not support the fuel tank by the fuel feed hose

(12).
7.1 – 7.5 in (1)
(180 – 190 mm)
WARNING
Gasoline is highly flammable and
explosive.
You can be burned or seriously injured (2)
0 – 0.4 in
when handling fuel. (16) (0 – 10 mm)
• Stop the engine and keep heat, sparks (1) fuel feed hose (2) clamp
and flame away. (16) cushion rubbers
• Handle fuel only outdoors. 2. Install the fuel tank (3) on the frame.
• Wipe up spills immediately. 3. Install the collar and fuel tank bolt (4).
4. Hook the air cleaner rubber (5) and the fuel
tank band (6).
(14)
(4)

(5)
(15)
(6)

(3)

(12)

(12) fuel feed hose (15) fuel tank stopper cable

(14) fuel tank (3) fuel tank
(4) collar and fuel tank bolt
(5) air cleaner rubber
(6) fuel tank band

(cont’d)

Servicing Your Honda 35

Fuel Tank
5. Put the breather tube (7) in the steering stem 9. Slide the shrouds (12) toward the rear so that
nut (8). the shroud tabs (14) and the tabs on the air
6. Remove the hose clamp (9) from the breather cleaner housing covers (15) are aligned.
tube. 10. Install the shroud B bolts (16), collars and
shroud A bolts (17).
(7)
Tighten the shroud B bolts to the specified
torque:
3.8 lbf·ft (5.2 N·m, 0.5 kgf·m)

(9) (12)

(8)
(16)

(14)
(7) breather tube (9) hose clamp
(8) steering stem nut

7. Align the shroud hooks (10) with the recesses

(11) of the fuel tank. (17)
(15)
8. Turn the shrouds (12) and hook them onto the
frame (13). (12) shrouds
(11) (10) (14) shroud tabs
(13) (15) air cleaner housing cover tabs
(16) shroud B bolts
(17) collars and shroud A bolts

11. Install the seat (page 33).

(12)

(10) shroud hooks

(11) recesses
(12) shrouds
(13) frame

36 Servicing Your Honda

Subframe

Subframe
Refer to Important Safety Precautions on page 23. 5. Remove the air cleaner mounting bolts (5) and Installation
unhook the fuel tank band (6). 1. Loosely attach the upper and lower ends of the
Removal
subframe to the main frame and loosely install
1. Remove the seat (page 33).
all subframe bolts.
2. Remove the right and left mufflers (page 98). (6)
2. Align the subframe with the rear wheel and
3. Remove the rear fender mounting bolts (1) and
tighten the subframe upper bolts (1) and
slightly pull the rear fender (2) backward.
subframe lower bolts (2) to the specified
torque:
(1)
(5) subframe upper bolts:
24 lbf·ft (32 N·m, 3.3 kgf·m)
subframe lower bolts:
36 lbf·ft (49 N·m, 5.0 kgf·m)
Left side: Right side:

(5) air cleaner mounting bolts

(6) fuel tank band

(2) 6. Remove the subframe lower bolts (7) and

subframe upper bolts (8). (1) (1)
(1) rear fender mounting bolts Remove the subframe (9). (2) (2)
(2) rear fender
Left side: Right side:
4. Remove the air cleaner box (3) from the
subframe (4).
(3) (1) subframe upper bolts
(4) (2) subframe lower bolts
(9) (9)
(8) (8)

(4) (7) (7)

(7) subframe lower bolts

(8) subframe upper bolts
(9) subframe

(3) air cleaner box

(4) subframe

(cont’d)

Servicing Your Honda 37

Subframe
3. Install the air cleaner box (3) to the subframe 5. Hook the fuel tank band (6).
(4). 6. Install the air cleaner mounting bolts (7).
(3) (6)
(4)

(7)
(4)

(3) air cleaner box (6) fuel tank band

(4) subframe (7) air cleaner mounting bolts

4. Slide the rear fender toward the front to align 7. Install the left and right mufflers (page 99).
the hole in the rear fender with the hole in the 8. Install the seat (page 33).
subframe, and then install the rear fender
mounting bolts (5).

(5)

(5) rear fender mounting bolts

38 Servicing Your Honda

Fuel System

Fuel System
Refer to Important Safety Precautions on page 23.
Refueling Procedure WARNING
Gasoline is highly flammable and
Fuel 1. To open the fuel fill cap (1), pull the breather explosive. You can be burned or seriously
tube (2) out of the steering stem nut (3). Turn injured when handling fuel.
Type Unleaded the fuel fill cap counterclockwise and remove
Pump Octane Number 91 (or higher) it. • Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
Use only unleaded fuel in your CRF. If you ride (3)
• Wipe up spills immediately.
your CRF in a country where leaded fuel might be
available, take precautions to use only unleaded
fuel. (2) 3. Close the fuel fill cap and insert the breather
tube in the steering stem nut.
Your engine is designed to use any unleaded
gasoline that has a pump octane number of 91 or (1) Fuel Line Inspection
higher. Gasoline pumps at service stations
normally display the pump octane number. 1. Hang the fuel tank to the left side of the frame
For information on the use of oxygenated fuels, see (4) (page 34).
page 153. 2. Remove the fuel quick connect fitting cover
(1) fuel fill cap (3) steering stem nut
(1).
Use of lower octane gasoline can cause persistent (2) breather tube (4) filler neck bottom
3. Check the fuel line (2) for cracks,
“pinging” or “spark knock” (a louder rapping
2. Add fuel until the level reaches the bottom of deterioration, damage or leakage. Replace the
noise) which, if severe, can lead to engine damage.
the filler neck (4). fuel line, if necessary.
(Light pinging experienced while operating under
a heavy load, such as climbing a hill, is no cause Fuel Tank Capacity: 1.66 US gal (6.3 ℓ)
for concern.)
• Be careful not to damage the fuel pump while
If pinging or spark knock occurs at a steady engine filling the fuel tank.
speed under normal load, change brands of • Avoid overfilling the tank. There should be no (2)
gasoline. If pinging or spark knock persists, fuel in the filler neck.
consult your dealer. (1)

Never use stale or contaminated gasoline. Avoid

getting dirt, dust or water in the fuel tank.

(1) fuel quick connect fitting cover

(2) fuel line

4. Install the fuel quick connect fitting cover.

5. Install the fuel tank (page 35).

Servicing Your Honda 39

Fuel System
6. Place a shop towel (6) over the fuel quick
Fuel Pressure Relieving Fuel Line Replacement connect fitting.
Injector side: Fuel Pump side:
1. Hang the fuel tank to the left side of the frame Disconnection
(page 34). 1. Relieve the fuel pressure (this page). (6)
2. Disconnect the fuel pump connector (1). 2. Hang the fuel tank to the left side of the frame.
3. Remove the fuel quick connect fitting cover
(1) from the fuel pump (2).
4. Check the fuel quick connect fitting (3) for
dirt, and clean if necessary.
(1)
Injector side: Fuel Pump side:
(3)
(1)

(6) shop towel

(1) fuel pump connector

3. Reposition the fuel tank and start the engine

(2)
and let it idle until the engine stalls.
(1) fuel quick connect fitting cover
(2) fuel pump
(3) fuel quick connect fitting

5. Remove the bolt (4), clamp and setting rubber

(5).
(4)

(5)

(4) bolt (5) clamp and setting rubber

40 Servicing Your Honda

 Fuel System
7. Unlock the slide retainer (7) of the quick 8. Remove the rubber cover (10) from the fuel Connection
connect fitting by completely pulling it up. joint of the fuel pump. 1. Install the rubber cover (1) onto the fuel joint
Release the fuel quick connect fitting from the (2) of the fuel pump as shown.
fuel joint (8) while holding the connector (10)
housing (9).
• Use a shop towel to absorb the remaining (2) (1)
fuel in the fuel feed hose.
• Be careful not to damage the hose or other
parts.
• Do not use tools.
• Dirt intruding into the connector housing
may cause slide retainer sticking.
WARNING
Gasoline is highly flammable and (10) rubber cover
explosive. You can be burned or seriously
injured when handling fuel. 9. To prevent damage and keep foreign matter (1) rubber cover
out, cover the disconnected connectors (11) (2) fuel joint
• Stop the engine and keep heat, sparks and fuel joints (8) with plastic bags (12).
and flame away. 2. Be sure that the slide retainer (3) is completely
• Handle fuel only outdoors. (12) (11) pulled up before connecting the quick connect
• Wipe up spills immediately. fitting.
• Do not bend or twist the fuel feed hose.
Injector side: Fuel Pump side:
• Do not reuse the kinked or damaged fuel
(7) (7)
hose.
• Do not use gloves or a shop towel while
(8) installing the quick connect fitting.
(9)
(3)
(8)
(8)
(8) fuel joint
(11) disconnected connectors
(9) (12) plastic bags

(7) slide retainer

(8) fuel joint
(9) connector housing

(3) slide retainer

(cont’d)

Servicing Your Honda 41

Fuel System
3. Connect the quick connect fitting to the fuel 4. Install the setting rubber (5), clamp (6) and bolt 5. Install the fuel quick connect fitting cover (10).
joint (2) until you hear the “click” while (7) by aligning the clamp tab (8) with the
holding the connector housing (4). Lock the groove (9) of the stay. Be sure the rubber cover (1) is properly installed
slide retainer (3) by pushing it until you hear between the fuel quick connect fitting cover and
the “click”. (7) (8) fuel pump.
If it is hard to connect, put a small amount of en-
(5)
gine oil on the pipe end of the fuel joint. (10)
Injector side: Fuel pump side: (6)
(3) (3)

(2)
(4)
(9)

(2) (5) setting rubber (8) clamp tab (1)

(6) clamp (9) groove
(7) bolt
(4) (1) rubber cover
(10) fuel quick connect fitting cover
(2) fuel joint
(3) slide retainer 6. Increase the fuel pressure (page 47).
(4) connector housing

42 Servicing Your Honda

 Fuel System
Removal 5. Remove the fuel pump unit (8) and O-rings (9).
Fuel Pump Filter Replacement 1. Relieve the fuel pressure (page 40).
2. Disconnect the fuel line (page 40). Be careful not to damage the fuel pump unit.
Empty the fuel tank into an approved gasoline 3. Remove the fuel pump mounting bolts (1),
container using a commercially available hand stopper cable guide (2), stopper cable (3), (8)
siphon or an equivalent method. washers (4), collars (5), conical spring washers
Be careful not to damage the fuel pump while (6) and fuel pump plate (7) while holding the
draining the fuel in the fuel tank. fuel tank.
4. Remove the fuel tank.

WARNING Be careful not to drop the fuel tank when removing

the stopper cable. (9)
Gasoline is highly flammable and
explosive. You can be burned or seriously (3)
injured when handling fuel. (2)
(1)
• Stop the engine and keep heat, sparks (8) fuel pump unit (9) O-rings
and flame away. (4)
• Handle fuel only outdoors. 6. Disconnect the fuel pump wire terminals (10)
• Wipe up spills immediately. (5) from the fuel pump base (11).
(6) Be careful not to damage the wires when
disconnecting the fuel pump wire terminals.

(7)

(10)

(11)

(10) fuel pump wire terminals

(1) fuel pump mounting bolts
(11) fuel pump base
(2) stopper cable guide
(3) stopper cable
(4) washers
(5) collars
(6) conical spring washers
(7) fuel pump plate

(cont’d)

Servicing Your Honda 43

Fuel System
7. Check the hooks (12) of the fuel pump unit 9. Remove the fuel pump unit holder assembly 11. Remove the fuel pump assembly (20) with fuel
holder and tabs (13) on the fuel pump base for (15) from the fuel pump base (16) and remove pump filter (21), O-ring (22) from the fuel
damage or discoloration. the O-ring (17). pump unit holder (23).
If the hooks and tabs are damaged or
discolored, replace the fuel pump unit as an Wipe the spilled out fuel immediately.
assembly.
8. Release the hooks of the fuel pump unit holder
from the grooves (14) in the fuel pump base (20)
tabs while pushing the holder against the base
and slightly spreading the base tabs. (15)
(21)

Be careful not to damage the hooks and tabs.

(13) (14) (23)
(22)
(17)

(16) (20) fuel pump assembly

(21) fuel pump filter
(15) fuel pump unit holder assembly (22) O-ring
(16) fuel pump base (23) fuel pump unit holder
(12) (17) O-ring
12. Check the fuel pump filter (21) for clog,
(14) 10. Remove the fuel pump stopper (18) and damage or deterioration and replace it if
(13)
damper rubber (19). necessary.
13. Remove the fuel pump filter from the fuel
pump assembly (20).
(12) hooks (14) grooves (18)
(13) tabs
(20)
(19)

(21)

(18) fuel pump stopper

(19) damper rubber
(20) fuel pump assembly
(21) fuel pump filter

44 Servicing Your Honda

 Fuel System
Installation 2. Apply small amount of engine oil to a new 5. Apply small amount of engine oil to a new
1. Install a new fuel pump filter (1) onto the fuel O-ring (5). O-ring (13).
pump assembly (2) aligning its hook (3) with Install a new O-ring to the fuel pump assembly Install a new O-ring to the fuel pump base (14).
the joint boss (4) completely. (6). 6. Install the fuel pump unit holder assembly (15)
3. Install the fuel pump assembly with fuel pump into the fuel pump base while aligning its
Be careful not to damage the hook. filter into the fuel pump unit holder (7) while hooks (16) with the grooves (17) in the fuel
routing the fuel pump red (8) and black (9) pump base tabs (18).
(2)
wires through the holder grooves (10) as If the gap between the hooks and tabs is more
shown. than 0.04 in (1.0 mm), replace the fuel pump
unit.
(3) (8)
(8)
(10) Be sure that the hooks are completely seated.
(4) (10) (16) (15)
(10)
(6) (9)
(1)

(1) fuel pump filter (new) (3) hook (17) (18)

(7) (9) (5) (17) (18)
(2) fuel pump assembly (4) joint boss

(13)
(5) O-ring (new) (8) red wire
(6) fuel pump assembly (9) black wire (14)
(7) fuel pump unit holder (10) grooves
(13) O-ring (new)
4. Install a new damper rubber (11) to the fuel (14) fuel pump base
pump filter as shown. (15) fuel pump unit holder assembly
Install fuel pump stopper (12). (16) hooks
(17) grooves
(18) tabs
(12)

(11)

(11) damper rubber (new) (12) fuel pump stopper

(cont’d)

Servicing Your Honda 45

Fuel System
7. Connect the fuel pump red (19) and black (20) 9. Install a new O-ring (24) into the fuel tank 12. Install the conical spring washers (29), collars
wire terminals to the fuel pump base terminals groove. (30), washers (31), stopper cable (32), stopper
(21). Push the wire terminals until they stop as 10. Install the fuel pump unit (25) into the fuel tank cable guide (33) and fuel pump mounting bolts
shown. (26). (34).
Be careful not to damage the wires. Be careful not to damage the wires. 13. Install the fuel tank.
8. Apply 0.02 oz (0.5 g) maximum of engine oil (25)
Make sure that the convex surfaces of the conical
to a new O-ring (22).
(26) spring washers are upside.
Install a new O-ring onto the fuel pump unit (32)
(23). (29) (30) (34)

(24) (29) (30)

(31) (34)
(23)

(19) (20) (24) O-ring (new) (26) fuel tank (33)

(25) fuel pump unit (29) conical spring washers
(30) collars
(22) 11. Install the fuel pump plate (27) with its (31) washers
(21) (32) stopper cable
identification mark (28) facing toward the (33) stopper cable guide
front side and facing up. (34) fuel pump mounting bolts
(19) (20)

14. Tighten the fuel pump mounting bolts to the

(28)
specified torque in the specified sequence as
shown:
8 lbf·ft (11 N·m, 1.1 kgf·m)
(21)
3
(19) red wire terminal
(20) black wire terminal 1
5
(21) fuel pump base terminals
(22) O-ring (new)
(23) fuel pump unit
(27)
6
(27) fuel pump plate
(28) identification mark
4 2

15. Connect the fuel line (page 41).

16. Increase the fuel pressure (page 47).

46 Servicing Your Honda

 Fuel System
3. Before connecting the battery harness cables to 6. Position the fuel tank on the main frame.
Fuel Pressure Increasing a 12V battery (3), make sure that the battery 7. Turn the “PUMP” selector switch (9) ON.
harness selector switches (4) are OFF. The selector switches can be used to change
Make sure the fuel remains enough (0.3 US gal 4. Connect the battery harness positive (+) cable power delivery as follows:
(1.0 Ɛ) minimum) in the fuel tank and add fuel if (5) first, then connect the battery harness – “ECM” selector switch ON:
necessary before increasing fuel pressure. negative (–) cable (6) to the terminals of a 12 V Power to ECM only.
battery. – “PUMP” selector switch ON:
1. Connect the fuel pump connector (1). 5. Connect the battery harness adaptor (7) Power to fuel pump only.
between the battery harness (8) and the DLC/ – Both selector switches ON:
fuel pump sub harness connectors (2) as Power to ECM and fuel pump.
shown. 8. Run the fuel pump for about 3 – 5 seconds, and
(1)
• Battery harness 070MZ-MENA100 fuel pressure will rise.
• Battery harness adaptor 070MZ-KRN0100 9. Turn the “PUMP” selector switch OFF.
(4) Check that there is no leakage in the fuel line.

(8) (9)

(5) (6)

(1) fuel pump connector (2)

2. Disconnect the DLC/fuel pump sub harness

connector (2). (3)

(7)

(2) DLC/fuel pump sub harness connectors (9) “PUMP” selector switch
(3) 12 V battery
(4) battery harness selector switches 10. Make sure that the battery harness selector
(5) battery harness positive (+) cable
(6) battery harness negative (–) cable
switches are OFF.
(7) battery harness adaptor 11. Disconnect the battery harness negative (–)
(2) (8) battery harness cable from the battery first, then disconnect the
battery harness positive (+) cable.
12. Remove the battery harness and battery
harness adaptor.
(2) DLC/fuel pump sub harness connector 13. Connect the DLC/fuel pump sub harness
connector.
14. Install the fuel tank (page 35).

Servicing Your Honda 47

Engine Oil

Engine Oil
Refer to Important Safety Precautions on page 23. • Your CRF does not need oil additives. JASO T 903 standard
Use the recommended oil. The JASO T 903 standard is an index for engine
Using the proper oil, and regularly checking, • Do not use API SH or higher 4-stroke engine oils oils for 4-stroke motorcycle engines.
adding, and changing oil will help extend the displaying a circular API “energy conserving” or There are two classes: MA and MB.
service life of the engine. Even the best oil wears “resource conserving” service label on the Oil conforming to the standard is labeled on the oil
out. Changing oil helps get rid of dirt and deposits. container. They may affect lubrication. container. For example, the following label shows
Operating the engine with old or dirty oil can the MA classification.
damage your engine. Running the engine with
(1)
insufficient oil can cause serious damage to the
engine.

Oil Recommendation NOT RECOMMENDED OK (2)

API SG or higher except oils

Other viscosities shown in the following chart may
classification labeled as energy be used when the average temperature in your
(1) oil code
conserving or resource riding area is within the indicated range. (2) oil classification
conserving on the circular
API service label
viscosity SAE 10W-30
(weight)
JASO T 903 standard MA
suggested oil* Pro Honda GN4 4-stroke
Oil (USA & Canada), or
Honda 4-stroke oil, or an
equivalent motorcycle oil

* Suggested 4-stroke engine oils are equal performance

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

48 Servicing Your Honda

 Engine Oil
6. Check that the O-ring (4) is in good condition
Checking & Adding Oil and replace it if necessary. Changing Engine Oil & Filter
7. Reinstall the engine oil fill cap/dipstick (1).
1. Run the engine at idle for 3 minutes, then shut 1. Run the engine at idle for 3 minutes, then shut it off.
it off. 2. Support the CRF in an upright position on a
2. Wait 3 minutes after shutting off the engine to (4) level surface.
allow the oil to properly distribute itself in the 3. Remove the engine oil fill cap/dipstick (1)
engine. from the left crankcase cover.
3. Support the CRF in an upright position on a 4. Place an oil drain pan under the engine to catch
level surface. the oil. Then remove the engine oil drain bolt
4. Remove the engine oil fill cap/dipstick (1), (2) and sealing washer (3).
wipe it clean, and insert it without screwing it 5. With the engine stop button pushed, repeat
in. Remove the oil fill cap/dipstick. (1)
kickstarter operation approximately five times
5. Check that the oil level is between the upper to drain the engine oil completely.
(2) and lower (3) level marks on the engine oil 6. After the oil has drained, apply engine oil to
fill cap/dipstick.
the drain bolt threads and seating surface, then
• If the oil is at or near the upper level mark, (1) engine oil fill cap/dipstick
you do not have to add oil. (4) O-ring tighten it with a new sealing washer to the
• If the oil is below or near the lower level specified torque:
mark, add the recommended oil until it 8. Check for oil leaks. 12 lbf·ft (16 N·m, 1.6 kgf·m)
reaches the upper level mark. (Do not Pour the drained oil into a suitable container and
overfill.) dispose of it in an approved manner (page 144).
Reinstall the engine oil fill cap/dipstick.
Repeat steps 1 – 5.
NOTICE
Improper disposal of drained fluids is harmful to
(2) the environment.

(3)

(3)

(1)

(1) engine oil fill cap/dipstick

(2) upper level mark
(3) lower level mark (1) (2)

(1) engine oil fill cap/dipstick

(2) engine oil drain bolt
(3) sealing washer
(cont’d)

Servicing Your Honda 49

Engine Oil
7. It is recommended to replace the oil and filter 9. Remove the oil filter cover bolts (7) and oil
NOTICE
every 6 races or about every 15.0 hours. filter cover (8).
However, if you replace only the oil before the 10. Remove the oil filter (9) and O-ring (10) from If the oil filter is not installed properly, it will
recommended interval, see page 25. the oil filter cover. cause serious engine damage.
8. Remove the left engine guard bolt/washer (4), 11. Remove the spring (11).
collar (5) and left engine guard (6). 14. Apply engine oil to a new O-ring and install it
(13) to the oil filter cover.
(12) 15. Install the oil filter cover being careful not to
(6)
(5) damage the O-ring, then tighten the oil filter
(4) cover bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
16. Install the left engine guard and collar, then
tighten the left engine guard bolt to the
(11) specified torque:
(9) 7 lbf·ft (10 N·m, 1.0 kgf·m)
(10) (7)
(8) 17. Fill the crankcase with the recommended oil.
Capacity: 0.66 US qt (0.62 ℓ)
(4) left engine guard bolt/washer
(7) oil filter cover bolts after draining and filter change
(8) oil filter cover
(5) collar (9) oil filter 0.61 US qt (0.58 ℓ)
(6) left engine guard (10) O-ring after draining
(11) spring 18. Install the engine oil fill cap/dipstick.
(12) rubber seal 19. Check the engine oil level by following the
(13) “OUT-SIDE” mark
steps in Checking & Adding Oil (page 49).

NOTICE Pour the drained oil into a suitable container and

dispose of it in an approved manner (page 144).
Using the wrong oil filter may result in leaks or
engine damage. NOTICE
12. Apply grease to the filter side of the spring end, Improper disposal of drained fluids is harmful to
then install the spring into the new oil filter. the environment.
13. Position the spring against the engine
crankcase and install a new oil filter with the
rubber seal (12) facing out, away from the
engine. You should see the “OUT-SIDE” mark
(13) on the filter body, near the seal.
Use a new Honda Genuine oil filter or a filter
of equal quality specified for your model.

50 Servicing Your Honda

Transmission Oil

Transmission Oil
Refer to Important Safety Precautions on page 23. Other viscosities shown in the following chart may
Oil Recommendation be used when the average temperature in your
Using the proper oil, and regularly checking, riding area is within the indicated range.
adding, and changing oil will help extend the API classification SG or higher except oils
service life of the transmission and clutch. Even (4-stroke engine oil labeled as energy
only) conserving or resource
the best oil wears out. Changing oil helps get rid of conserving on the circular
dirt and deposits. Operating the engine with old or API service label
dirty oil can damage your engine. viscosity SAE 10W-30
Running the engine with insufficient oil can cause (weight)
serious damage to the clutch and transmission. JASO T903 MA
standard
others without friction modifiers as
molybdenum additives
suggested oil* Pro Honda GN4 4-stroke Oil
(USA & Canada), or Honda
4-stroke oil, or an equivalent
motorcycle oil JASO T 903 standard
The JASO T 903 standard is an index for engine
* Suggested 4-stroke engine oils are equal performance
oils for 4-stroke motorcycle engines.
to SJ oils that are not labeled as energy conserving or
There are two classes: MA and MB.
resource conserving on the circular API service label.
Oil conforming to the standard is labeled on the oil
container. For example, the following label shows
• Your CRF does not need oil additives. Use the the MA classification.
recommended oil.
(1)
• Do not use oils with graphite or molybdenum
additives. They may adversely affect clutch
operation.
• Do not use API SH or higher 4-stroke engine oils (2)
displaying a circular API “energy conserving” or
“resource conserving” service label on the
container. They may affect lubrication and
clutch performance. (1) oil code
(2) oil classification

NOT RECOMMENDED OK

Servicing Your Honda 51

Transmission Oil
6. Check that the O-ring (4) is in good condition
Checking & Adding Oil and replace it if necessary. (3)
7. Reinstall the transmission oil fill cap (1).
1. Run the engine at idle for 3 minutes, then shut
8. Check for oil leaks.
it off.
2. Wait 3 minutes after shutting off the engine to (1)
allow the oil to properly distribute itself in the
clutch and transmission.
3. Support the CRF in an upright position on a
level surface.
4. Remove the transmission oil fill cap (1), oil
check bolt (2) and sealing washer (3) from the (1) (2)
right crankcase cover. A small amount of oil
should flow out of the oil check bolt hole. (1) transmission oil fill cap
Allow any excess oil to flow out of the oil (2) transmission oil drain bolt
(3) sealing washer
check bolt hole. (4)
If no oil flows out of the oil check bolt hole, 6. Fill the crankcase with recommended oil.
add oil slowly through the transmission oil fill (1) transmission oil fill cap Capacity:
hole until oil starts to flow out of the oil check (4) O-ring
0.68 US qt (0.64 ℓ) after draining
bolt hole. 7. Install the transmission oil fill cap.
Install the oil check bolt with the sealing 8. Check the transmission oil level by following
washer and transmission oil fill cap. Repeat Replacing Transmission Oil the steps in Checking & Adding Oil (this page).
steps 1 – 4.
1. Run the engine at idle for 3 minutes, then shut Pour the drained oil into a suitable container and
it off. dispose of it in an approved manner (page 144).
2. Support the CRF in an upright position on a
(3)
level surface.
3. Remove the transmission oil fill cap (1) from NOTICE
the right crankcase cover.
Improper disposal of drained fluids is harmful to
4. Place an oil drain pan under the engine to catch
the environment.
the oil. Then remove the transmission oil drain
bolt (2) and sealing washer (3).
5. After the oil has drained, apply engine oil to
the drain bolt threads and seating surface, then
(1) (2) tighten it with a new sealing washer to the
specified torque:
(1) transmission oil fill cap (3) sealing washer 12 lbf·ft (16 N·m, 1.6 kgf·m)
(2) oil check bolt

5. After inspecting the oil level or adding oil,

tighten the oil check bolt with a new sealing
washer to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)

52 Servicing Your Honda

Coolant

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 system (3)
(1)
surrounds the cylinder and cylinder head. performance. Higher concentrations of antifreeze
(up to 60%) should only be used to provide
Maintaining the coolant will allow the cooling additional protection against freezing.
system to work properly and prevent freezing, Check the cooling system frequently during
overheating, and corrosion. freezing weather.

Coolant Recommendation Checking & Adding Coolant (2)

Use Pro Honda HP Coolant or an equivalent high Refer to Important Safety Precautions on page 23.
quality ethylene glycol antifreeze containing
corrosion protection inhibitors specifically 1. Position your CRF on an optional workstand or
recommended for use in aluminum engines. Check equivalent support so that it is securely held in
(1) radiator cap (3) air bleed bolt
(2) radiator filler neck
the antifreeze container label. place in an upright position.
2. With the engine cold, remove the radiator cap 3. If the coolant level is low, remove the air bleed
Use only distilled water as a part of the coolant (1) and check coolant level. The coolant level
solution. Water that is high in mineral content or bolt (3) on the left radiator upper tank, and then
is correct when it is at the bottom of the add the coolant up to the filler neck.
salt may be harmful to the aluminum engine. radiator filler neck (2). Inspect the coolant level before each outing.
A coolant loss of 0.7 – 2.0 US oz (20 – 60 cm3)
NOTICE WARNING through the over flow tube is normal. If coolant
Removing the radiator cap while the loss is more than this, inspect the cooling
Using coolant with silicate inhibitors may cause engine is hot can cause the coolant to system.
premature wear of the mechanical seal or spray out, seriously scalding you. Capacity:
blockage of the radiator passages. Using tap
1.08 US qt (1.02 ℓ) after disassembly
water may cause engine damage. Always let the engine and radiator cool 0.99 US qt (0.94 ℓ) after draining
down before removing the radiator cap. 4. Tighten the air bleed bolt to the specified
The factory provides a 50/50 solution of antifreeze
and water in this motorcycle. This coolant solution torque:
is recommended for most operating temperatures 1.2 lbf·ft (1.6 N·m, 0.2 kgf·m)
and provides good corrosion protection. 5. Install the radiator cap securely.

Decreasing the concentration of antifreeze to less NOTICE

than 40% will not provide proper corrosion
protection. If the radiator cap is not installed properly, it will
cause excessive coolant loss and may result in
overheating and engine damage.

Servicing Your Honda 53

Coolant
7. Check the bleed hole (5) below the water pump
Cooling System Inspection cover (6) for leakage. Clean away any clogged Coolant Replacement
dirt or sand, if necessary. Check for signs of
1. Check the cooling system for leaks (see an seal leakage. If water leaks through the bleed Refer to Important Safety Precautions on page 23.
official Honda Service Manual for hole, replace the mechanical seal. If oil leaks
troubleshooting of leaks). through the bleed hole, replace the oil seal. Coolant should be replaced by your dealer, unless
2. Check the water hoses (1) for cracks, Make sure that there is no continuous coolant you have the proper tools and service data and are
deterioration, and radiator hose clamps for leakage from the bleed hole while operating mechanically qualified. Refer to an official Honda
looseness. the engine. Service Manual (page 160).
3. Check the radiator mount for looseness. A small amount of coolant weeping from the
4. Make sure the overflow hose (2) is connected bleed hole is normal. See an official Honda WARNING
and not clogged. Service Manual or consult your dealer for
5. Check the radiator fins (3) for clogging. replacing the mechanical seal or oil seal.
Removing the radiator cap while the
6. Check the air bleed bolt (4) for looseness. Both seals should be replaced at the same time.
engine is hot can cause the coolant to
spray out, seriously scalding you.
(1) (2)
(4) (3) Always let the engine and radiator cool
down before removing the radiator cap.

To properly dispose of drained coolant, refer to

You & the Environment on page 144.

NOTICE

(1) (6) (5) Improper disposal of drained fluids is harmful to

the environment.
(5) bleed hole
(6) water pump cover
(3)

(1) water hoses (3) radiator fins

(2) overflow hose (4) air bleed bolt

54 Servicing Your Honda

Air Cleaner

Air Cleaner
Refer to Important Safety Precautions on page 23. Proper air cleaner maintenance can prevent
premature engine wear or damage, expensive Cleaning
The air cleaner uses polyurethane inner and outer repairs, low engine power, poor gas mileage, and
pieces which can’t be separated. spark plug fouling. 1. Remove the seat (page 33).
A dirty air cleaner will reduce engine power. 2. Remove the air cleaner retaining bolt (1) and
air cleaner assembly (2).
Proper air cleaner maintenance is very important NOTICE
for off-road vehicles. A dirty, water-soaked, worn- Improper or lack of proper air cleaner
out, or defective air cleaner will allow dirt, dust, maintenance can cause poor performance and
mud, and other impurities to pass into the engine. premature engine wear.
(2)
Service the air cleaner more frequently if you ride
in unusually wet or dusty areas. Your dealer can
help you determine the correct service interval for
your riding conditions.

Your CRF’s air cleaner has very specific (1)

performance requirements. Use a new Honda
Genuine air cleaner specified for your model or an
air cleaner of equal quality. (1) air cleaner retaining bolt
(2) air cleaner assembly

NOTICE
Using the wrong air cleaner may result in
premature engine wear.

(cont’d)

Servicing Your Honda 55

Air Cleaner
3. Remove the air cleaner element (3) from the air 11. Install and tighten the air cleaner retaining bolt
cleaner holder (4) by releasing the holder tabs (1) securely.
(5) from the holes (6) of the air cleaner
element.
(7)
(5)

(6) (3)

(7) plastic bag (1)

7. Assemble the air cleaner element and holder.

Install the holder tabs in the holes of the air (1) air cleaner retaining bolt
cleaner element.
(4)
(5) 8. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda
White Lithium Grease or equivalent to the air NOTICE
(6) cleaner housing contact area of the air cleaner Improper installation of the air cleaner assembly
element. may allow dirt and dust to enter the engine and
(3) air cleaner element (5) holder tabs
(4) air cleaner holder (6) holes 9. Install the air cleaner assembly (2) into the air cause rapid wear of the piston rings and cylinder.
cleaner housing by aligning its tabs (8) with the
4. Wash the air cleaner in clean non-flammable stay (9) of the air cleaner housing. 12. Install the seat (page 33).
cleaning solvent. Then wash in hot, soapy 10. Carefully position the sealing flange of the
water, rinse well, and allow to dry thoroughly. element to prevent dirt intrusion.
The air cleaner element is made in two pieces: (8)
inner and outer, which cannot be separated.
5. Clean the inside of the air cleaner housing. (9)
6. Allow the air cleaner to dry thoroughly. After
drying, apply 1.7 US oz (50 cm3) of clean Pro
Honda Foam Filter Oil or an equivalent air
cleaner oil from the inside of the element.
Place the element into a plastic bag (7) and
spread the oil evenly by hand.

(2)

(2) air cleaner assembly

(8) air cleaner assembly tabs
(9) air cleaner housing stay

56 Servicing Your Honda

Crankcase Breather

Crankcase Breather
Refer to Important Safety Precautions on page 23.

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 plugs (1)
from the crankcase breather tubes (2) and drain
deposits into a suitable container.
2. Reinstall the crankcase breather tube plugs.

(2)

(1)

(1) crankcase breather tube plugs

(2) crankcase breather tubes

Servicing Your Honda 57

Throttle

Throttle
Refer to Important Safety Precautions on page 23. Upper Adjustment Lower Adjustment
Minor adjustments are generally made with the The lower adjuster is used for major freeplay
upper adjuster. adjustment, such as after replacing the throttle
Throttle Freeplay cables or removing the throttle body. It is also used
1. Pull the dust cover (1) back. if you cannot get the proper adjustment with the
Inspection 2. Loosen the lock nut (2). upper adjuster.
Check freeplay (1). 3. Turn the adjuster (3).
Freeplay: 1/16 – 1/4 in (2 – 6 mm) Turning the adjuster in direction (–) will 1. Hang the fuel tank to the left side of the frame
If necessary, adjust to the specified range. decrease freeplay and turning it in direction (+) (page 34).
will increase freeplay. 2. Loosen the lock nut (1).
(1) 3. Turn the adjuster (2) in direction (–) to
(1) decrease freeplay, and in direction (+) to
(+)
increase freeplay.
(2)

(+) (2)
(3) (–)

(–) (1)
(1) freeplay
(1) dust cover (+) increase freeplay
(2) lock nut (–) decrease freeplay
(3) adjuster
(1) lock nut (+) increase freeplay
4. Tighten the lock nut to the specified torque: (2) adjuster (–) decrease freeplay
3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
Return the dust cover to its normal position. 4. Tighten the lock nut to the specified torque:
5. After adjustment, check for smooth rotation of 3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
the throttle grip from fully closed to fully open 5. Operate the throttle grip to ensure that it
in all steering positions. functions smoothly and returns completely.
If the adjuster is threaded out near its limit or 6. Install the fuel tank (page 35).
the correct freeplay cannot be reached, turn the
adjuster all the way in and back out one turn. If you can’t get the freeplay within the specified
Tighten the lock nut to the specified torque: range, contact your dealer.
3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
Install the dust cover and make the adjustment
with the lower adjuster.

58 Servicing Your Honda

 Throttle
3. Inspect the condition of the throttle cables
Throttle Inspection from the throttle grip down to the throttle body.
If the cable is kinked or chafed, have it
1. Check that the throttle assembly is positioned replaced.
properly (the end of the throttle housing (1) is 4. Check the cables for tension or stress in all
aligned with the paint mark (2) on the steering positions.
handlebar) and the securing bolts are tight. 5. Lubricate the cables with a commercially
available cable lubricant to prevent premature
rust and corrosion.

(2) (1)

(1) throttle housing

(2) paint mark

2. Check for smooth rotation of the throttle (3)

from fully open to fully closed in all steering
positions. If there is a problem, see your dealer.

(3)

(3) throttle

Servicing Your Honda 59

Engine Idle Speed

Engine Idle Speed

Refer to Important Safety Precautions on page 23.

Remember, idle speed adjustment is not a “cure-

all” for other problems in your engine’s PGM-FI
system. Adjusting the idle will not compensate for
a fault elsewhere.

The engine must be at normal operating

temperature for accurate idle speed adjustment.
When pushed in, the fast idle knob acts as the idle
adjust screw.
Turning it counterclockwise results in a faster/
higher idle speed.
Turning it clockwise results in a slower/lower idle
speed.

Idle Speed Adjustment

1. If the engine is cold, start it and warm it up 3
minutes. Then shut it off.
2. Connect a tachometer to the engine.
3. Shift the transmission into neutral. Start the
engine.
4. Keep the motorcycle in an upright position.
5. Adjust idle speed with the fast idle knob (1).
Idle speed: 2,000 ± 100 rpm

(–)

(+)
(1)

(1) fast idle knob

(+) increase
(–) decrease

60 Servicing Your Honda

Clutch System

Clutch System
Refer to Important Safety Precautions on page 23. 4. Turn the cable end adjuster (3) in direction (+)
until it seats lightly and then turn it out five Clutch Lever Freeplay
turns.
Clutch Lever Adjustment Inspection
Check freeplay (1).
The distance between the tip of the clutch lever and (–)
Freeplay: 3/8 – 13/16 in (10 – 20 mm)
the grip may be adjusted. If necessary, adjust to the specified range.
Make sure to adjust the clutch lever freeplay after (1)
the clutch lever position adjustment or clutch cable (+)
disconnected. (3)

1. Loosen the lock nut (1).

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

(+)

(5)
(1) lock nut
(2) adjuster

(4) lock nut

(5) integral cable adjuster
(+) increase freeplay
(–) decrease freeplay

6. Adjust the cable end adjuster for minor

adjustment (page 62).

Servicing Your Honda 61

Clutch System
Cable End Adjustment Integral Cable Adjustment
Minor adjustments are generally made with the The integral cable adjuster is used if the cable end Other Inspections & Lubrication
clutch cable end adjuster. adjuster is threaded out near its limit — or the
correct freeplay cannot be obtained. • Check that the clutch lever assembly is
Turning the cable end adjuster (1) in direction (+) positioned properly (the end of the holder (1) is
will increase freeplay and turning it in direction (–) 1. Turn the cable end adjuster in direction (+) aligned with the paint mark (2) on the
will decrease freeplay. until it seats lightly and then turn it out five handlebar) and the securing bolts are tight.
turns.
(–) 2. Loosen the lock nut (1).
(2) (1)
3. Turn the integral cable adjuster (2) to obtain
the specified freeplay.
4. Tighten the lock nut. Check the freeplay.
(+) (1) (–)
(1)

(+)
(1) cable end adjuster
(+) increase freeplay (2)
(–) decrease freeplay
(1) holder
(2) paint mark
If the adjuster is threaded out near its limit or the
correct freeplay cannot be reached, turn the • Check the clutch cable for kinks or signs of
adjuster all the way in and back out one turn and (1) lock nut (+) increase freeplay
wear. If necessary, have it replaced.
(2) integral cable adjuster (–) decrease freeplay
make the adjustment with the integral cable • Lubricate the clutch cable with a commercially
adjuster. 5. Start the engine, pull the clutch lever in, and available cable lubricant to prevent premature
shift into gear. Make sure the engine does not wear and corrosion.
stall and the motorcycle does not creep.
Gradually release the clutch lever and open the
Clutch Operation
throttle. Your CRF should move smoothly and
accelerate gradually. 1. Check for smooth clutch lever operation. If
If you can’t get proper adjustment, or the clutch necessary, lubricate the clutch lever pivot bolt
does not work properly, the cable may be kinked or sliding surface with grease and/or clutch cable
worn, or the clutch discs may be worn. with commercially available cable lubricant.
Inspect the clutch discs and plates (page 64). 2. Check the clutch cable for deterioration, kinks,
or damage.

62 Servicing Your Honda

 Clutch System
4. Remove the six clutch spring bolts and springs 7. Disassemble the clutch lifter (10), needle
Clutch Disc/Plate Removal (6). bearing (11) and washer (12) by removing the
Loosen the bolts in a crisscross pattern in two or clip (13). Turn the needle bearing with your
1. Drain the transmission oil (page 52). three progressive steps. finger. The needle bearing should turn
2. Remove the rear brake pedal (1) by removing smoothly and quietly.
its pivot bolt (2), washer and dust seals (3). 5. Remove the clutch pressure plate (7). Replace the needle bearing and washer if the
needle bearing does not turn smoothly.
(1) (13)
(3)
(6)
(12)

(11)

(7)
(2) (10)

(1) rear brake pedal (3) washer and dust seals (6) clutch spring bolts and springs
(2) brake pedal pivot bolt (7) clutch pressure plate (10) clutch lifter (12) washer
(11) needle bearing (13) clip
3. Remove the five clutch cover bolts (4) and 6. Remove the clutch lifter assembly (8) first,
clutch cover (5). then remove the clutch lifter rod (9). 8. Remove the eight clutch discs, seven clutch
plates, judder spring and spring seat (14).

(4)

(9)
(14)

(5)

(8)

(4) clutch cover bolts (5) clutch cover (8) clutch lifter assembly (9) clutch lifter rod
(14) clutch discs, clutch plates, judder spring and spring
seat

Servicing Your Honda 63

Clutch System
• If you feel the clutch slippage when replacing the 3. Insert the clutch lifter rod (6) into the
Clutch Disc/Plate Inspection clutch discs and plates, replace the clutch mainshaft.
springs.
• Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Clutch Disc/Plate Installation
Service Limit: 0.112 in (2.85 mm) 1. Install the spring seat (1) and judder spring (2)
Replace the clutch discs and clutch plates as a onto the clutch center as shown.
set. Coat the clutch discs with engine oil. (6)
2. Install the clutch disc A (larger I.D. disc) (3)
onto the clutch outer.
Stack the seven clutch plates (4) and seven
(1) clutch discs B (5) alternately.
(1)
(5) (6) clutch lifter rod

4. Apply engine oil to the needle bearing (7).

Install the needle bearing and washer (8) onto
the clutch lifter (9). Then, install a new clip
(10) by fitting it into the groove in the clutch
(1) clutch discs lifter.
• Check the clutch plates (2) for excessive (2)
warpage or discoloration.
Check the plate warpage on a surface plate using (3) (10)
a feeler gauge. (4)
Service Limit: 0.006 in (0.15 mm)
Replace the clutch discs and plates as a set. (1) spring seat (4) clutch plates
(8)
(2) judder spring (5) clutch discs B
(3) clutch disc A

(2) (7)

(9)

(7) needle bearing (9) clutch lifter

(8) washer (10) clip (new)

(2) clutch plates

64 Servicing Your Honda

 Clutch System
5. Install the clutch lifter assembly (11) onto the 9. Apply engine oil to a new O-ring (14) and 14. Install the pivot bolt with the washer (19) and
rod. install it in the groove of the clutch cover (15). tighten the pivot bolt to the specified torque:
10. Install the cover by tightening the five cover 27 lbf·ft (36 N·m, 3.7 kgf·m)
bolts in a crisscross pattern in two or three Connect the brake pedal return spring (20) if it
steps to the specified torque: is removed.
7 lbf·ft (10 N·m, 1.0 kgf·m)
(18)
(16)

(17)

(11)

(11) clutch lifter assembly

(20) (19)
(16)
6. Install the clutch pressure plate (12). (15)
(14) (16) dust seals
7. Install the six clutch springs and bolts (13). (17) brake pedal pivot bolt
8. Tighten the bolts in a crisscross pattern in two (14) O-ring (new) (18) rear brake pedal
or three steps to the specified torque: (15) clutch cover (19) washer
(20) brake pedal return spring
9 lbf·ft (12 N·m, 1.2 kgf·m)
11. Lubricate the dust seals (16) and rear brake
pedal pivot bolt (17) with urea based 15. Fill the crankcase with transmission oil
multipurpose grease or equivalent. (page 52).
(13) 12. Apply locking agent to the brake pedal pivot
bolt threads.
13. Install the dust seals into the rear brake pedal
(18).

(12)

(12) clutch pressure plate

(13) clutch springs and bolts

Servicing Your Honda 65

Spark Plug

Spark Plug
Refer to Important Safety Precautions on page 23. 7. To obtain accurate spark plug readings,
Spark Plug Inspection & Replacement accelerate up to speed on a straightaway.
Press and hold the engine stop button and
Spark Plug Recommendation 1. Remove the seat and hang the fuel tank to the disengage the clutch by pulling the lever in.
left of the frame (pages 33, 34). Coast to a stop, then remove and inspect the
The recommended standard spark plug is 2. Disconnect the spark plug cap (1). spark plug. The porcelain insulator around the
satisfactory for most racing conditions. 3. Clean any dirt from around the spark plug center electrode should appear tan or medium
Standard SILMAR9A – 9S (NGK) base. gray.
Optional SILMAR10A – 9S (NGK)
4. Remove the spark plug (2). If you’re using a new plug, ride for at least 10
minutes before taking a plug reading; a brand-new
Use only the recommended type of spark plugs in
(1) (2) plug will not color initially.
the recommended heat range. If the electrodes appear burnt, or the insulator is
white or light gray (lean) or the electrodes and
insulator are black or fouled (rich), there is a
NOTICE problem elsewhere (page 134).
Using a spark plug with an improper heat range or Check the PGM-FI system and ignition timing.
incorrect reach can cause engine damage.
8. With the sealing gasket attached, thread the
Using a non-resistor spark plug may cause spark plug in by hand to prevent cross-
ignition problems. threading.
9. Tighten the spark plug.
This motorcycle uses a spark plug that has an
• If the old plug is good:
iridium tip in the center electrode and a platinum (1) spark plug cap (2) spark plug
1/12 turn after it seats.
tip in the side electrode. • If installing a new plug, tighten it twice to
5. Check the electrodes for wear or deposits, the prevent loosening:
Be sure to observe the following when servicing sealing gasket (3) for damage, and the insulator a) First, tighten the plug:
the spark plug. for cracks. Replace if you detect them. 1/4 turn after it seats.
• Do not clean the spark plug. If an electrode is 6. Check the spark plug gap (4), using a wire-type b) Then loosen the plug.
contaminated with accumulated objects or dirt, feeler gauge. If the gap is out of specifications, c) Next, tighten the plug again:
replace the spark plug with a new one. replace the plug with a new one. 1/12 turn after it seats.
• To check the spark plug gap, use only a “wire- The recommended spark plug gap is:
type feeler gauge.” To prevent damaging the 0.031 – 0.035 in (0.8 – 0.9 mm)
iridium tip of the center electrode and platinum NOTICE
(3)
tip of the side electrode, never use a “leaf-type An improperly tightened spark plug can damage
feeler gauge.” the engine. If a plug is too loose, a piston may be
• Do not adjust the spark plug gap. If the gap is out damaged. If a plug is too tight, the threads may be
of specification, replace the spark plug with a damaged.
new one. (4)
10. Connect the spark plug cap. Take care to avoid
(3) sealing gasket pinching any cables or wires.
(4) spark plug gap 11. Install the fuel tank and seat (pages 33, 35).

66 Servicing Your Honda

Valve Clearance

Valve Clearance
Refer to Important Safety Precautions on page 23.
Cylinder Head Cover Removal Positioning At TDC On The
Excessive valve clearance will cause noise and Compression Stroke
eventual engine damage. Little or no clearance will Before inspection, clean the engine thoroughly to
prevent the valve from closing and cause valve keep dirt from entering the engine. 1. Remove the crankshaft hole cap (1).
damage and power loss. Check valve clearance
when the engine is cold at the intervals specified in 1. Remove the seat and hang the fuel tank to the
the Maintenance Schedule (page 25). left of the frame (pages 33, 34).
2. Disconnect the breather tube (1) and spark
The checking or adjusting of the valve clearance plug cap (2).
should be performed while the engine is cold.
The valve clearance will change as engine (1) (2)
(1)
temperature rises.

(1) crankshaft hole cap

2. Remove the spark plug (page 66).

3. Remove the cylinder head cover (this page).

(1) breather tube (2) spark plug cap

3. Remove the cylinder head cover socket bolts

(3), rubber seals (4) and cylinder head cover
(5).

(3)

(4)

(5)

(3) cylinder head cover socket bolts

(4) cylinder head cover rubber seals
(5) cylinder head cover (cont’d)

Servicing Your Honda 67

Valve Clearance
4. Rotate the crankshaft by turning the primary
drive gear bolt (2) clockwise until the punch Valve Clearance Inspection
mark (3) on the primary drive gear aligns with
the index mark (4) on the right crankcase 1. Set the piston at TDC on the compression
cover. In this position, the piston may either be (5) stroke (page 67).
on the compression or exhaust stroke. 2. Measure the intake valve clearance by
If the crankshaft passed the punch mark, rotate inserting a feeler gauge (1) between the valve
the primary drive gear bolt clockwise again lifters and cam lobes (2).
and align the punch mark with the index mark.
The inspection must be made when the piston (2)
is at the top of the compression stroke when
both the intake and exhaust valves are closed.
This condition can be determined by moving (5) exhaust rocker arms
the exhaust rocker arms (5). If they are free, it
is an indication that the valves are closed and (1)
that the piston is on the compression stroke. If
they are tight and the valves are open, rotate
the primary drive gear bolt 360° and realign the
punch mark with the index mark. (1)
(3) (4)
(1) feeler gauge
(2) valve lifters and cam lobes

(2)
(2) primary drive gear bolt (4) index mark
(3) punch mark

68 Servicing Your Honda

 Valve Clearance
3. Measure the exhaust valve clearance by 4. Insert the tensioner stopper (4) into the cam
inserting a feeler gauge (1) between the Camshaft Removal chain tensioner lifter (5).
exhaust rocker arms (3) and shims (4). Turn the tensioner stopper clockwise and lock
1. Record the intake valve and exhaust valve the cam chain tensioner lifter by pushing the
clearances (page 68). handle (6) to the cam chain tensioner lifter.
Make sure the piston is at TDC on the • Tensioner stopper 07AMG-001A100
compression stroke (page 67).
2. Remove the condenser (1) and disconnect the (6)
(4)
(3) condenser connector.

(1)

(1) (5)

(1) feeler gauge

(3) exhaust rocker arms (4)
(4) exhaust valve shims

Valve Clearance: (4) tensioner stopper

IN: 0.006 ± 0.001 in (0.16 ± 0.03 mm) (5) cam chain tensioner lifter
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm) (6) handle
(1) condenser

If intake valve clearance and exhaust valve 3. Remove the cam chain tensioner lifter cover
clearance need adjustment, see Camshaft Removal bolt (2) and sealing washer (3).
(this page) and select the correct shim for each
valve.
(2)

(3)

(2) cam chain tensioner lifter cover bolt

(3) sealing washer

(cont’d)

Servicing Your Honda 69

Valve Clearance
5. Make sure the piston is at TDC on the 6. Slide the left camshaft bearing (10) and 7. Remove the intake valve lifters (13).
compression stroke (page 67). remove the camshaft (11) by removing the cam
Loosen the camshaft holder bolts (7) in a chain (12). Keep the intake valve lifters and shims separate so
crisscross pattern in two or three steps. you can easily identify the originally installed
Remove the camshaft holder bolts, set rings (8) location such as intake or exhaust, right or left.
NOTICE
and camshaft holder (9).
Do not let the cam chain fall into the crankcase.
As you remove the camshaft holder, set rings may
be sticking in the camshaft holder.
(12)

(13)
(9)

(11)
(8)

(13) intake valve lifters

(10)
(7) 8. Remove the valve shims (14).
(10) left camshaft bearing
(7) camshaft holder bolts (11) camshaft
(8) set rings (12) cam chain
(9) camshaft holder

NOTICE (14)
(14)
Do not let the set rings fall into the crankcase.

If the set rings are remained on the camshaft

holder, remove the set rings carefully.

(14) valve shims

70 Servicing Your Honda

 Valve Clearance
2. Measure the shim thickness with a micrometer 3. Calculate the new shim thickness using the
Shim Selection and record it. equation below.
Seventy-three different shims (2) are available
1. Clean the valve shim contact area in the valve in 0.025 mm thickness intervals, from 1.200 A = (B – C) + D
lifter (1) with compressed air. mm (the thinnest) to 3.000 mm (the thickest).
A: New shim thickness
(1) B : Recorded valve clearance
(2) C : Specified valve clearance
D: Old shim thickness

• Make sure of the correct shim thickness by

measuring the shim with a micrometer.
• Reface the exhaust valve seat if carbon deposits
result in a calculated dimension of over 3.000
mm.

NOTICE
(1) valve lifter (2) shim Do not lap the intake valves. They are titanium and
have a thin oxide coating. Lapping will damage
this coating.

If a calculated dimension is out of specifications,

have your motorcycle inspected by your dealer.

1.80 mm 1.825 mm 1.85 mm 1.875 mm

Servicing Your Honda 71

Valve Clearance
3. Install the valve lifters (3) in their original 5. Make sure the piston is at TDC on the
Camshaft Installation locations into the cylinder head (4). compression stroke (page 67).
6. Install the camshaft (7) onto the cylinder head
1. Install the newly selected shims (1) on the (4) with intake cam lobes (8) facing up as
valve spring retainers (2). illustrated below.
(8)
NOTICE
Do not let the shims fall into the crankcase.
(2)
(3)
(7)

(1)
(1) (3) valve lifters
(4) cylinder head
(7) camshaft (8) intake cam lobes
4. Check the operation of the plunger (5) by
turning the decompressor weight (6) with your 7. Install the cam chain (9) over the cam sprocket
(2) finger; The plunger should be retracted and (10).
protruded smoothly. While holding the left camshaft bearing (11) to
(1) shims
(2) valve spring retainers the left fully, install the camshaft (7) onto the
cylinder head (4).
2. Apply molybdenum disulfide oil (a mixture of
(10)
1/2 engine oil and 1/2 molybdenum disulfide (9)
grease containing more than 3% molybdenum (6)
disulfide additive) to the following parts.
– camshaft cam lobes
(5)
– each valve lifter outer surface
(7)
– plunger whole surface (4)

(5) plunger
(6) decompressor weight (11)

If the operation is not smooth, refer to an official (4) cylinder head (10) cam sprocket
(7) camshaft (11) left camshaft bearing
Honda Service Manual (page 160) for (9) cam chain
decompressor disassembly or see your dealer.

72 Servicing Your Honda

 Valve Clearance
8. Make sure that the timing mark (12) on the cam 12. Remove the tensioner stopper (22) from the
sprocket aligns with the camshaft holder cam chain tensioner lifter.
mating surface (13) of the cylinder head. (22)

Align (13) (16) (17)

(16) set rings

(12) (17) camshaft bearing grooves
(22) tensioner stopper
(12) timing mark 11. Apply engine oil to the camshaft holder bolt
(13) camshaft holder mating surface threads. 13. Make sure that the piston is at TDC on the
Install the camshaft holder (18) with the “ ” compression stroke (page 67).
9. Make sure that the dowel pins (14) are installed mark (19) facing forward. Check that the timing mark (12) on the cam
into the camshaft holder (15). Tighten the camshaft holder bolts (20) (21) to sprocket aligns with the camshaft holder
the specified torque: mating surface (13) of the cylinder head.
(14)
10 lbf·ft (14 N·m, 1.4 kgf·m)
If the timing mark doesn’t align with the camshaft
Tighten the camshaft holder bolts in a crisscross holder mating surface, remove the cam chain and
pattern in two or three steps. realign the timing mark.
(18)

Align (13)

(15) (20)
(21)

(14) dowel pins (15) camshaft holder

10. Install the set rings (16) on the camshaft

bearing grooves (17). (12)
(19)

NOTICE (18) camshaft holder (20) camshaft holder bolts (long) (12) timing mark
(19) “ ” mark (21) camshaft holder bolts (short) (13) camshaft holder mating surface
Do not let the set rings fall into the crankcase.

(cont’d)

Servicing Your Honda 73

Valve Clearance
14. Measure the intake valve and exhaust valve 16. Connect the condenser connector and install
clearances by inserting a feeler gauge (23). the condenser (26). Crankshaft Hole Cap Installation
Valve Clearance:
IN: 0.006 ± 0.001 in (0.16 ± 0.03 mm) (26) 1. Install the spark plug (page 66).
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm) 2. Coat a new O-ring (1) with engine oil and
install it onto the crankshaft hole cap (2).
(23) Apply grease to the crankshaft hole cap
(23) threads. Install and tighten the crankshaft hole
cap to the specified torque:
11 lbf·ft (15 N·m, 1.5 kgf·m)

(2)

(26) condenser

(23) feeler gauge

15. Install a new sealing washer (24) and tighten (1)

the cam chain tensioner lifter cover bolt (25).
(1) O-ring (new)
(25) (2) crankshaft hole cap

(24)

(24) sealing washer (new)

(25) cam chain tensioner lifter cover bolt

74 Servicing Your Honda

 Valve Clearance
3. Check that the rubber seals (4) are in good 5. Connect the spark plug cap (7) and breather
Cylinder Head Cover Installation condition, replace them if necessary. tube (8).
Install the rubber seals onto the cylinder head
1. Check that the spark plug hole packing (1) is in cover with the “UP” marks (5) facing up. (8) (7)
good condition and replace it if necessary.
Apply engine oil to the spark plug hole packing (4) (5)
and install it to the cylinder head cover (2).
2. Check that the cylinder head cover packing (3)
is in good condition and replace it if necessary.
Install the cylinder head cover packing into the
cylinder head cover groove.

(1)

(5)
(4) rubber seals (7) spark plug cap
(5) “UP” marks (8) breather tube
(2)

4. Install and tighten the cylinder head cover 6. Install the fuel tank and seat (pages 33, 35).
socket bolts (6) to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(3)

(1) spark plug hole packing (6)

(2) cylinder head cover
(3) cylinder head cover packing

(6) cylinder head cover socket bolts

Servicing Your Honda 75

Piston/Piston Rings/Piston Pin

Piston/Piston Rings/Piston Pin

11. Disconnect the ECT sensor connector (4). 13. Disconnect the crankcase breather tubes A (7)
Cylinder Head Removal and B (8) from the air cleaner connecting tube.
(4) 14. Disconnect the IAT sensor connector (9).
1. Clean the area above the engine before
disassembly to prevent dirt falling into the (7)
engine.
2. Drain the radiator coolant after cooling the
motorcycle (page 143).
3. Remove the seat and hang the fuel tank (pages
33, 34).
4. Remove the left and right mufflers (page 98)
and subframe (page 37).
5. Remove the exhaust pipe (page 101).
6. Remove the spark plug (page 66). (8)
7. Remove the cylinder head cover (page 67). (4) ECT sensor connector (9)
8. Set the piston at TDC on the compression
stroke (page 67). 12. Loosen the radiator hose clamp screws (5) and (7) crankcase breather tube A
9. Remove the camshaft holder, camshaft, valve disconnect the radiator hoses (6). (8) crankcase breather tube B
(9) IAT sensor connector
lifters and shims (page 69).
(6) (6)
10. Disconnect the ignition coil connectors (1). 15. Loosen the screw (10) on the air cleaner
Remove the ignition coil (2) by removing the connecting tube clamp (11).
bolts (3).
(11)
(2)

(5) (5)

(1) (5) radiator hose clamp screws

(6) radiator hoses
(3)
(10)
(1) ignition coil connectors (3) bolts
(2) ignition coil
(10) screw
(11) air cleaner connecting tube clamp

76 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
16. Remove the air cleaner case (12) along with air 18. Remove the cylinder head hanger bolts (15). 19. Loosen the insulator band screw (19) and pull
cleaner connecting tube. Remove the cylinder head hanger plate bolts the throttle body (20) out from the insulator
(16), left cylinder head hanger plate (17) and (21).
right cylinder head hanger plate (18).
(12) Leftside:
Left side: Do not hang the throttle body and support it with a
(16) suitable strap.
(17)
(21) (20)

(12) air cleaner case (15)

17. Remove the rear shock absorber upper nut (13) Right side: (19)
and bolt (14).
(18)
(16) (19) insulator band screw
(14) (20) throttle body
(21) insulator

(15)

(13) (15) cylinder head hanger bolts

(16) cylinder head hanger plate bolts
(17) left cylinder head hanger plate
(13) rear shock absorber upper nut (18) right cylinder head hanger plate
(14) bolt

(cont’d)

Servicing Your Honda 77

Piston/Piston Rings/Piston Pin
20. Remove the cylinder bolt (22). 22. Remove the dowel pins (25) and cylinder head
21. Remove the cylinder head bolts, washers (23) gasket (26). Cylinder Removal
and the cylinder head (24).
1. Remove the water hose joint bolts (1), water
NOTICE hose joint (2) and O-ring (3).
Loosen the bolts in a crisscross pattern in two or
three steps. Do not let the dowel pins and cam chain fall into (2)
the crankcase. (3)
NOTICE
(25)
Do not let the washers and cam chain fall into the
crankcase.
(22)

(1)

(24) (23) (1) water hose joint bolts (3) O-ring

(26) (2) water hose joint

(25) dowel pins

(26) cylinder head gasket
2. Remove the cylinder (4) while holding the
piston (5).
23. Remove the cam chain guide (27) from the NOTICE
(22) cylinder bolt cylinder (28).
(23) cylinder head bolts and washers Do not let the cam chain fall into the crankcase.
(24) cylinder head Do not pry on or strike the cylinder.
(4)
(28)

(27)

(27) cam chain guide (5)

(28) cylinder
(4) cylinder (5) piston

78 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
3. Remove the dowel pins (6) and cylinder gasket
(7). Piston Removal Piston Ring Removal
NOTICE 1. Place clean shop towels in the crankcase to Spread each piston ring (1) and remove by lifting it
keep the piston pin clips, or other parts, from up at a point just opposite the gap.
Do not let the dowel pins fall into the crankcase. falling into the crankcase.
(6) 2. Remove the piston pin clips (1) using a pair of NOTICE
needle-nose pliers.
3. Press the piston pin (2) out of the piston (3), Do not damage the piston ring by spreading the
and remove the piston. ends too far.
Under racing conditions, the piston and rings
should be replaced every 6 races or about every
15.0 hours of running. Replace the piston pin every
(1)
6 races or about every 15.0 hours of running.
(3)
(7)

(6) dowel pins (7) cylinder gasket

(1)

(1) piston ring

(2)

(1) piston pin clips (3) piston

(2) piston pin

Servicing Your Honda 79

Piston/Piston Rings/Piston Pin
5. After installing the piston rings they should
Piston/Piston Pin/Piston Ring Inspection Piston Ring Installation rotate freely, without sticking.
Space the ring end gaps 180 degrees apart
We recommend you consult an official Honda 1. Remove the carbon deposits from the piston between top ring and upper side rail.
Service Manual or your dealer for correct Service head and piston ring grooves. Space the ring end gaps 90 degrees apart
Limit measurements. between upper side rail, spacer and lower side
NOTICE rail.
Do not damage the piston when removing the (4)
carbon deposit.
(2)
2. Apply engine oil to each piston ring whole
(1)
surface.
3. Install the spacer (1) first, then install the side (2)
rails (2) to the piston (3).
4. Install the top ring (4) to the piston with “R”
mark (5) side facing up. (5)

(4)
NOTICE
(2)
Do not damage the piston ring by spreading the (1)
ends too far. (2)
Do not damage the piston during piston ring
installation.

(3)

(1) spacer (4) top ring

(2) side rails (5) “R” mark
(3) piston

80 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
3. Install the piston (3) with the “IN” mark (4)
Piston Installation and/or the large valve recesses (5) facing the (8) (6) (7)
intake side of the engine.
1. Place clean shop towels (1) over the crankcase
opening to keep the piston pin clips from (4)
falling into the crankcase.
2. Apply molybdenum disulfide oil (a mixture of (3)
1/2 engine oil and 1/2 molybdenum disulfide
grease containing more than 3% molybdenum
disulfide additive) to the connecting rod small (7)
end (2) inner surface.
(6)
(2) (1)
(6) piston pin (8) piston cutout
(7) piston pin clips (new)

(5)

(3) piston (5) large valve recesses

(4) “IN” mark

4. Apply molybdenum disulfide oil (a mixture of

1/2 engine oil and 1/2 molybdenum disulfide
grease containing more than 3% molybdenum
disulfide additive) to the piston pin (6) outer
(1) shop towels surface.
(2) connecting rod small end
Apply engine oil to the piston outer surface and
piston pin hole inner surface.
Install the piston pin and new piston pin clips
(7).

NOTICE
Use new pin clips. Never reuse old clips.
Do not let the clips fall into the crankcase.
Do not align the piston pin clip end gap with the
piston cutout (8).

Servicing Your Honda 81

Piston/Piston Rings/Piston Pin
4. Clean any gasket material off cylinder (3). 6. Install a new O-ring (6) to the water hose joint
Cylinder Installation 5. Apply engine oil to the cylinder wall, piston (7).
outer surface and piston rings (4). Install the water hose joint and bolts (8), and
1. Clean off any gasket material from the gasket Route the cam chain (5) through the cylinder. tighten them to the specified torque:
surface of the crankcase, being careful not to Install the cylinder over the piston rings by 7 lbf·ft (10 N·m, 1.0 kgf·m)
let any material fall into the crankcase. hand while compressing the piston rings.
Be careful not to remove any coating from the (7) (8)
gasket surface of the crankcase.
NOTICE
2. Remove the shop towels. Do not let any gasket
Do not damage the piston rings and cylinder
debris fall into the crankcase.
walls.
3. Install a new cylinder gasket (1) and dowel
pins (2). (3)

NOTICE
Do not let the dowel pins fall into the crankcase. (6)

(2)
(6) O-ring (new) (8) bolts
(7) water hose joint
(5)

(4)

(3) cylinder (5) cam chain

(4) piston rings

(1)

(1) cylinder gasket (2) dowel pins

82 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
3. Install the dowel pins (4) and a new cylinder 6. Install the cylinder bolt (8) and tighten it to the
Cylinder Head Installation head gasket (5). specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
1. Clean any gasket material off cylinder head.
2. Install the cam chain guide (1) and fit the cam NOTICE (8)
chain guide tabs (2) in the cylinder cutouts (3). Do not let the dowel pins fall into the crankcase.
Push the guide until it bottoms in the crankcase
guide groove. (4)

(6) (7)

(1)
(2)

(6) cylinder head

(7) washers and cylinder head bolts
(5)
(3) (8) cylinder bolt
(4) dowel pins
(5) cylinder head gasket (new)
(1) cam chain guide (3) cylinder cutouts
(2) cam chain guide tabs 4. Route the cam chain through the cylinder head
and install the cylinder head (6).

NOTICE
Do not damage mating surfaces when installing
the cylinder head.

5. Apply engine oil to all cylinder head bolt

threads and seating surface.
Install the washers and cylinder head bolts (7)
and tighten them to the specified torque in a
crisscross pattern in two or three steps:
38 lbf·ft (51 N·m, 5.2 kgf·m)

NOTICE
Do not let the washers fall into the crankcase.

(cont’d)

Servicing Your Honda 83

Piston/Piston Rings/Piston Pin
7. Install the left cylinder head hanger plate (9) 8. Install the throttle body (13) to the insulator
and right cylinder head hanger plate (10), then (14) by aligning the tab of the throttle body (16) (17) (18)
loosely install the cylinder head hanger plate with the groove of the insulator and tighten the
bolts (11) and cylinder head hanger bolts (12). insulator band screw (15) so the distance
Tighten the cylinder head hanger bolts and between the band ends is 0.43 ± 0.04 in (11.0
cylinder head hanger plate bolts to the ± 1.0 mm).
specified torque: Align
cylinder head hanger bolts:
40 lbf·ft (54 N·m, 5.5 kgf·m)
(14)
cylinder head hanger plate bolts: (13)
24 lbf·ft (32 N·m, 3.3 kgf·m) Align
Left side:
(11)
(16) rear shock absorber (18) nut
(9) (17) rear shock absorber upper bolt

(15) 10. Install the air cleaner connecting tube (19)

along with air cleaner case to the throttle body
0.43 ± 0.04 in (20).
(11.0 ± 1.0 mm) Tighten the air cleaner connecting tube band
screw (21) so the distance between the band
ends is 0.30 ± 0.06 in (7.5 ± 1.5 mm).
(13) throttle body (15) insulator band screw
(12) (14) insulator (19)

Right side: (11) 9. Set the rear shock absorber (16) and install the (20)
rear shock absorber upper bolt (17) and nut
(10)
(18) as shown.
Tighten the rear shock absorber upper nut to
the specified torque:
32 lbf·ft (44 N·m, 4.5 kgf·m)

(21)

0.30 ± 0.06 in
(12) (7.5 ± 1.5 mm)

(19) air cleaner connecting tube

(9) left cylinder head hanger plate (20) throttle body
(10) right cylinder head hanger plate (21) air cleaner connecting tube band screw
(11) cylinder head hanger plate bolts
(12) cylinder head hanger bolts

84 Servicing Your Honda

 Piston/Piston Rings/Piston Pin
11. Connect the breather tubes A (22) and B (23). 13. Tighten the radiator hose clamp screw (27) as 15. Install the ignition coil (29) and tighten the
Connect the IAT sensor connector (24). illustrated below. ignition coil bolts (30) to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
0 – 0.04 in
(22)
(0 – 1.0 mm)
Connect the ignition coil connectors (31).
(29)

(23) (31)
(27)
(24)

(22) breather tube A (27) radiator hose clamp screw (30)

(23) breather tube B
(24) IAT sensor connector 14. Connect the ECT sensor connector (28). (29) ignition coil
(30) ignition coil bolts
12. Connect the radiator hose (25) to the water (28)
(31) ignition coil connectors
hose joint (26) of the cylinder head.
16. Install the shims, valve lifters, camshaft and
camshaft holder (page 72).
17. Install the crankshaft hole cap (page 74).
18. Install the cylinder head cover (page 75).
19. Install the spark plug (page 66).
20. Install the exhaust pipe (page 101).
21. Install the subframe (page 37) and left and
right mufflers (page 99).
22. Install the fuel tank and seat (pages 33, 35).
(25)
23. Fill and bleed the cooling system (page 143).
(28) ECT sensor connector Check for the following:
(26)
– compression leaks
– abnormal engine noise
(25) radiator hose
(26) water hose joint – secondary air leaks
– exhaust gas leaks
– coolant leaks
– oil leaks

Servicing Your Honda 85

Suspension

Suspension
Refer to Important Safety Precautions on page 23. • Refer to Suspension Adjustment Guidelines
(page 131). Make all rebound and compression (4)
0.06 in (1.5 mm)
Loose, worn, or damaged suspension components damping adjustments in one-click increments.
may adversely affect the handling and stability of (Adjusting two or more clicks at a time may
your CRF. If any suspension components appear cause you to pass over the best adjustment.)
worn or damaged, see your dealer for further Test ride after each adjustment.
inspection. Your dealer is qualified to determine • If you become confused about adjustment
whether or not replacement parts or repairs are settings, return to the standard position and
needed. start over. (3) (3)
• If the fork is still too stiff/soft after adjusting
compression damping, determine which
Front Suspension Inspection
portion of the travel is still too stiff/soft. This is (3) wear rings (4) outer tube
• When your CRF is new, break it in for an important step that will help you solve
approximately 1 hour to ensure that the suspension problems.
suspension has worked in (page 19). (3)
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 the
your CRF is ridden.
fork after riding your CRF for 3 hours.
See page 114 for fork disassembly.
• Adjust the PSF air pressure each race or 2.5 (1)
hours of running. See page 113 for PSF air (5)
pressure adjustment.
• Replace the fork oil every 3 races or 7.5 hours (3) wear rings (5) end gaps
of running. See page 87 for oil capacity 4. Make a quick check of fork operation by
adjustment after changing the fork oil. locking the front brake and pushing down on
• Use KHL15-11(KYB) which contains special the handlebar several times.
additives to assure maximum performance of
your CRF’s front suspension. (2)
• Periodically check and clean all front
suspension parts to assure top performance. (1) fork protectors (2) dust seals
Check the dust seals for dust, dirt, and foreign
materials. Check the oil for any contamination. 3. Inspect the wear rings (3) for wear or damage.
Replace the wear ring if it is 0.06 in (1.5 mm)
or flush with the outer tube (4). Remove the
fork leg when replacing the wear ring.
Install the wear ring with its end gap (5) facing
rearward.

86 Servicing Your Honda

 Suspension
1. Bounce the rear of the motorcycle up and down
Rear Suspension Inspection and check for smooth suspension action. Recommended Fork Oil
The swingarm is controlled by one hydraulic shock suggested oil KHL15-11 (KYB)
absorber with an aluminum reservoir for oil and
nitrogen gas pressure. The gas pressure in the
reservoir is contained within a rubber bladder. Fork Oil Change
The rear suspension’s spring pre-load and damping Refer to Front Suspension Disassembly on
adjustments (compression and rebound) should be page 114 and Front Suspension Assembly on
adjusted for the rider’s weight and track conditions page 118 for fork oil change.
(pages 128, 133).

Do not attempt to disassemble, service, or dispose

of the damper; see your dealer.
The instructions found in this owner’s manual are
limited to adjustments of the shock assembly only. 2. Remove the right and left mufflers (page 98),
subframe (page 37) and air cleaner case along
• When your CRF is new, break it in for with air cleaner connecting tube (page 77).
approximately 1 hour with the standard 3. Check for a broken or collapsed spring.
suspension settings before attempting to adjust 4. Check the rear shock absorber (1) for a bent
the rear suspension. rod or oil leaks.
• Refer to Suspension Adjustment Information
(page 133) for making all rebound and (1)
compression damping adjustments in one click
increments. (Adjusting two or more clicks at a
time may cause you to pass over the best
adjustment.)
Test ride after each adjustment.
• If the rear suspension is too stiff/soft, adjust it
by turning all the compression and rebound
adjusters according to the procedures
described in page 127. After adjusting the
adjusters simultaneously, suspension may be
fine-tuned by turning one of the compression
and rebound damping adjusters in one click (1) rear shock absorber
increments.
• If you have a problem finding an acceptable 5. Push the rear wheel sideways to check for
adjustment, return to the standard position and worn or loose swingarm bearings. There
begin again. should be no movement. If there is, have the
bearings replaced by your dealer.

Servicing Your Honda 87

Brakes

Brakes
Refer to Important Safety Precautions on page 23.
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 fluid 1. Loosen the lock nut (1). The rear brake pedal height should be
level will drop. A leak in the system will also cause 2. To position the front brake lever farther away approximately level with the right footpeg.
the level to drop. from the handgrip, turn the adjuster (2)
clockwise. 1. Loosen the lock nut (1) and turn the push rod
Frequently inspect the system to ensure there are To position the front brake lever closer to the (2) in direction (+) to raise the rear brake pedal
no fluid leaks. Periodically inspect the brake fluid handgrip, turn the adjuster counterclockwise. (3) or in direction (–) to lower it.
level and the brake pads for wear. 3. While holding the adjuster, tighten the lock nut 2. Tighten the push rod lock nut to the specified
to the specified torque: torque at the desired pedal height.
If the braking response of the front brake lever or 4.4 lbf·ft (5.9 N·m, 0.6 kgf·m) 4.4 lbf·ft (5.9 N·m, 0.6 kgf·m)
rear pedal feels unusual, check the brake pads. If 4. Apply silicone grease to the contacting areas of
the brake pads are not worn beyond the the adjuster and knocker arm (3). (3)
recommended limit (page 91), there is probably air (2)
in the brake system. (3) (2)
Refer to an official Honda Service Manual or see
your dealer to have the air bled from the system. (–)
(+)

(1)
(1)
(1) lock nut (+) raise the pedal height
(1) lock nut (3) knocker arm (2) push rod (–) lower the pedal height
(2) adjuster (3) rear brake pedal

88 Servicing Your Honda

 Brakes
Rear Brake Fluid Level Check
Fluid Level Inspection

Front Brake Fluid Level Check

(1)

(1) LOWER mark

(1)
With the motorcycle in an upright position, check
(1) LWR mark the fluid level.
It should be above the LOWER mark (1). If the
With the motorcycle in an upright position, check level is at or below the LOWER mark, check the
the fluid level. brake pads for wear (page 91).
It should be above the LWR mark (1). If the level Worn brake pads should be replaced. If the pads
is at or below the LWR mark, check the brake pads are not worn, have your brake system inspected for
for wear (page 91). leaks.
Worn brake pads should be replaced. If the pads If the travel for the rear brake pedal feels
are not worn, have your brake system inspected for excessive, there is probably air in the brake system
leaks. and it must be bled. Refer to an official Honda
If the pulling distance for the front brake lever Service Manual or see your dealer for brake
feels excessive, there is probably air in the brake bleeding.
system and it must be bled. Refer to an official
Honda Service Manual or see your dealer for brake Honda recommends using Pro Honda DOT 4
bleeding. Brake Fluid from a sealed container, or an
equivalent.
Honda recommends using Pro Honda DOT 4
Brake Fluid from a sealed container, or an Other Checks:
equivalent. Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
Other Checks:
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.

Servicing Your Honda 89

Brakes
Adding Front Brake Fluid Adding Rear Brake Fluid 3. Install the diaphragm, set plate and reservoir
cap.
NOTICE NOTICE 4. Tighten the rear brake reservoir cap bolts to the
specified torque:
Spilled brake fluid will severely damage painted Spilled brake fluid will severely damage painted 0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)
surfaces. It is also harmful to some rubber parts. surfaces. It is also harmful to some rubber parts.
Be careful whenever you remove the reservoir Be careful whenever you remove the reservoir
cap; make sure the reservoir is horizontal first. cap; make sure the reservoir is horizontal first.

• Always use fresh DOT4 brake fluid from a • Always use fresh DOT4 brake fluid from a
sealed container when servicing the system. Do sealed container when servicing the system. Do
not mix different types of fluid, they may not be not mix different types of fluid, they may not be
compatible. compatible.
• The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda
DOT 4 Brake Fluid or an equivalent. DOT 4 Brake Fluid or an equivalent.

1. Remove the front brake reservoir cap screws 1. Remove the rear brake reservoir cap bolts (1),
(1), reservoir cap (2) and diaphragm (3). reservoir cap (2), set plate (3) and diaphragm
2. Fill the reservoir with DOT4 brake fluid to the (4).
upper level mark (4). Do not overfill. 2. Fill the reservoir with DOT4 brake fluid to the
3. Install the diaphragm and reservoir cap. upper level mark (5). Do not overfill.
4. Tighten the front brake reservoir cap screws to
the specified torque: (1)
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m) (5)
(1) (4)
(3)
(2)

(3) (2)

(4)

(1) rear brake reservoir cap bolts

(2) reservoir cap
(3) set plate
(4) diaphragm
(1) front brake reservoir cap screws (5) upper level mark
(2) reservoir cap
(3) diaphragm
(4) upper level mark

90 Servicing Your Honda

 Brakes
Rear Brake Pads
Brake Pad Wear Inspect the brake pads (1) from the rear side of the Other Inspections
caliper to determine the brake pad wear. If either
Brake pad wear depends on the severity of usage brake pad is worn anywhere to a thickness of 0.04 Check that the front brake lever and rear brake
and track conditions. (Generally, the pads will in (1.0 mm), both brake pads must be replaced. pedal assemblies are positioned properly (page 88)
wear faster with wet and dirty track conditions.) and the securing bolts are tight.
Inspect the brake pads at each regular maintenance
interval (page 25). (2) Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
Front Brake Pads
Inspect the brake pads (1) through the front wheel minimum thickness
indicator
to determine the brake pad wear. If either brake
0.04 in
pad is worn anywhere to a thickness of 0.04 in (1.0 (1.0 mm)
mm), both brake pads must be replaced.
(1)

(3)
minimum thickness
indicator
(2) replace
0.04 in
(1.0 mm)
(1) (3)

(1) brake pads (3) brake disc

(2) rear brake caliper
replace

(1)
0.04 in
(1.0 mm)

wear indicator
grooves

(1) brake pads (3) brake disc

(2) front brake caliper

Servicing Your Honda 91

Wheels

Wheels
Refer to Important Safety Precautions on page 23.
Wheel Rims & Spokes Axles & Wheel Bearings
Keeping the wheels true (round) and maintaining
correct spoke tension are critical to safe 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Service Manual for
motorcycle operation. During the first few rides, damage. inspection information:
spokes will loosen more rapidly due to the initial 2. Tighten, any loose spokes and rim locks (3) to
seating of the parts. Excessively loose spokes may the specified torque: 1. Check the axle shaft for runout.
result in instability at high speeds and the possible Spokes: 2.7 lbf·ft (3.7 N·m, 0.4 kgf·m) 2. Check the condition of the wheel bearings.
loss of control. It’s also important that the rim Rim Locks: 9 lbf·ft (12 N·m, 1.2 kgf·m)
locks are secure to prevent tire slippage. 3. Check wheel rim runout. If runout is
noticeable, see an official Honda Service
Manual for inspection instructions.

(3)

(2)

(1)

(1) wheel rim (3) rim lock

(2) spokes

92 Servicing Your Honda

Tires & Tubes

Tires & Tubes

Refer to Important Safety Precautions on page 23. Always check air pressure when your tires are
“cold.” If you check air pressure when your tires Tube Replacement
To safely operate your CRF, the tires must be the are “warm” — even if your CRF has only been
proper type (off-road) and size, in good condition ridden for a few miles — the readings will be If a tube is punctured or damaged, you should
with adequate tread, and correctly inflated. higher. If you let air out of warm tires to match the replace it as soon as possible. A repaired tube may
recommended cold pressures, the tires will be not have the same reliability as a new one, and it
underinflated. may fail while you are riding.
WARNING The correct “cold” tire pressures are:
Using tires that are excessively worn or Use a replacement tube equivalent to the original.
improperly inflated can cause a crash in Front 15 psi (100 kPa, 1.0 kgf/cm2)
which you can be seriously hurt or killed. Rear 15 psi (100 kPa, 1.0 kgf/cm2)
Follow all instructions in this owner’s
manual regarding tire inflation and If you decide to adjust tire pressures for a
maintenance. particular riding condition, make changes a little at
a time.

The following pages give detailed information on Inspection

how and when to check your air pressure, how to
inspect your tires for wear and damage, and our Take time to inspect your tires and wheels before
recommendations on tire repair and replacement. you ride.
• Inspect carefully for bumps or bulges in the
Air Pressure side of the tire or the tread. Replace any tire
that has a bump or bulge.
Properly inflated tires provide the best • Look closely for cuts, slits, or cracks in the
combination of handling, tread life, and riding tires. Replace a tire if you can see fabric or
comfort. Generally, underinflated tires wear cord.
unevenly, adversely affect handling, and are more • Check for rocks or other objects embedded in
likely to fail from being overheated. the tire or tread. Remove any objects.
Underinflated tires can also cause wheel damage • Check the position of both valve stems. A
on hard terrain. Overinflated tires make your CRF tilted valve stem indicates the tube is slipping
ride harshly, are more prone to damage from inside the tire or the tire is slipping on the rim.
surface hazards, and wear unevenly.

Make sure the valve stem caps are secure. If

necessary, install new caps.

Servicing Your Honda 93

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 MX52F
120/80-19 63M
Rear
DUNLOP MX52
Type bias-ply, tube

• When replacing, use the original equipment

tires or equivalent tires of the same size,
construction, speed rating, and load range as
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.

94 Servicing Your Honda

Drive Chain

Drive Chain
Refer to Important Safety Precautions on page 23.
Drive Chain Sliders
The service life of the chain depends on proper (1) 1 – 1 3/8 in (25 – 35 mm)
lubrication and adjustment. Poor maintenance can 1. Check the chain slider (1) for wear.
cause premature wear or damage to the drive chain Replace it if below the service limit.
or sprockets. SERVICE LIMIT:
upper side: 0.2 in (5 mm)
When the motorcycle is ridden on unusually dusty lower side: 0.10 in (2.5 mm)
or muddy tracks, more frequent maintenance will
0.2 in
be necessary. (5 mm)
(3) (1)
(2)
Before servicing your drive chain, turn the engine
OFF and check that your transmission is in neutral.
(1) drive chain slack (3) driven sprocket
(2) drive sprocket
Inspection
3. Check drive chain slack at several points along
1. Turn the engine off, raise the rear wheel off the the chain. The slack should remain constant. If
ground by placing an optional workstand or it isn’t, some links may be kinked and binding. (1)
equivalent support under the engine and shift Lubricating the chain will often eliminate
the transmission into neutral. binding and kinking.
2. Check the drive chain slack (1) in the upper
drive chain run midway between the drive NOTICE 0.10 in
sprocket (2) and driven sprocket (3). Drive (2.5 mm)
chain slack should allow the following vertical Excessive chain slack may allow the drive chain to
movement by hand: damage the engine cases.
(1) chain slider
1 – 1 3/8 in (25 – 35 mm)
4. Inspect the drive chain for: 2. Check the chain guide slider (2) for wear.
• damaged rollers Replace the guide slider if it is worn to the
• loose pins bottom of the wear limit (3).
• dry or rusted links (2)
• kinked or binding links
• excessive wear
Replace the drive chain (page 97) if it has damaged
rollers, loose pins, or kinks that cannot be free.
Lubricate the drive chain (page 96) if it appears
dry or shows signs of rust. Lubricate any kinked or
binding links and work them free.
Adjust chain slack if needed (page 96).
(3)

(2) chain guide slider (3) wear limit

Servicing Your Honda 95

Drive Chain
Drive Chain Rollers Adjustment Lubrication
Check the upper drive chain roller (1) and lower 1. Loosen the rear axle nut (1). Commercially prepared drive chain lubricants may
drive chain roller (2) for wear or damage. 2. Loosen the chain adjuster lock nuts (2) and be purchased at most motorcycle shops and should
Measure the diameter of the drive chain rollers and turn the adjusting bolts (3) counterclockwise to be used in preference to motor oil. Pro Honda HP
replace them if below the service limit. decrease slack or clockwise to increase slack. Chain Lube or an equivalent is recommended.
Service Limit: Align the index marks (4) of the axle plates (5)
Upper roller: 1.3 in (33 mm) with the same reference marks (6) on both Saturate each chain joint so that the lubricant
Lower roller: 1.4 in (35 mm) sides of the swingarm. penetrates the space between adjacent surfaces of
the link plates and rollers.
Replace the roller if necessary as follows. (6) (4)
Install the upper drive chain roller (Green) with the
(2)
“ ” mark (3) facing toward the bracket and lower
drive chain roller (Black) with the large concave
facing outside. (5)
Install the drive chain roller bolt and nut.
(3)

(3)
(1)
(6)

(1) (1) rear axle nut (4) index marks

(2) chain adjuster lock nuts (5) axle plates
(3) adjusting bolts (6) reference marks

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.
(2) 5. Turn the adjusting bolt counterclockwise until
it touches the axle plates lightly. Then tighten
(1) upper drive chain roller (Green) the chain adjuster lock nuts to the specified
(2) lower drive chain roller (Black)
(3) “ ” mark
torque while holding the adjusting bolts with a
wrench:
Tighten the drive chain roller bolt and nut to the 20 lbf·ft (27 N·m, 2.8 kgf·m)
specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)

96 Servicing Your Honda

 Drive Chain
5. Inspect the sprocket teeth for wear or damage.
Removal, Cleaning & Replacement We recommend replacing the sprocket Service limit: 10.20 in (259.0 mm)
For maximum service life, the drive chain should whenever a new chain is installed.
be cleaned, lubricated, and adjusted before each Both chain and sprockets must be in good
outing. condition, or the new replacement chain or MEASURE A SPAN OF 17 PINS (16 PITCHES)
sprocket(s) will wear rapidly.
1. Remove the master link retaining clip (1) with Excessively worn sprocket teeth have a
pliers. hooked, worn appearance.
Do not bend or twist the clip. Replace any sprocket which is damaged or
2. Remove the master link (2). Remove the drive excessively worn.
chain. 8. Lubricate the drive chain (page 96).
Damaged Sprocket Worn Sprocket 9. Pass the chain over the sprockets and join the
Teeth Teeth ends of the chain with the master link. For ease
of assembly, hold the chain ends against
adjacent driven sprocket teeth while inserting
(2)
REPLACE REPLACE 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.
10. Recheck chain slack and adjust as necessary.

(1) Normal Sprocket Teeth

More About Drive Chain
GOOD
• The master link is the most critical element of
(1) master link retaining clip NOTICE drive chain security. Master links are reusable,
(2) master link as long as they remain in excellent condition.
Use of a new chain with worn sprockets will cause We recommend installing a new master link
3. Clean the drive chain in high flash-point rapid chain wear. retaining clip when the drive chain is
solvent and allow it to dry. reassembled.
4. Inspect the drive chain for possible wear or 6. Install the chain. • You may find it easier to install a new chain by
damage. Replace the drive chain if it has 7. Measure a section of the drive chain to connecting it to the old chain with a master link
damaged rollers, loose fitting links, or determine whether the chain is worn beyond its and pulling the old chain to position the new
otherwise appears unserviceable. service limit. Put the transmission in gear, and chain on the sprockets.
then turn the rear wheel forward until the lower
Chain: section of the chain is pulled taut. With the
Size/link: D.I.D 520DMA4/116RB chain held taut and any kinked joints
RK520TXZ/116RJ 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.

Servicing Your Honda 97

Exhaust Pipe/Muffler

Exhaust Pipe/Muffler
4. Remove the right muffler mounting bolt (5),
Exhaust Pipe/Muffler Inspection Muffler Removal washer (6) and right muffler (7).
Check the mounting bolts and exhaust pipe joint 1. Remove the seat (page 33). (6) (5)
nuts for tightness. 2. Remove the side covers (1) and air cleaner
Check the exhaust pipe and mufflers for cracks or housing covers (2) by removing the bolts (3).
deformation.
(2)
A damaged exhaust pipe and mufflers may reduce
engine performance.
(7)

(1)

(5) right muffler mounting bolt

(6) washer
(3) (7) right muffler

(1) side covers (3) bolts 5. Remove the mud guard (8) by removing the
(2) air cleaner housing covers screws (9).

3. Loosen the right muffler clamp bolt (4). (9)

(8)
(4)
(8) mud guard (9) screws

(4) right muffler clamp bolt

98 Servicing Your Honda

 Exhaust Pipe/Muffler
6. Loosen the left muffler clamp bolt (10). 5. Install the washer B (7), left muffler mounting
Muffler Installation B bolt (8), washer A (9), and left muffler
mounting A bolt (10).
1. Remove the gasket (1).
2. Install the left muffler clamp (2) and a new (8) (10)
gasket onto the exhaust pipe (3). (7)

(2) (3)

(10)

(1) (9)
(10) left muffler clamp bolt

7. Remove the left muffler mounting A bolt (11),

washer A (12), left muffler mounting B bolt (7) washer B
(13), washer B (14) and left muffler (15). (8) left muffler mounting B bolt
(1) gasket (3) exhaust pipe (9) washer A
Right side: Left side: (2) left muffler clamp (10) left muffler mounting A bolt
(14)
(12) 3. Install the left muffler (4). 6. Tighten the left muffler clamp bolt (11) to the
(13)
4. Install the left muffler clamp (2) by aligning specified torque:
the tab (5) of the left muffler clamp with the 15 lbf·ft (20 N·m, 2.0 kgf·m)
cutout (6) of the left muffler.
(6) (2)

(11)

(15)

(11) left muffler mounting A bolt

(12) washer A
(13) left muffler mounting B bolt (4) (11)
(14) washer B
(15) left muffler
(5)
(11) left muffler clamp bolt
(2) left muffler clamp (5) tab
(4) left muffler (6) cutout

Servicing Your Honda 99

Exhaust Pipe/Muffler
7. Tighten the left muffler mounting B bolt (8) 9. Remove the gasket (14). 14. Tighten the right muffler mounting bolt (16) to
and left muffler mounting A bolt (10) to the 10. Install a new gasket onto the left muffler (4). the specified torque:
specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m)
19 lbf·ft (26 N·m, 2.7 kgf·m) (4)
(16)
Right side: Left side:

(14)
(10) (8)
(18)
(4) left muffler
(14) gasket (16) right muffler mounting bolt
(8) left muffler mounting B bolt (18) right muffler clamp bolt
(10) left muffler mounting A bolt 11. Install the right muffler (15).
12. Install the right muffler mounting bolt (16) and 15. Install the air cleaner housing covers (19) and
8. Install the mud guard (12), and then tighten the washer (17). side covers (20), and then tighten the bolts
screws (13) to the specified torque: (21).
1.1 lbf·ft (1.5 N·m, 0.2 kgf·m) (17) (16)
(19)
(13)

(15) (20)

(21)
(12) (15) right muffler
(16) right muffler mounting bolt (19) air cleaner housing covers (21) bolts
(17) washer (20) side covers
(12) mud guard (13) screws

13. Tighten the right muffler clamp bolt (18) to the 16. Install the seat (page 33).
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)

100 Servicing Your Honda

 Exhaust Pipe/Muffler

Exhaust Pipe Removal Exhaust Pipe Installation

1. Remove the right and left mufflers (page 98). 1. Install a new exhaust pipe gasket (1) as shown.
2. Remove the exhaust pipe joint nuts (1), 2. Install the exhaust pipe (2) and exhaust pipe
exhaust pipe (2) and gasket (3). joint nuts (3) but do not tighten the nuts yet.
(3)
(1)

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

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

3. Install the left muffler (page 99) but do not

tighten the bolts yet.
4. Tighten the exhaust pipe joint nuts to the
specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
5. Tighten the left muffler clamp bolt, left muffler
mounting A bolt and B bolt (page 99).
6. Install the mud guard (page 100).
7. Install the right muffler (page 100).

(cont’d)

Servicing Your Honda 101

Steering Damper

Steering Damper
Refer to Safety Precaution on page 23. 2. Check the steering damper (4) for deformation
Steering Damper Operation Inspection or oil leaks.
Loose, worn or damaged steering damper Check the damper rod (5) for bending or
components may adversely affect the handling and • When your CRF is new, break it in for damage.
stability of your CRF. If any steering damper approximately 1 hour to ensure that the steering Replace the damper case or damper rod if there
components appear worn or damaged, see your damper has worked in (page 19). is any abnormality.
dealer for further inspection. Your dealer is • After break-in, test run your CRF with the Refer to an official Honda Service Manual or
qualified to determine whether or not replacement steering damper at the standard setting before see your dealer for steering damper
parts are needed. making any adjustments. disassembly.
Do not attempt to disassemble the steering damper; • Check the spherical bearings and dust seal for Check the torque of the steering damper
see your dealer. dust, dirt, and foreign materials. mounting bolts (6):
The instructions found in this owner’s manual are • Make all damping adjustments in one-click 15 lbf·ft (20 N·m, 2.0 kgf·m)
limited to adjustment and service of the steering increments. (Adjusting two or more clicks at a
damper assembly only. time may cause you to pass over the best (4)
adjustment.) Test ride after each adjustment.
• If you have a problem finding an acceptable
adjustment, return to the standard position and
begin again. (6)

1. Unlock the number plate tab (1) from the

handlebar pad.
Remove the bolts (2) and number plate (3).
(1) (5)

(4) steering damper

(2) (5) damper rod
(6) steering damper mounting bolts

(3)

(1) number plate tab (3) number plate

(2) bolts

102 Servicing Your Honda

 Steering Damper
3. With your CRF on a box or an optional
workstand (front wheel elevated), check that Removal Inspection
the steering moves smoothly from side-to-side.
1. Remove the number plate (page 102). 1. Check the damper rod (1) operation.
2. Remove the steering damper mounting bolts The damper rod is fully extended and
(1), collar (2) and steering damper (3). compressed by hand. Release the damper rod,
then check that it extends to its maximum
(3)
(2) length.

If the damper rod does not extend to its maximum

length, refer to an official Honda Service Manual
for disassembly and inspection instructions or see
your dealer.
(1)

4. Install the number plate (3) by aligning its

holes (7) with the tabs (8) on the steering stem.
Install and tighten the bolts (2). (1) steering damper mounting bolts
Route the number plate tab (1) around the (2) collar
handlebar pad (9) as shown. (3) steering damper (1)

(9) (1) (1) damper rod

(2)

(7)

(8) (3)

(1) number plate tab (7) holes

(2) bolts (8) tabs
(3) number plate (9) handlebar pad

Servicing Your Honda 103

Steering Damper
2. Check the condition of the spherical bearings 5. With your CRF on a box or an optional
(2). Installation workstand (front wheel elevated), check that
Move the spherical bearing with your finger. the steering moves smoothly from side to side.
The spherical bearing should move smoothly 1. Clean and apply a locking agent to the steering
and quietly. damper mounting bolt threads.
2. Install the steering damper (1) with its “UP”
Replace the spherical bearing if it does not move mark (2) facing up and forward. Turn the
smoothly and quietly. damper rod and its stopper ring (3) facing
Refer to an official Honda Service Manual or see toward the front side.
your dealer. 3. Install the collar (4) and steering damper
mounting bolts (5).
Be sure to install the collar with its wide flange
side facing toward the steering head pipe side.

4. Tighten the steering damper mounting bolts to

the specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m) 6. Install the number plate (page 103).
(4)
(3)
(1)
(2)
(5)

(2) spherical bearings

(2)

(1) steering damper

(2) “UP” mark
(3) stopper ring
(4) collar
(5) steering damper mounting bolts

104 Servicing Your Honda

Additional Maintenance Procedures

Additional Maintenance Procedures

Refer to Important Safety Precautions on page 23.
Control Cables
Steering Head Bearing Inspection Periodically, disconnect the throttle and clutch
cables at their upper ends. Thoroughly lubricate
1. With your CRF on a box or optional workstand the cable pivot points with a commercially
(front wheel elevated), turn the handlebar to available cable lubricant. If the clutch lever and
the right and left to check for roughness in the throttle operation is not smooth, replace the cable.
steering head bearings. Be sure the throttle returns freely from fully open
to fully closed automatically, in all steering
positions.

Handlebar Inspection
1. Check the handlebar (1) for bends or cracks.
2. Check that the handlebar has not moved from
its original position where the end of the right
handlebar holders (2) is aligned with the paint
mark (3).
3. Check the torque of the handlebar upper holder
2. Stand in front of your CRF, grab the fork (at bolts (4):
the axle), look at the steering head, and push 16 lbf·ft (22 N·m, 2.2 kgf·m)
the fork in and out (toward the engine) to check Tighten the front bolts first.
for play in the steering head bearings. (4) (4)
If any roughness or play is felt, but you do not see
any movement in the steering head, the fork
bushings may be worn.
Refer to an official Honda Service Manual for
replacement or adjustment procedures, or see your
dealer.

(1) (2) (3)

(1) handlebar
(2) right handlebar holders
(3) paint mark
(4) handlebar upper holder bolts

Servicing Your Honda 105

Additional Maintenance Procedures
RIGHT SIDE LEFT SIDE
Nuts, Bolts, Fasteners
(13) (1) (1)
(7)
Check and tighten nuts, bolts, and fasteners before
every outing. (7)
(2) (8)
ENGINE
Torque
Item
lbf•ft N•m kgf•m
(5)
1 Cylinder head cover (9)
socket bolts 7 10 1.0
2 Clutch cover bolts 7 10 1.0
3 Water pump cover bolts 7 10 1.0
4 Transmission oil check
bolt 9 12 1.2
(3)
5 Crankshaft hole cap 11 15 1.5
6 Oil filter cover bolts 7 10 1.0 (6)
(12)
7 Cylinder head bolts 38 51 5.2 (4) (11)
(10)
8 Exhaust pipe joint nuts 15 21 2.1
9 Drive sprocket bolt 23 31 3.2 (1) cylinder head cover socket bolts (1) cylinder head cover socket bolts
(2) clutch cover bolts (6) oil filter cover bolts
10 Engine oil drain bolt 12 16 1.6 (3) water pump cover bolts (7) cylinder head bolts
11 Transmission oil drain (4) transmission oil check bolt (8) exhaust pipe joint nuts
bolt 12 16 1.6 (5) crankshaft hole cap (9) drive sprocket bolt
(7) cylinder head bolts (11) transmission oil drain bolt
12 Coolant drain bolt 7 10 1.0 (10) engine oil drain bolt
13 Water hose joint bolts 7 10 1.0 (12) coolant drain bolt
(13) water hose joint bolts

106 Servicing Your Honda

Appearance Care

Appearance Care
Refer to Important Safety Precautions on page 23. 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 brake master cylinders Detergent
CRF looking newer longer. Frequent cleaning also drive chain
identifies you as an owner who values his electrical circuit Allow the engine, muffler, brakes, and other high-
motorcycle. A clean CRF is also easier to inspect muffler outlet temperature parts to cool before washing.
and service. steering head bearings 1. Rinse your CRF thoroughly using a garden
suspension pivot points hose to remove loose dirt.
While you’re cleaning, be sure to look for damage, throttle body
wear, and gasoline or oil leaks. 2. Fill a bucket with cool water. Mix in a mild,
under fuel tank neutral detergent, such as dish washing liquid
under seat or a product made especially for washing
General Recommendations motorcycles or automobiles.
(1) 3. Wash your CRF with a sponge or a soft towel.
• To clean your CRF you may use: As you wash, check for heavy grime. If
– water necessary, use a mild cleaner/degreaser to
– Hondabrite remove the grime.
– a mild, neutral detergent and water
– a mild spray and wipe cleaner/polisher
NOTICE
– a mild spray and rinse cleaner/degreaser and
water Do not use steel wool to clean the frame as it could
• Avoid products that contain harsh detergents damage or discolor the frame surface.
or chemical solvents that could damage the Muffler stain remover (Scotch Brite Hand Pad
(2)
metal, paint, and plastic on your CRF or #7447-maroon) is for removing stains on the non-
discolor the seat and decals. (1) steering head bearings coated aluminum frame only.
• If your CRF is still warm from recent (2) suspension pivot points
operation, give the engine and exhaust system 4. After washing, rinse your CRF thoroughly
time to cool off. with plenty of clean water to remove any
• We recommend the use of a garden hose to NOTICE residue.
wash your CRF. High pressure washers (like High pressure water (or air) can damage certain Detergent residue can corrode alloy parts.
those at coin-operated car washes) can damage parts of your CRF. 5. Dry your CRF with a chamois or a soft towel.
certain parts of your CRF. The force of water Leaving water on the surface to air dry can
under extreme pressure can penetrate the dust You may use Pro Honda Hondabrite, a multi- cause dulling and water spots. As you dry,
seals of the suspension pivot points and surface cleaner/degreaser, to remove both dirt and inspect for chips and scratches.
steering head bearings-driving dirt inside and petroleum-based grime from paint, alloy, plastic, 6. Lubricate the drive chain to prevent rusting.
needed lubrication out. and rubber surfaces. Wet any heavy deposits with 7. Start the engine and let it idle for several
water first. Then spray on the Pro Honda minutes. The engine heat will help dry moist
Hondabrite and rinse with a garden hose at full areas.
pressure. Stubborn deposits may require a quick 8. As a precaution, ride at a slow speed and apply
wipe with a sponge. the brakes several times. This will help dry the
brakes and restore normal braking
performance.

Servicing Your Honda 107

Appearance Care

Condensation Control Aluminum Frame Maintenance Exhaust Pipe and Muffler Maintenance
Some condensation can form within the Aluminum corrodes when it comes in contact with The exhaust pipe and muffler are stainless steel but
transmission cavity as well. This is natural and just dust, mud and road salt. may became stained by mud or dust.
one more reason you should change the engine and
transmission oil often. To remove stains, use Scotch Brite Hand Pad To remove mud or dust, use a wet sponge and a
#7447 (maroon) or an equivalent. liquid kitchen abrasive, then rinse well with clean
Wet the pad and polish the surface using strokes water. Dry with chamois or a soft towel.
After Cleaning Lubrication parallel to the length of the frame.
If necessary, remove heat stains by using a
There are some things you should do just after Clean the frame using a wet sponge and a mild commercially available fine texture compound.
washing your CRF to help prevent rust and detergent, then rinse well with clean water. Dry the Then rinse by the same manner as removing mud
corrosion. frame with a soft clean cloth, using strokes parallel or dust.
to the length of the frame.
Once your CRF is clean and dry, you should
protect any bare steel from rusting by applying a
light coating of a rust-inhibitor. Lubricate the drive NOTICE
chain and drive sprocket after removing and Do not use steel wool to clean the frame as it could
thoroughly cleaning in solvent. Be sure the chain is damage or discolor the frame surface.
wiped clean and is dry before applying the chain Muffler stain remover (Scotch Brite Hand Pad
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.

108 Servicing Your Honda

Adjustments for Competition

Adjustments for Competition

This section tells you how to fine tune your CRF Engine Mode Select Button ...........................110
for maximum competition performance. Current Mode.............................................110
Mode Selection ..........................................110
Initial suspension adjustments should be Front Suspension Adjustments ......................111
performed after a minimum of 2 hours of easy Front Suspension Damping........................111
break-in time. Fork Springs...............................................113
Front Suspension Disassembly ..................114
Optional rear suspension springs are available in Front Suspension Assembly.......................118
order to tailor your CRF specifically for your Rear Suspension Adjustments........................126
weight, riding style and course conditions. Rear Suspension Spring Pre-Load .............126
Rear Suspension Damping.........................127
Follow the instructions given in the rear
Rear Suspension Race Sag.........................128
suspension sag setting section of Rear Suspension
Suspension Adjustments for
Adjustments to determine if your combined rider
Track Conditions............................................130
and sprung machine weight (rider fully dressed for
Suspension Adjustment Guidelines ...............131
competition and machine coolant, oil and fuel
Tuning Tips....................................................134
levels ready for competition) requires an optional
Spark Plug Reading ...................................134
stiffer or softer rear spring. The need for either
Steering Damper Adjustment.........................135
optional rear spring may need to be balanced by
Steering Damper Damping ........................135
adjusting the PSF air pressure and oil capacity.
Steering Damper Adjustment Guidelines ......136
Chassis Adjustments ......................................137
Rear End ....................................................137
Fork Height/Angle .....................................137
Wheelbase..................................................137
Gearing...........................................................138
Tire Selection for Track Conditions ..............139
Personal Fit Adjustments ...............................140
Control Positioning ....................................140
Handlebar Position, Width & Shape..........140

Adjustments for Competition 109

Engine Mode Select Button

Engine Mode Select Button

Current Mode Mode Selection

Start the engine and push the engine mode select 1. Start the engine.
button (1) with your CRF stopped. The mode 2. With your CRF stopped and the throttle closed,
indicator (2) in the engine mode select button push and hold the engine mode select button
indicate a selected mode by the number of times for 1 or more second.
the indicator blinks. 3. Release the engine mode select button. The
mode indicator will indicate a selected mode
by the number of times the indicator blinks.
4. Repeat steps 2 – 3 until the desired mode is
(1)
indicated.
(1) engine mode select button PGM-FI mode 1

You can change engine output characteristic

depending on track conditions by using the engine
mode select button (1). PGM-FI mode 2
(1) (2)
• PGM-FI mode 1: standard setting
• PGM-FI mode 2: smooth setting (reduce (1) engine mode select button (2) mode indicator
throttle response from the standard setting) PGM-FI mode 3
• PGM-FI mode 3: aggressive setting (increase PGM-FI mode 1:
throttle response from the standard setting) The indicator
blinks once and
repeats it 3 times.
An optional PGM-FI setting tool can change the
ignition timing and amount of the fuel injection
PGM-FI mode 2:
and save the setting data on the PGM-FI mode 2 or The indicator
3 (page 157). blinks 2 times and
repeats it 3 times.

PGM-FI mode 3:
The indicator
blinks 3 times and
repeats it 3 times.

110 Adjustments for Competition

Front Suspension Adjustments

Front Suspension Adjustments

The front suspension can be adjusted for the rider’s High Speed Damping:
weight and riding conditions by using one or more Front Suspension Damping The high speed damping can be adjusted by
of the following methods: turning the screw (silver) of the compression
Compression Damping damping adjuster.
• Compression damping — Turning the high Compression damping may be adjusted in two
speed compression damping adjuster (1) and stages with separate adjusters. The high speed compression damping adjuster has
low speed compression damping adjuster (2) 20 positions or more.
adjust how quickly the fork compresses. The high speed damping adjuster (1) is effective
• Rebound damping — Turning the high speed when damping adjustment is desired for high To adjust to the standard position:
rebound damping adjuster (3) and low speed speed operation. The low speed damping adjuster 1. Turn the adjuster clockwise until it will no
rebound damping adjuster (4) adjust how (2) should be used when damping adjustment is longer turn. This is the full hard setting.
quickly the fork extends. desired at relatively low speeds. 2. Turn the adjuster counterclockwise 11 clicks.
• Fork spring — Adjusting the PSF air pressure
and oil capacity adjusts the spring rate from • Both the high and low speed compression Low Speed Damping:
soft to sfiff. damping can be increased by turning the The low speed damping can be adjusted by turning
appropriate adjuster clockwise. the screw (blue) of the compression damping
Left side: Right side: • Adjust the high and low speed compression adjuster.
damping adjuster in one-click increments.
(2) (4) A
The low speed compression damping adjuster has
Left side:
20 positions or more.
(2) To adjust to the standard position:
1. Turn the adjuster clockwise until it will no
longer turn. This is the full hard setting.
2. Turn the adjuster counterclockwise 12 clicks.

(1) (3)

(1) high speed compression damping adjuster (1)

(2) low speed compression damping adjuster
(3) high speed rebound damping adjuster
(4) low speed rebound damping adjuster (1) high speed compression damping adjuster
(2) low speed compression damping adjuster

Adjustments for Competition 111

Front Suspension Adjustments
Rebound Damping High Speed Damping:
NOTICE
Rebound damping may be adjusted in two stages The high speed damping can be adjusted by
with separate adjusters. turning the screw (silver) of the rebound damping Always start with full hard when adjusting
adjuster. damping.
The high speed damping adjuster (3) is effective Do not turn the adjuster screw more than the given
when damping adjustment is desired for high The high speed rebound damping adjuster has 20 positions or the adjuster may be damaged.
speed operation. The low speed damping adjuster positions or more. Be sure that the compression and rebound
(4) should be used when damping adjustment is damping adjusters are firmly located in a detent,
desired at relatively low speeds. and not between positions.
To adjust to the standard position:
• Both the high and low speed rebound damping 1. Turn the adjuster clockwise until it will no Left side: Right side:
can be increased by turning the appropriate longer turn. This is the full hard setting. (2) (4)
adjuster clockwise. 2. Turn the adjuster counterclockwise 8 clicks.
• Adjust the high and low speed rebound damping
adjuster in one-click increments. Low Speed Damping:
The low speed damping can be adjusted by turning
Right side:
the screw (red) of the rebound damping adjuster.
(4) The low speed rebound damping adjuster has 20
positions or more.
(1) (3)
To adjust to the standard position:
1. Turn the adjuster clockwise until it will no (1) high speed compression damping adjuster
longer turn. This is the full hard setting. (2) low speed compression damping adjuster
2. Turn the adjuster counterclockwise 9 clicks. (3) high speed rebound damping adjuster
(4) low speed rebound damping adjuster
(3)

(3) high speed rebound damping adjuster

(4) low speed rebound damping adjuster

112 Adjustments for Competition

 Front Suspension Adjustments
Do not adjust the PSF air pressure to a level that is Oil level
Fork Springs outside the minimum or maximum level. • To adjust the oil level refer to Fork Assembly on
page 118.
The CRF uses a pneumatic spring in the front fork. The correct “cold” PSF air pressures are:
The front fork spring rate can be adjusted by standard: 35 psi (240 kPa, 2.4 kgf/cm2) Oil levels are:
changing the fork air pressure and oil capacity.
The forks on CRF’s are about right for riders soft (minimum) 4.4 in (112 mm)
weighing between 170 lb (77 kg) and 200 lb (91 soft (minimum) 31 psi (220 kPa, 2.2 kgf/cm2)
standard 3.6 in (92 mm)
kg) (less riding gear). So if you're a heavier rider, medium-soft 33 psi (230 kPa, 2.3 kgf/cm2)
you have to go up on the oil capacity or air stiff (maximum) 3.4 in (87 mm)
pressure. standard 35 psi (240 kPa, 2.4 kgf/cm2)
Do not adjust the oil capacity or PSF air pressure When adjusting oil levels, bear in mind that the air
to a level that is outside the minimum or maximum medium-stiff 36 psi (250 kPa, 2.5 kgf/cm2)
in the fork will increase in pressure while riding;
level. therefore, the higher the oil level, the higher the
stiff (maximum) 37 psi (260 kPa, 2.6 kgf/cm2)
eventual pressure of any air in the fork.
PSF Air Pressure
• Adjust the PSF air pressure when the fork is cold with standard PSF air pressure:
as follows: with standard oil level:
PSF air pressure (MAX) Oil level (MAX)
1. Place an optional workstand under the engine, 37 psi (260 kpa, 2.6 kgf/cm2) 3.4 in (87 mm)

so that the front wheel is off the ground. PSF air pressure (STANDARD) Oil level (STANDARD)
3.6 in (92 mm)
2. Remove the valve caps and clean the area 35 psi (240 kpa, 2.4 kgf/cm2)

Force (lbf/N)
Force (lbf/N)
Oil level (MIN)
around the PSF air valve (1). PSF air pressure (MIN)
31 psi (220 kpa, 2.2 kgf/cm2) 4.4 in (112 mm)

Stroke (in/mm) Stroke (in/mm)

The higher or lower PSF air pressure affects the

entire range of fork travel.
(1)
4. Check that there is no air leakage. If there is
(1) PSF air valve any air leakage, replace the air valve assembly.
5. Make sure the valve caps are secure. If
3. Adjust the PSF air pressure. necessary, install new caps.
• Air fork pump, 0-60 psi 07AMJ-MENA300
If you need to adjust the PSF air pressure when the
front forks are warm (after driving), refer to page
30.

Adjustments for Competition 113

Front Suspension Adjustments
1. Remove the number plate (page 102). 4. Remove the disc cover socket bolts (7) and
Front Suspension Disassembly 2. Place your CRF on an optional workstand or disc cover (8).
equivalent support with the front wheel off the
• If your CRF is brand-new, put enough part- ground.
throttle break-in time (about 1 hour) on it to 3. Remove the handlebar lower holder nuts,
(8)
ensure that the suspension has worked in. washers, mounting rubbers (5) and handlebar
• For optimum performance, and extended fork (6).
life, the fork should be completely disassembled
and cleaned after the first 3 hours of riding. See
an official Honda Service Manual or your dealer NOTICE
for this service. Keep the master cylinder upright to prevent air
• When disassembling the fork, turn the high from entering system.
speed compression damping adjuster (1), low
speed compression damping adjuster (2), high (7)
speed rebound damping adjuster (3) and low
speed rebound damping adjuster (4) (7) disc cover socket bolts
(8) disc cover
counterclockwise to the softest position to
prevent damaging the adjustment needle (be sure 5. Remove the front axle nut (9) and loosen the
to record the number of turns from the starting axle pinch bolts (10) on both forks.
position). Pull the front axle shaft (11) out of the wheel
hub and remove the front wheel with collars.
(2) (4)
(6) (10) (10)
(5)

(5) handlebar lower holder nuts, washers and mounting

rubbers
(6) handlebar

(1) (3)

(1) high speed compression damping adjuster (9) (11)

(2) low speed compression damping adjuster
(3) high speed rebound damping adjuster (9) front axle nut (11) front axle shaft
(4) low speed rebound damping adjuster (10) axle pinch bolts

114 Adjustments for Competition

 Front Suspension Adjustments
6. Remove the brake hose clamp bolts (12), stay 8. Remove the fork protector socket bolts (17) 11. Remove the valve cap and release the PSF air
A (13) and stay B (14). and fork protectors (18). pressure.
7. Remove the brake caliper mounting bolts (15) (17)
and brake caliper (16).
• Do not support the brake caliper by the brake
hose.
• Do not operate the brake lever after the front
wheel is removed. To do so will cause difficulty
in fitting the brake disc between the brake pads.
(18)
(14) (15)
(13)
(17)
(17)

(17) fork protector socket bolts 12. Loosen the fork bridge upper pinch bolts (22).
(18) fork protectors

9. Clean the air valve and surrounding area, and

(12) then apply the specified PSF air pressure (22)
(page 113).
(16) Measure the distance (19) between the outer
tube and the axle holder.
(12) brake hose clamp bolts
(13) stay A 10. Clean the fork assembly, especially the sliding
(14) stay B surface (20) of the slider and fork dust seal
(15) brake caliper mounting bolts (21).
(16) brake caliper
(21)

(19)
(20) (22) fork bridge upper pinch bolts

(19)

(19) distance
(20) sliding surface
(21) fork dust seal

(cont’d)

Adjustments for Competition 115

Front Suspension Adjustments
13. Loosen the fork cap (23). 14. Loosen the fork bridge lower pinch bolts (24),
NOTICE
then pull the fork legs down and out.
The outer tube (25) can drop on the slider (27) and
damage the fork dust seal (21).
To avoid damage, hold both the outer tube and
slider when removing the fork damper.

NO GOOD (21)

(23)
(24)
(23) fork cap
(24) fork bridge lower pinch bolts

15. Hold the outer tube (25), then remove the fork (27) (25)
cap (23) from the outer tube. Gently slide the
outer tube down onto the lower end (axle (21) fork dust seal (27) slider
holder) (26). (25) outer tube

(23) 16. Remove the O-ring (28) form the fork cap (23).
Hold the fork damper lock nut (29) with the 15
mm open end wrench and loosen the fork cap.
Remove the fork cap.

(23)
(25)

(28)
(26)

(23) fork cap (26) axle holder

(25) outer tube (29)

(23) fork cap (29) fork damper lock nut

(28) O-ring

116 Adjustments for Competition

 Front Suspension Adjustments
17. Pour out the fork fluid. Empty the fork fluid 19. Holding the fork damper (31) using the 21. Remove the fork damper (35) from the fork
from the fork damper rod (30) by pumping the following tools: assembly (36).
damper several time. • Fork damper holder (32) 07TMB-001010A Remove the fork from the vise.
• Fork damper attachment (33) 070MB-MEN0200
(30)
(33)
NOTICE
(31)
Do not attempt to separate the fork assembly and
drop the axle holder out from the outer tube, which
can damage the guide bushings (37).
To avoid damage, hold both the outer tube and
slider.
(37)
NO GOOD
(32)

(30) fork damper rod (31) fork damper (33) fork damper attachment
(32) fork damper holder
18. Place the lower end (axle holder) (26) of the
slider in a vise with a piece of wood or soft 20. Remove the fork center bolt (34) from the axle
jaws to avoid damage. holder (26).
(37) guide bushings
NOTICE
(26)
Over-tightening the vice can damage the axle
holder. (35)

(34)
(26)

(26) axle holder (34) fork center bolt

(36)

(35) fork damper

(36) fork assembly

(26) axle holder

Adjustments for Competition 117

Front Suspension Adjustments
3. Holding the fork damper (2) using the 4. Place the lower end (axle holder) of the slider
Front Suspension Assembly following tools: in a vise with a piece of wood or soft jaws to
• Fork damper holder (4) 07TMB-001010A avoid damage.
1. Tighten the fork damper lock nut (1) fully and • Fork damper attachment (5) 070MB-MEN0200
measure the thread length (A) as shown.
Standard: 0.7 – 0.8 in (19 – 20 mm) (5)
NOTICE
Wipe the oil completely off the fork damper. (2) Over-tightening the vise can damage the axle
holder.
(A) 5. Apply fork oil to a new sealing washer (6) and
a new O-ring (7) and install them to the fork
center bolt (8).

(6) (8)

(4)

(2) fork damper (5) fork damper attachment

(1) (4) fork damper holder

(1) fork damper lock nut (A) thread length

2. Install the fork damper (2) into the fork (7)

assembly (3).
(6) sealing washer (new) (8) fork center bolt
(2) (7) O-ring (new)

(3)

(2) fork damper

(3) fork assembly

118 Adjustments for Competition

 Front Suspension Adjustments
6. Apply locking agent to the fork center bolt 8. Pour the recommended fork oil into the fork 10. Measure the length of the fork damper lock nut
threads. Install the fork center bolt (8) to the damper rod (10) and up to the upper surface of (1) and fork cap (12) clearance.
fork damper. Tighten the fork center bolt to the the outer tube (9). Standard: 0.04 - 0.08 in (1.0 - 2.0 mm)
specified torque: Recommended Oil:
32 lbf·ft (43 N·m, 4.4 kgf·m) KHL15-11 (KYB) If the clearance is out of specification, check the
fork damper lock nut and fork cap installation.
(9)

(8) (12)
(10)

(9)
(1)

(8) fork center bolt (9) outer tube

(10) fork damper rod (1) fork damper lock nut
(12) fork cap
7. Slide the outer tube (9) down onto the axle
holder slowly to avoid damaging the dust seal. 9. Apply fork oil to a new O-ring (11) and install
Compress the fork damper fully. it to the fork cap (12). Install the fork cap to the 11. Tighten the fork damper lock nut (1) to the fork
fork damper rod (10). Tighten the fork cap cap (12) closely by hand. Tighten the fork
(9) fully by hand. damper lock nut to the specified torque:
21 lbf·ft (29 N·m, 3.0 kgf·m)
(11) (12)

(12)

(1)
(10)

(9) outer tube

(10) fork damper rod (1) fork damper lock nut

(11) O-ring (new) (12) fork cap
(12) fork cap

(cont’d)

Adjustments for Competition 119

Front Suspension Adjustments
12. Temporarily insert both fork legs into the fork 14. Cover the fork leg with shop towel (15) to 15. Apply air pressure of 44 psi (300 kPa, 3.1 kgf/
clamps. Tighten the fork bridge lower pinch prevent fork damage. Pump the outer tube (9) cm2) to the fork assembly and check that there
bolts (13) to the specified torque: up and down until resistance is felt. is no air leakage.
15 lbf·ft (20 N·m, 2.0 kgf·m) 16. Cover the fork leg with shop towel (15) to
(9) prevent fork damage.
Compress the outer tube (9) 5.9 in (150 mm)
from fully extended position.
Repeat above procedure about 10 times.
(9)

5.9 in (150 mm)

(13) (15)

(13) fork bridge lower pinch bolts (9) outer tube

(15) shop towel
13. Tighten the fork cap (12) to the specified (15)
torque using the open end wrench (14):
33 lbf·ft (45 N·m, 4.6 kgf·m) (9) outer tube
Loosen the fork bridge lower pinch bolts, then (15) shop towel
pull the fork legs down and out.

(14) (12)

(12) fork cap

(14) open end wrench

120 Adjustments for Competition

 Front Suspension Adjustments
17. Release the PSF air pressure. 19. Adjust the oil level by removing the oil with an Fork Oil level:
Remove the fork cap (page 114). after market syringe (17).
Slide the outer tube (9) down onto the axle After the oil level (18) stabilizes, measure the Standard oil 3.6 in
level (92 mm)
holder slowly it avoid damaging the dust seal. oil level from the top of the outer tube (9) with [capacity] 22.39 US oz
Compress the fork damper fully. the outer tube and fork damper rod fully on (662.0 cm3)
pressed. Maximum 3.4 in Slightly stiffer as
(9) oil level (87 mm) it nears full
(17) (9) [capacity] 22.66 US oz compression.
(669.9 cm3)
Minimum oil 4.4 in Slightly softer as
level (112 mm) it nears full
[capacity] 21.33 US oz compression.
(630.6 cm3)

• Be sure the oil level is the same in both fork legs.

• Always use the after market syringe while
(18) adjusting the oil level. If it isn't used, air may get
into the fork.
• If a syringe is not available, first set the oil level
(9) outer tube somewhat lower than the normal level, then add
small amounts of oil until the correct level is
18. Pour the recommended fork oil to the upper obtained, measuring the level each time oil is
surface of the slider (16). added.
Recommended Oil:
KHL15-11 (KYB) (9) outer tube
(17) syringe
(18) oil level

(9)

(16)

(10)

(9)

(9) outer tube

(10) fork damper rod
(16) slider

(cont’d)

Adjustments for Competition 121

Front Suspension Adjustments
20. Apply fork oil to the O-ring (11) and install it 22. Tighten the fork damper lock nut (1) to the fork 24. Tighten the fork cap (12) to the specified
to the fork cap (12). Install the fork cap to the cap (12) closely by hand. Tighten the fork torque using the open end wrench (14):
fork damper rod (10). Tighten the fork cap damper lock nut to the specified torque: 33 lbf·ft (45N·m, 4.6 kgf·m)
fully by hand. 21 lbf·ft (29 N·m, 3.0 kgf·m)
(14) (12)
(11) (12)

(12)

(1)
(10)

(12) fork cap

(10) fork damper rod (1) fork damper lock nut (14) open end wrench
(11) O-ring (12) fork cap
(12) fork cap 25. Adjust the air pressure to specification.
23. Insert both fork legs into the fork clamps. Specified air pressure:
21. Measure the length of the fork damper lock nut Tighten the fork bridge lower pinch bolts (13) 35 psi (240 kPa, 2.4 kgf/cm2)
(1) and fork cap (12) clearance. to the specified torque:
Standard: 0.04 – 0.08 in (1.0 – 2.0 mm) 15 lbf·ft (20 N·m, 2.0 kgf·m)
If the clearance is out of specification, check the
fork damper lock nut and fork cap installation.

(12)

(13)
(1)

(13) fork bridge lower pinch bolts

(1) fork damper lock nut

(12) fork cap

122 Adjustments for Competition

 Front Suspension Adjustments
26. Measure the length between the axle holder 28. Tighten the fork bride lower pinch bolts (13) to 30. Clean the threads of the fork protector socket
and outer tube. the specified torque: bolts (22) and axle holder thoroughly.
Standard: 12.44 ± 0.08 in (316.0 ± 2.0 mm) 15 lbf·ft (20 N·m, 2.0 kgf·m) Apply locking agent to the bolt threads.
Compare the length (19) at assembly and at 29. Tighten the fork bridge upper pinch bolts (21) Install the fork protectors (23) and fork
disassembly. They should be the same length. to the specified torque: protector socket bolts.
If the length at assembly is longer than at 16 lbf·ft (22 N·m, 2.2 kgf·m) Tighten the fork protector socket bolts to the
disassembly, check the fork cap and lock nut specified torque:
installation. NOTICE 5.2 lbf·ft (7.0 N·m, 0.7 kgf·m)
(22)
Over-tightening the pinch bolts can deform the
(19)
outer tubes. Deformed outer tubes must be
replaced.

(13) (23)
(19)

(22)
(22)

(19) length (22) fork protector socket bolts

(23) fork protectors
27. For ease of adjusting air pressure after the (21)
forks are installed, loosen the fork bridge lower
pinch bolts and position the outer tubes so that (13) fork bridge lower pinch bolts
the PSF air valves are in front of the damping (21) fork bridge upper pinch bolts
adjusters. Align the top of the outer tube (9)
with the top surface of the top bridge (20).

(20)

Align (9)

(9) outer tube (20) top bridge

Adjustments for Competition 123

Front Suspension Adjustments
31. Align the brake caliper (24) and hose (25) with 34. Clean the surfaces where the axle and axle
the left fork leg, making sure that the brake clamps contact each other. (34)
hose is not twisted. An improperly routed Apply grease to each dust seal lips of the front
brake hose may rupture and cause a loss of wheel.
braking efficiency. Install the left side collar (31) and right side
32. Clean the threads of the brake caliper collar (32) into the wheel hub.
mounting bolts (26) and brake caliper
thoroughly. (31) (32)
Apply locking agent to the bolt threads.
Install the brake caliper (24) on the slider and
tighten the brake caliper mounting bolts to the
(33)
specified torque:
22 lbf·ft (30 N·m, 3.1 kgf·m) (33) front axle nut
33. Align the upper surface of the brake hose (34) left axle pinch bolts
protector (27), stay A (28) and stay B (29), and
assemble them. Install and tighten them to the 37. Install the handlebar (35), mounting rubbers,
left fork protector using the brake hose clamp washers and handlebar lower holder nuts (36)
bolts (30). and tighten the handlebar holder nuts to the
(31) left side collar (32) right side collar specified torque:
(29) (26) 32 lbf·ft (44 N·m, 4.5 kgf·m)
(28)
(25)
35. Install the front wheel between the fork legs
while inserting the disc between the pads, (36)
Align being careful not to damage the pads.
36. Insert the front axle shaft through the forks and
wheel hub from the right side. Make sure that
the front axle shaft is seated firmly onto the left
fork leg clamp inner surface. Tighten the front
(30)
(27) axle nut (33) to the specified torque:
(24) 65 lbf·ft (88 N·m, 9.0 kgf·m)
Tighten the left axle pinch bolts (34) to the
(24) brake caliper specified torque: (35)
(25) brake hose 15 lbf·ft (20 N·m, 2.0 kgf·m)
(26) brake caliper mounting bolts
(27) brake hose protector (35) handlebar
(28) stay A (36) mounting rubbers, washers and handlebar lower
(29) stay B holder nuts
(30) brake hose clamp bolts

124 Adjustments for Competition

 Front Suspension Adjustments
38. Install the number plate (page 102). 41. Install the disc cover (38) and tighten the disc
39. With the front brake applied, pump the fork up cover socket bolts (39) to the specified torque:
and down several times to seat the axle and 10 lbf·ft (13 N·m, 1.3 kgf·m)
check front brake operation.
(38)

(39)

(38) disc cover

(39) disc cover socket bolts
40. While keeping the forks parallel, alternately
tighten the right axle pinch bolts (37) to the 42. Turn the high speed rebound damping (40),
specified torque: low speed rebound damping (41), high speed
15 lbf·ft (20 N·m, 2.0 kgf·m) compression damping (42) and low speed
compression damping (43) adjuster screws
(37) back to their original settings. Make sure the
valve caps are secure. If necessary, install new
caps.

(43) (41)

(37) right axle pinch bolts

(42) (40)
NOTICE
To avoid damage when torquing the axle pinch (40) high speed rebound damping adjuster
bolts, be sure the axle is seated firmly onto the left (41) low speed rebound damping adjuster
fork leg clamp inner surface. (42) high speed compression damping adjuster
(43) low speed compression damping adjuster

Adjustments for Competition 125

Rear Suspension Adjustments

Rear Suspension Adjustments

The rear suspension can be adjusted for the rider’s Refer to the following pages for the installation
weight and riding conditions by changing the Rear Suspension Spring Pre-Load procedure of the removed parts:
spring pre-load and the rebound and compression • air cleaner case and air cleaner connecting
damping. Pre-load should be adjusted when the engine is tube: page 84 (Cylinder Head Installation)
cold because it is necessary to remove the muffler. • subframe: page 37
The rear suspension assembly includes a damper An optional pin spanner is available for turning the
unit that contains high pressure nitrogen gas. Do shock spring lock nut and adjusting nut to adjust To increase spring pre-load
not attempt to disassemble, service, or dispose of spring pre-load. Loosen the shock spring lock nut with the optional
the damper; see your dealer. The instructions pin spanners (3) and turn the adjusting nut to
found in this owner’s manual are limited to 1. Place your CRF on an optional workstand or shorten the spring length (4). Do not shorten to less
adjustments of the shock assembly only. equivalent support with the rear wheel off the than:
ground. Standard (Medium) spring (308.3 lbf/in (54 N/mm)):
Puncture or exposure to flame may also result in an 2. Remove the subframe (page 37). 9.49 in (241.0 mm)
explosion, causing serious injury. 3. Remove the air cleaner case along with air Optional Soft spring (296.9 lbf/in (52 N/mm)):
Service or disposal should only be done by your cleaner connecting tube (page 77). 9.45 in (240.0 mm)
dealer or a qualified mechanic, equipped with the 4. Check that the spring pre-load is adjusted to Optional Stiff spring (319.8 lbf/in (56 N/mm)):
proper tools, safety equipment and an official the standard length. Adjust as necessary by 9.41 in (239.0 mm)
Honda Service Manual. loosening the shock spring lock nut (1) and
turning the adjusting nut (2). To decrease spring pre-load
If your CRF is new, put enough part-throttle break- Each complete turn of the adjusting nut Loosen the shock spring lock nut with the optional
in time (about 1 hour) on it to ensure that the changes the spring length by 0.06 in (1.5 mm). pin spanners (3) and turn the adjusting nut to
suspension has worked in. After adjustment, hold the adjusting nut and increase the spring length (4). Do not increase to
tighten the shock spring lock nut to the more than:
specified torque: 9.98 in (253.5 mm)
21 lbf·ft (28 N·m, 2.9 kgf·m)
Each turn of the adjusting nut changes spring
length and spring pre-load. One turn equals: spring
(1) length/spring pre-load:
Standard: 0.06 in (1.5 mm)/18.21 lbf (81 N)

(4) Pin spanners should be used for turning the shock

spring lock nut and adjusting nut. See page 156 for
optional pin spanners.
(2) Spring pre-load length (Standard spring)
(3)
Standard: 9.94 in (252.5 mm)
Max. : 9.98 in (253.5 mm)
Min. : 9.49 in (241.0 mm)
(1) shock spring lock nut (3) pin spanners
(2) adjusting nut (4) spring length

126 Adjustments for Competition

 Rear Suspension Adjustments
High Speed Damping: Rebound Damping
Rear Suspension Damping The high speed damping can be adjusted by The rebound damping can be adjusted by turning
turning the screw (blue) of the compression the screw (red) of the rebound adjuster.
Compression Damping adjuster.
Compression damping may be adjusted in two The rebound damping adjuster (3) has 20 positions
stages with separate adjusters. The high speed compression adjuster has 20 or more.
positions or more.
The high speed damping adjuster (1) is effective • Rebound damping can be increased by turning
when damping adjustment is desired for high To adjust to the standard position: the adjuster clockwise.
speed operation. The low speed damping adjuster 1. Turn the adjuster clockwise until it will no
(2) should be used when damping adjustment is longer turn. This is the full hard setting. To adjust to the standard position:
desired at relatively low speeds. 2. Turn the adjuster counterclockwise 18 clicks. 1. Turn the adjuster clockwise until it will no
longer turn. This is the full hard position.
• Both the high and low speed compression Low Speed Damping: 2. Turn the adjuster counterclockwise 4 clicks.
damping can be increased by turning the The low speed damping can be adjusted by turning
appropriate adjuster clockwise. the screw (silver) of the compression adjuster.
• Adjust the high speed compression adjuster in
one click increments. The low speed compression adjuster has 20
positions or more.

To adjust to the standard position:

1. Turn the adjuster clockwise until it will no
longer turn. This is the full hard setting.
2. Turn the adjuster counterclockwise 15 clicks.
(1)
(2)

(3)

(1) high speed compression damping adjuster

(2) low speed compression damping adjuster
(3) rebound damping adjuster

Adjustments for Competition 127

Rear Suspension Adjustments
unloaded: motorcycle on an optional workstand Ask the other helper to measure the loaded
Rear Suspension Race Sag with rear suspension fully extended, no rider. with rider dimension.
loaded with rider: motorcycle on ground, with
Setting the proper race sag (ride height) is very SEAT MOUNTING BOLT
rider.
important for competition use.
1. Support your CRF on an optional workstand
Race sag refers to the amount of rear wheel travel with the rear wheel off the ground.
used by your CRF at rest, ready to ride, with you 2. Measure the unloaded dimension. LOADED MEASUREMENT
(with rider)
on the seat. As a general rule of thumb, the race sag SEAT MOUNTING BOLT EXAMPLE: 20.7 in (525 mm)
dimension should be about one-third of the
maximum travel.

On your CRF, ride height is changed by adjusting UNLOADED MEASUREMENT

(without rider)
the rear suspension spring pre-load. EXAMPLE: 24.6 in (625 mm)

Spring Pre-load & Race Sag Adjustment

The following adjustment procedure establishes CHAIN ADJUSTER LOCK NUT
the correct starting point for any suspension tuning
— the proper rear suspension spring preload Example:
adjustment for your specific needs. Unloaded = 24.6 in (625 mm)
Your CRF should be at normal racing weight, – Loaded = 20.7 in (525 mm)
including fuel, oil and coolant. You should be CHAIN ADJUSTER LOCK NUT Race Sag = 3.9 in (100 mm)
wearing all your normal protective apparel. You
will need two helpers. 3. Measure the loaded with rider dimension. 4. Calculate the race sag dimension.
Remove the workstand. With two helpers To do this, subtract the loaded with rider
To calculate the proper adjustment, it is necessary available, sit as far forward as possible on your dimension (step 3) from the unloaded
to measure between two fixed points — from the CRF’s seat, wearing your riding apparel. dimension (step 2).
center of the seat mounting bolt to the center of the Ask one helper to steady your CRF perfectly Standard Race Sag: 4.1 in (105 mm)
chain adjuster lock nut as illustrated here — for upright so you can put both feet on the pegs.
two different situations: Bounce your weight on the seat a couple of Adjust spring pre-load as necessary to obtain
times to help the suspension overcome any the desired handling results.
situation and settle to a good reference point. Decreasing the race sag dimension (example:
3.7 in, 95 mm) improves turning ability for
tight terrain at the cost of slightly reduced
straight line stability.
Increasing the race sag dimension (example:
4.5 in, 115 mm) may improve stability on
faster terrain with less turns, but will reduce
turning performance slightly and may upset the
balance between the front and rear suspension,
producing a harsher ride. This will happen if
the adjustment shifts the effective wheel travel
toward the more progressive end of its range.

128 Adjustments for Competition

 Rear Suspension Adjustments
Spring Rates A spring that is too stiff for your weight will not
If you are lighter or heavier than the average rider allow the rear tire to hook up under acceleration
and cannot set the proper ride height without and will pass more bumps on to you.
altering the correct spring pre-load, consider an
aftermarket rear shock 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.

Because of the great absorption quality of the

shock bumper rubber, it may be difficult for you to
notice when your CRF’s suspension is bottoming.
Some riders may think the damping or perhaps the
leverage ratio is too harsh. In reality, the problem
is most likely insufficient spring pre-load or a
spring that is too soft. Either situation prevents
utilizing the full travel.

Keep in mind that a properly adjusted suspension

system may bottom slightly every few minutes at
full speed. Adjusting the suspension to avoid this
occasional bottoming may cost more in overall
suspension performance than it is worth.

Adjustments for Competition 129

Suspension Adjustments for Track Conditions

Suspension Adjustments for Track Conditions

Soft Surface
On soft ground, sand, and especially mud, consider
increasing compression damping front and rear.

Sand often requires a bit more rebound damping to

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

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, the PSF air pressure adjustment

for front suspension and stiffer aftermarket spring
for rear suspension may help, especially if you are
heavier than the average rider. Your CRF may be
under-sprung 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.

130 Adjustments for Competition

Suspension Adjustment Guidelines

Suspension Adjustment Guidelines

Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 111 – 129. 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.
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.

Adjustments for Too Soft/Stiff Damping

Symptom Action
Soft suspension Initial travel too soft: – Test stiffer high and low speed compression damping adjustments in one-click
• Steering is too quick. increments.
• Front end darts while cornering or riding in a straight line. – Test stiffer high and low speed rebound damping in one-click increments.
Middle travel too soft: If suspension isn’t stiff in initial travel:
• Front end dives when cornering. – Test stiffer high and low speed compression damping adjustments in one-click
increments.
If initial travel becomes stiff because of the above adjustment:
– Reduce the high and low speed rebound damping in one-click increments.
– Test softer compression damping adjustments in one-click increments.
Final travel too soft: If initial and middle travel aren’t stiff:
• Bottoms on landings. – Test stiffer high and low speed compression damping adjustments in one-click
• Bottoms on large bumps, especially downhill bumps. increments.
If final travel is soft:
– Increase the fork oil capacity in increments of 0.2 US oz (5 cm3).
Entire travel too soft: – Test stiffer high and low speed compression damping adjustments in one-click
• Front end shakes. increments.
• Fork bottoms over any type of terrain. – Increase high and low speed rebound damping in one-click increments.
– Adjust the PSF air pressure.

Adjustments for Competition 131

Suspension Adjustment Guidelines
Symptom Action
Stiff suspension Initial travel too stiff: – Test softer high and low speed compression damping adjustments in one-click
• Stiff on small bumps while riding at full throttle in a straight line. increments.
• Stiff on small cornering bumps. – Reduce the high and low speed rebound damping adjustments in one-click
• Front end wanders while riding at full throttle in a straight line. increments.
– Check for dirt in the dust seals. Check the fork oil for any contamination.
If the front end dives while cornering after the above adjustment: Reduce the
rebound damping in one click increments.
Middle travel too stiff: If initial travel isn’t stiff:
• Stiff on bumps when cornering. – Test stiffer high and low speed compression damping adjustments in one-click
• Front end wanders when cornering. increments. (This 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 high and low speed compression damping adjustments in one-click
increments.
– Reduce the high and low speed 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 high and low speed compression damping adjustments in one-click
• Stiff on large bumps, especially downhill bumps. increments. (This 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:
– Test softer high and low speed compression damping adjustments in one-click
increments.
If the entire travel feels stiff after the above adjustment:
– Test softer high and low speed compression damping adjustments in one-click
increments until the desired initial travel compression damping is obtained.
– Lower the oil capacity by 0.2 US oz (5 cm3).
Entire travel too stiff: – Test softer high and low speed compression damping adjustments in one-click
• Stiff suspension on any type of terrain. increments.
– Reduce the high and low speed rebound damping in one-click increments.
– Lower the oil capacity by 0.2 US oz (5 cm3).
– Adjust the PSF air pressure.

132 Adjustments for Competition

 Suspension Adjustment Guidelines
Rear Suspension Adjustment
Adjustments for Type of Track
Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below.
Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load).
Example: – 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 an 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 one-click 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 bumps 1. Test softer low speed compression adjustment.
2. If it still feels stiff, further test softer low and high speed compression adjustments simultaneously.
Suspension feels stiff on large bumps 1. Test softer high speed compression adjustment.
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 stiffer 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 Suspension bottoms at landing after 1. Test stiffer high speed compression adjustment.
bottoms jumping 2. If it still bottoms, test stiffer high and low speed compression adjustments, and replace the spring with a stiffer
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 stiffer
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 stiffer spring (optional) if necessary.

Adjustments for Competition 133

Tuning Tips

Tuning Tips
An optional PGM-FI setting tool can change the
NOTICE NOTICE
ignition timing and amount of the fuel injection
(page 157). Using spark plugs with an improper heat range or An improperly tightened spark plug can damage
Be sure to observe the PGM-FI setting by checking incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may be
the spark plug. damaged. If a plug is too tight, the threads may be
Ride for 10 – 15 minutes before taking a plug damaged.
reading. A new plug will not color immediately.
Spark Plug Reading (2)
Before removing the spark plug, clean the spark
Refer to Spark Plug on page 66. plug area thoroughly to prevent dirt from entering
the cylinder.
The following procedure is recommended.
You may not get an accurate reading if you simply To obtain an accurate reading of a new spark plug:
turn off the engine and pull the plug for inspection. 1. Accelerate at full throttle on a straight. (1)
2. Depress and hold the engine stop button and
Use a new spark plug. Inspect the plug before
pull the clutch lever in.
installing it. (1) porcelain insulator (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. Overheating Light gray or white color lean
Light gray or white color streaks the porcelain (Lean)
insulator and center electrode indicate lean air- Wet (Rich) Wet or sooty rich
fuel mixture. Wet or black sooty streaks on the
porcelain indicate rich air-fuel mixture. Remember that in addition to improper air-fuel
mixture:
• 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.
• A rich condition can be caused by a plugged or
dirty air cleaner, use of a more-restrictive
aftermarket exhaust system, or excessive oil on
the air cleaner.
Excessive smoking will occur.

134 Adjustments for Competition

Steering Damper Adjustment

Steering Damper Adjustment

The steering damper can be adjusted for riding
conditions by using following method: Steering Damper Damping
• Damping – Turning the steering damper
adjuster adjusts how quickly the steering The steering damper adjuster (1) has 13 positions
damper compresses or extends. or more. Turning the adjuster one full turn
clockwise advances the adjuster six positions. To
adjust the adjuster to the standard setting, proceed
as follows:
Turn the adjuster clockwise until it will no longer
turn. This is the full hard position.
The adjuster is set in the standard position when
the adjuster is turned counterclockwise 9 – 12
clicks.
Damping can be increased by turning the adjuster
clockwise.

NOTICE
Always start with full hard when adjusting
damping.
Do not turn the adjuster more than the given
positions or the adjuster may be damaged.
Be sure that the steering damper adjuster is firmly
located in a detent, and not between positions.

(1)

(1) steering damper adjuster

Adjustments for Competition 135

Steering Damper Adjustment Guidelines

Steering Damper Adjustment Guidelines

Follow the procedures described below to accurately adjust your CRF.

Symptoms and Adjustment

• Always begin with the standard settings.
• Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment.
Test ride after each adjustment.

Symptom Action
Steering is wobbling on large bumps Adjust the steering damper adjuster to a stiffer setting.
Steering is wobbling on a sand track Adjust the steering damper adjuster to a stiffer setting.
Steering is heavy when cornering Adjust the steering damper adjuster to a softer setting.

136 Adjustments for Competition

Chassis Adjustments

Chassis Adjustments
The following suggestions may improve a specific
concern. Subtle changes in overall handling may Fork Height/Angle Wheelbase
also be noted.
The position of the fork tube in the clamp is not Adjusting your CRF’s wheelbase can offer subtle
adjustable. Align the top of the outer tube (not the changes in overall handling. You may adjust
Rear End top of the fork cap) with the top of the top bridge. wheelbase by adding or removing links on the
drive chain. If you change the wheelbase, be sure
If you have a problem with rear wheel traction, Standard Position to recheck race sag and adjust, if necessary.
raise the rear end of your CRF by increasing the The top of the outer tube (1) (not the top of the fork
rear suspension spring pre-load. Instead of running cap) is aligned with the top of the top bridge (2). In the past, a general rule was lengthen the
3.9 in (100 mm) of sag, you can run 3.5 in (90 mm) wheelbase to add straight line stability, shorten the
so the rear of the motorcycle will sit a little higher. (1) wheelbase to improve turning. However, we
This should produce more traction because of the suggest you do not lengthen the wheelbase of your
change to the swingarm and location of your CRF unless you are racing on a track with more
CRF’s center of gravity. fast sections than normal.
(2)
If you have a problem with the steering head As a general recommendation, keep the wheelbase
shaking when you use the front brake hard or if as short as possible. This positions the wheels
your CRF wants to turn too quickly, lower the rear closer together, improves turning response,
of the motorcycle by reducing the rear suspension increases weighting (traction) on the rear wheel,
spring pre-load. This will increase fork rake and (1) top of outer tube and lightens weighting on the front wheel.
(2) top bridge
trail and should improve stability in a straight line.
The effective suspension travel will be transferred With your CRF, you will probably find that the
toward the firmer end of wheel travel. standard setting or a shorter wheelbase will offer
more overall benefits.
Keep the race sag adjustment (page 128) in the 3.7
– 4.5 in (95 – 115 mm) range.

Adjustments for Competition 137

Gearing

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 • decreases top speed in each gear where you want to keep the front end light so it can
changing gearing. This allows you to utilize a • increases frequency of shifting (narrower gear float from the peak of one sand whoop to the next.
different portion of the engine’s power range at a ratios) Generally, with higher gearing, it is easier to
given throttle setting. New gearing may provide • increases engine rpm at a given throttle setting maintain that perfect attitude (maximum rear
the change you are looking for without the need to or ground speed (which may provide more wheel traction and a light front end) because you
consider further modifications. 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 use efficiently with throttle control and body English.
can be adjusted by changing the final drive ratio However:
with different sized driven 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 type • engine rpm may be too high choose to over-rev the engine temporarily rather
of terrain and the available traction. than shifting up, higher gearing might help.
Normally, a change of one tooth on the driven 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 good time. Your goal is the fastest overall lap time, even
drive ratios with two optional driven sprockets. to great and back to good and possibly ends the day if the cost is some sections where the gearing feels
Like the optional springs, these sprockets are listed with a slick rock-hard consistency. wrong.
in the Optional Parts List section of this manual Ideally, your gearing should be adjusted to suit all
(page 156). these conditions. If you decide to try a gearing change, have
someone check your times with a stopwatch
Unless you have the required mechanical know- • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate
how, tools, and an official Honda Service Manual, higher gear (less teeth) to keep engine rpm appraisal of the change. “Seat-of-the-pants”
sprocket changing should be done by your dealer. down, and avoid unwanted wheelspin. The feelings can’t be trusted. Eliminating wheelspin
engine may bog in certain corners so you’ll with a gearing change can make you feel like
Higher Gearing (less driven sprocket teeth) need to slip the clutch to compensate; you’re going slower when, in reality, you’ve
• increases top speed in each gear (provided the downshifting may be too drastic a change in decreased your time by increasing your speed with
engine will pull the higher gearing) speed. better traction.
• reduces frequency of shifting (wider gear • Average conditions: use the standard sprocket.
ratios) • Hard (but not slippery) track conditions: use These gearing recommendations should be
• reduces engine rpm at a given throttle setting lower gearing (more teeth) to keep the engine evaluated by considering your ability, your riding
or ground speed (which may allow better rear rpm high where the engine produces the most style, and the track.
wheel traction on slippery or loose terrain) power. This may require an extra upshift on
certain sections or perhaps you can just rev it
However: out a bit longer.
• the engine may not pull the higher gearing
• the spacing between gears may be too wide For tight tracks, consider lower gearing to avoid
• engine rpm may be too low having to slip the clutch frequently. Repeated
fanning or pulling of the clutch lever in a turn to
raise engine rpm may eventually damage the
clutch system.

138 Adjustments for Competition

Tire Selection for Track Conditions

Tire Selection for Track Conditions

Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for
compound can affect your placing in competition. added traction, remember that it may transfer
The tires on your CRF offer a “happy medium” for additional loads to the transmission because it
the variety of soil conditions the majority of riders grips so well, especially when riding in situations
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 do Complete consumer information can be obtained
switch, stay with the factory recommended sizes. from the various tire manufacturer representatives
Other tires may affect handling or acceleration. and dealers.

Be aware that tire sizes (width and aspect ratio) do Some general recommendations for specific
vary from manufacturer to manufacturer or even terrain follow:
among tires made by the same manufacturer.
Variations in tires, especially the sidewall profile, Hard, Slick Soil
can change the attitude of your CRF and its Use tires with many relatively short knobs that are
handling. Tire variations that raise or lower the close together in order to obtain the largest
rear of your CRF have a more significant effect on possible contact patch on the surface. The rubber
handling than variations in front tires which, compound needs to be softer for hard ground in
generally, don’t vary as much. order to hook up, but not so soft that the knobs roll
Often, you can see or feel the change in tire size. over easily and affect holding a straight line.
Another way to check is to measure the rolling These tires tend to wear more quickly than
circumference of the old and new tires. A higher standard tires because of the combination of soft
profile tire will have a larger rolling rubber and hard terrain.
circumference.
Muddy Soil
If you do switch to tires designed for special terrain Use a more open tread pattern to avoid clogging.
use, remember they will be less acceptable in other For these conditions, the relatively long knobs will
circumstances. For example, an aggressive mud probably be made from a harder rubber compound
tire will give excellent grip on wet, loamy terrain, to reduce any tendency to bend back under
but less impressive grip on a hard surface. acceleration or wear quickly.

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 139

Personal Fit Adjustments

Personal Fit Adjustments

The following suggestions may make your ride • Position the shift lever and rear 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, but hacksaw to better suit your particular shoulder
your control input. 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 front 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 Pro Honda Hondalock or an equivalent to

the threads of these bolts prior to adjustment to Handlebar Position, Width & Shape
help ensure the correct torque is retained.
• Position the handlebar so that both gripping the
Tighten the top bolts first.
bar and operating the controls are comfortable
while both seated and standing, while riding • Chamfer the edges to remove burrs and other
straight ahead and turning. irregularities or roughness after sawing the
Tighten the forward handlebar upper holder handlebar.
bolts first. • An alternate handlebar shape, through varying
• The handlebar position may be moved forward rise or rearward sweep dimensions, will
either 0.1 in (3 mm) (using optional handlebar provide further adjustment to riding position
(1) lower holders) or 0.2 in (6 mm) (by rotating the and may better suit your particular body size or
(1) standard holders 180 degrees). riding style. Each of the ergonomic dimensions
Refer to an official Honda Service Manual for of the machine were determined to suit the
installation instructions. Be sure to check greatest possible number of riders based on an
control cable and wiring harness routing after average size rider.
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.

140 Adjustments for Competition

Tips

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

Transporting Your Motorcycle...................... 142

Storing Your Honda ...................................... 143
Preparation for Storage.............................. 143
Removal from Storage .............................. 143
You & the Environment ................................ 144
Troubleshooting............................................. 145

Tips 141
Transporting Your Motorcycle

Transporting Your Motorcycle

If you use a truck or motorcycle trailer to transport To secure your CRF, brace the front wheel against
your CRF, we recommend that you follow these the front of the truck bed or trailer rail.
guidelines: Attach the lower ends of two straps to the tie-down
• Use a loading ramp. hooks on truck bed or trailer rail. Attach the upper
• Relieve the fuel pressure (page 40) and drain ends of the straps to the handlebar (one on the right
the fuel from the fuel tank into an approved side, the other on the left), close to the fork.
gasoline container.
• Secure the motorcycle in an upright position, Check that the tie-down straps do not contact any
using motorcycle tie-down straps. Avoid using control cables or electrical wiring.
rope, which can loosen and allow the
motorcycle to fall over. 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.

142 Tips
Storing Your Honda

Storing Your Honda

If you won’t be riding for an extended period, such
as during the winter, thoroughly inspect your CRF Removal from Storage
and correct any problem before storing it. That
way, needed repairs won’t be forgotten and it will 1. Uncover and clean your CRF.
be easier to get your CRF running again. (2) Change the engine and transmission oil if more
than 4 months have passed since the start of
To reduce or prevent deterioration that can occur storage.
during storage, also follow the following 2. Uncover the end of the muffler and remove the
procedures. rag from the muffler outlet.
(1) 3. Fill the fuel tank with the recommended fuel
(page 39) and increase the fuel pressure
Preparation for Storage (page 47).
4. Pour a fresh recommended coolant mixture
1. Completely clean all parts of your CRF. If your (1) coolant drain bolt and sealing washer slowly into the radiator fill hole up to the filler
CRF has been exposed to sea air or salt water, (2) water pump cover
neck (page 53).
wash it down with fresh water and wipe dry. Capacity:
2. Change the engine oil and filter (page 49). 5. Lubricate the drive chain.
6. Relieve the fuel pressure (page 40) and drain 1.08 US qt (1.02 ℓ)
3. Change the transmission oil (page 52). after disassembly
4. Remove the radiator cap and coolant drain bolt the fuel from the fuel tank into an approved
gasoline container. 0.99 US qt (0.94 ℓ)
and sealing washer (1) at the water pump cover after draining
(2) to drain coolant. 7. Inflate the tires to their recommended
After the coolant has been completely drained, pressures. Lean your CRF slightly right and left several
reinstall the drain bolt with a new sealing 8. Place your CRF on an optional workstand or times to bleed trapped air in the cooling
washer and radiator cap. equivalent to raise both tires off the ground. system.
Tighten the drain bolt to the specified torque: 9. Stuff a rag into the muffler outlet. Then tie a If the coolant level lowers, add coolant and
7 lbf·ft (10 N·m, 1.0 kgf·m) plastic bag over the end of the muffler to repeat the above procedure.
prevent moisture from entering. Install the radiator cap securely.
10. Store your CRF in an unheated area, free of
dampness, away from sunlight, with a 5. Perform all maintenance checks (page 13).
minimum of daily temperature variation.
11. Cover your CRF with a porous material.
Avoid using plastic or similar non-breathing,
coated materials that restrict air flow and allow
heat and moisture to accumulate.

Tips 143
You & the Environment

You & the Environment

Owning and riding a motorcycle can be enjoyable,
NOTICE
but you must do your part to protect nature. When
you show respect for the land, wildlife, and other Improper disposal of drained fluids is harmful to
people, you also help preserve the sport of off road the environment.
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
chlorofluorocarbons (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, coolant, 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 non
recyclable wastes.

144 Tips
Troubleshooting

Troubleshooting
The items that are serviceable using this Manual 7. Start by following ENGINE • Insulator leaking 7. Test cylinder LOW • Valve clearance too small
are followed by the page number reference in normal starting STARTS BUT • Improper ignition timing compression* • Valve stuck open
parenthesis. The items that require use of an procedure SOON STOPS (Faulty ECM or CKP
sensor)* CORRECT
• Worn cylinder and piston
ring*
official Honda Service Manual are followed by an • Fast idle knob stuck open • Damaged cylinder head
asterisk (*). or damaged gasket
• Fuel contaminated • Improper valve timing*
ENGINE DOES NOT START OR IS HARD TO START • Faulty decompressor
system*
CHECK POSSIBLE CAUSES ENGINE LACKS POWER 8. Check the PGM-FI INCORRECT • Faulty PGM-FI system
1. Check the spark INCORRECT • Incorrect spark plug heat CHECK POSSIBLE CAUSES system (p.7) (p.9)
plug condition range
(P.66) • Incorrect spark plug gap 1. Check the wheel INCORRECT • Brake dragging CORRECT
• Dirty air cleaner element spin smoothness • Worn or damaged wheel
CORRECT bearings
CORRECT • Bent axle shaft 9. Check the fuel INCORRECT • Faulty fuel pump unit*
• Drive chain too tight pump operation • Clogged fuel pump filter
2. Try spark test* WEAK OR • Faulty spark plug (P.66) and inspect the fuel (P.44)
NO SPARK • Fouled spark plug (P.66) 2. Check the tire INCORRECT • Faulty valve core flow*
GOOD SPARK • Faulty ECM* pressure (p.93) • Punctured tire
• Broken or shorted spark CORRECT
plug wire CORRECT
• Faulty alternator*
• Faulty ignition coil* 10.Check the spark INCORRECT • Incorrect spark plug
• Faulty engine stop 3. Check the engine NO GOOD • Clutch slipping plug condition • Incorrect spark plug gap
button* speed change • Improperly adjusted (p.66) • Dirty air cleaner element
• Loose or disconnected accordingly when clutch lever freeplay
ignition system wires clutch is engaged* (p.61) CORRECT
• Faulty CKP sensor* • Worn clutch discs/plates
• Faulty regulator/rectifier* GOOD (p.64)
• Faulty condenser* • Warped clutch discs/ 11.Check the engine INCORRECT • Engine oil level too high
plates (p.64) oil level and • Engine oil level too low
3. Check the PGM-FI INCORRECT • Faulty PGM-FI system
• Weak clutch springs* condition (p.49) • Contaminated engine oil
system (P.7) (P.9)
• Sticking clutch lifter
CORRECT • Additive in engine oil CORRECT
4. Check the engine NO GOOD • Dirty air cleaner element
speed increase • Clogged muffler
4. Check the fuel INCORRECT • Faulty fuel pump* • Fast idle knob stuck open 12.Remove the INCORRECT • Faulty oil pump*
GOOD or damaged cylinder head cover • Faulty pressure relief
pump operation • Clogged fuel pump filter
and inspect the fuel (P.44) • Restricted fuel fill cap and inspect valve*
flow* breather tube lubrication • Clogged oil passage*
• Restricted fuel flow • Clogged oil strainer
CORRECT screen*
5. Check the engine YES • Worn piston and cylinder*
knocking when • Use of poor quality fuel
accelerate or run • Excessive carbon buildup
5. Check the fuel INCORRECT • Faulty PGM-FI system the engine at high in combustion chamber
injector operating (P.9) speed • Ignition timing too
sound • Faulty fuel injector advance (Faulty ECM)*
NO • Lean fuel mixture
CORRECT

6. Check the ignition INCORRECT • Faulty ECM*

6. Test cylinder LOW • Valve clearance too small timing* • Faulty CKP sensor*
compression* • Valve stuck open
• Worn cylinder and piston CORRECT
CORRECT ring*
• Damaged cylinder head
gasket
• Improper valve timing*
• Seized valve

(cont’d)

Tips 145
Troubleshooting
POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED POOR HANDLING
CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES
Steering is heavy
• Steering stem adjusting nut too tight*
1. Check the spark INCORRECT • Incorrect spark plug heat 1. Check the ignition INCORRECT • Faulty ECM*
plug condition range timing* • Faulty CKP sensor*
(P.66) • Incorrect spark plug gap
CORRECT
• Damaged steering head bearings
• Faulty HPSD*
• Plug not serviced
CORRECT frequently enough
2. Remove the air DIRTY • Not cleaned frequently
2. Check the ignition INCORRECT • Faulty ECM*
cleaner (P.55) enough Either wheel is wobbling
timing* • Faulty CKP sensor* AIR CLEANER • Excessive wheel bearing play
CORRECT
NOT DIRTY • Bent rim
3. Check the PGM-FI INCORRECT • Faulty PGM-FI system
• Improperly installed wheel hub
3. Check the PGM-FI INCORRECT • Faulty PGM-FI system
system (P.7) (P.9) • Excessively worn swingarm pivot bearings
system (P.7) (P.9) CORRECT • Bent frame
CORRECT
4. Check the fuel pump INCORRECT • Faulty fuel pump unit* The motorcycle pulls to one side
operation and
inspect the fuel flow*
• Clogged fuel pump filter
(P.44)
• Front and rear wheels not aligned
INCORRECT
• Bent fork
4. Check the fuel • Faulty fuel pump unit*
pump operation • Clogged fuel pump filter
• Bent swingarm
CORRECT
and inspect the fuel (P.44)
• Bent axle shaft
flow*

• Bent frame
CORRECT 5. Check the valve INCORRECT • Camshaft not installed
timing properly (P.73)
CORRECT
5. Check the insulator INCORRECT • Loose insulator
for leaks • Damaged insulator
6. Check the valve INCORRECT • Faulty valve clearance
CORRECT clearance (P.67) • Faulty valve*
• Faulty valve seat*
CORRECT • Faulty camshaft*
6. Check the valve INCORRECT • Faulty valve clearance
clearance (P.67) • Faulty valve* 7. Check the valve WEAR • Faulty valve springs*
• Faulty valve seat* springs*
CORRECT • Faulty camshaft*
GOOD

7. Try spark test* WEAK OR • Faulty, carbon or wet

INTERMITTENT fouled spark plug (P.66) 8. Try spark test* WEAK OR • Faulty, carbon or wet
SPARK • Faulty ECM* INTERMITTENT fouled spark plug (P.66)
GOOD SPARK SPARK • Faulty ECM*
• Faulty alternator*
• Faulty ignition coil* • Faulty alternator*
• Faulty ignition coil*
• Broken or shorted spark
• Broken or shorted spark
plug wire. plug wire.
• Faulty CKP sensor* • Faulty CKP sensor*
• Loose or disconnected • Loose or disconnected
ignition system wires ignition system wires
• Faulty engine stop • Faulty engine stop
button* button*
• Faulty regulator/rectifier* • Faulty regulator/rectifier*
• Faulty condenser* • Faulty condenser*
9. Remove and WORN • Faulty camshaft*
inspect the cam
lobe height*
CORRECT

146 Tips
Technical Information

Technical Information
This section contains dimensions, capacities, and Vehicle Identification.....................................148
other technical data. Serial Numbers ..........................................148
Specifications.................................................149
Torque Specifications ....................................150
Nuts, Bolts, Fasteners ................................150
Oxygenated Fuels...........................................153
Competition Logbook ....................................154
Optional Parts List .........................................156
Spare Parts & Equipment...............................157
Spare Parts .................................................157
General Tools.............................................157
Honda Special Tools..................................157
Chemical Products .....................................157
Other Products ...........................................157
Wiring Diagram .............................................158

Technical Information 147

Vehicle Identification

Vehicle Identification
The engine number (2) is stamped on the left
Serial Numbers crankcase.
The VIN and engine serial number are required
when you register your CRF. They may also be
required when ordering replacement parts. You
may record these numbers in the Quick Reference
section at the rear of this manual.

The VIN (vehicle identification number) (1) is

stamped on the right side of the steering head.

(2)

(1) (2) engine number

(1) VIN

148 Technical Information

Specifications

Specifications
Item English Metric Item English Metric Item English Metric
Dimension Engine Drive train
Overall length 86.3 in 2,191 mm Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type
Overall width 32.6 in 827 mm Single 6°30’ inclined Transmission 5-speed, constant mesh
Cylinder arrangement
Overall height 50.0 in 1,271 mm from vertical Primary reduction 2.739
Wheelbase 58.7 in 1,492 mm Bore and stroke 3.78 x 2.44 in 96.0 x 62.1 mm Gear ratio I 1.800
Seat height 37.5 in 953 mm Displacement 27.43 cu-in 449.7 cm3 Gear ratio II 1.470
Footpeg height 16.5 in 420 mm Compression ratio 12.5 : 1 Gear ratio III 1.235
Ground clearance 13.0 in 330 mm Intake: 0.006 ± 0.001 in Gear ratio IV 1.050
(0.16 ± 0.03 mm)
Frame Valve clearance (cold) Exhaust: 0.011 ± 0.001 in Gear ratio V 0.909
Type Twin tube (0.28 ± 0.03 mm) Final reduction 3.692
Telescopic fork, Engine oil capacity Left foot-operated return
F. suspension travel 10.7 in (273 mm) Gear shift pattern system 1-N-2-3-4-5
after draining 0.61 US qt 0.58 ℓ
stroke 12.2 in (310 mm) Electrical
after draining and oil
PSF air pressure 35 psi filter change 0.66 US qt 0.62 ℓ Ignition ECM
(standard) (240 kPa, 2.4 kgf/cm2)
after disassembly 0.81 US qt 0.77 ℓ Starting system Kickstarter
Pro-link,
R. suspension Transmission oil capacity Spark plug : NGK
travel 12.4 in (315 mm)
80/100 – 21 51M after draining 0.68 US qt 0.64 ℓ Standard SILMAR9A-9S
Tire size, front after disassembly 0.76 US qt 0.72 ℓ
DUNLOP MX52F For extended high NGK
Throttle body speed riding SILMAR10A-9S
120/80 – 19 63M
Tire size, rear Identification number GQ2BA
DUNLOP MX52 0.031 – 0.035 in
Spark plug gap
Idle speed 2,000 ± 100 rpm (0.8 – 0.9 mm)
Tire type bias-ply, tube
Tire pressure, front (cold) 15 psi (100 kPa, 1.0 kgf/cm2) Cooling system
Tire pressure, rear (cold) 15 psi (100 kPa, 1.0 kgf/cm2) Cooling capacity
Single disc brake after draining 0.99 US qt 0.94 ℓ
F. brake, swept area
56.0 in2 (361.0 cm2) after disassembly 1.08 US qt 1.02 ℓ
Single disc brake
R. brake, swept area
60.5 in2 (390.3 cm2)
unleaded gasoline, pump
Fuel
octane number of 91 or higher
Fuel tank capacity 1.66 US gal 6.3 ℓ
Caster angle 27°4’
Trail length 4.6 in 116 mm
Fork oil capacity 22.39 US
662.0 cm3
(standard) oz

Technical Information 149

Torque Specifications

Torque Specifications

Nuts, Bolts, Fasteners ENGINE

Torque
Check and tighten nuts, bolts, and fasteners before every outing. Item
lbf•ft N•m kgf•m
Remarks

LEFT SIDE 1 Cylinder head cover

(1) socket bolts 7 10 1.0
(7)
2 Clutch cover bolts 7 10 1.0
3 Water pump cover bolts 7 10 1.0
(8)
4 Transmission oil check
bolt 9 12 1.2
5 Crankshaft hole cap 11 15 1.5 NOTE 1
6 Oil filter cover bolts 7 10 1.0
(9)
7 Cylinder head bolts 38 51 5.2 NOTE 2
8 Exhaust pipe joint nuts 15 21 2.1
9 Drive sprocket bolt 23 31 3.2
10 Engine oil drain bolt 12 16 1.6 NOTE 2
11 Transmission oil drain bolt 12 16 1.6 NOTE 2

(6) 12 Coolant drain bolt 7 10 1.0

13 Water hose joint bolts 7 10 1.0
(11)
NOTES: 1. Apply grease to the threads.
2. Apply engine oil to the threads and seating surface.
RIGHT SIDE
(13) (1)

(7)
(2)

(5)

(3)

(12)
(4)
(10)

150 Technical Information

 Torque Specifications
LEFT SIDE FRAME
(16) Torque
(4) Item Remarks
(2) lbf•ft N•m kgf•m
(21) 1 Steering stem nut 80 108 11.0
(1) 2 Fork bridge upper pinch
(14)
(13) bolts 16 22 2.2
(5)
3 Fork bridge lower pinch
(3) bolts 15 20 2.0
4 Handlebar upper holder
(17) bolts 16 22 2.2
5 Handlebar lower holder
(7) nuts 32 44 4.5
(9)
6 Front axle nut 65 88 9.0
7 Axle pinch bolts 15 20 2.0
8 Rear axle nut 94 128 13.1 NOTE 1
(6) 9 Chain adjuster lock nuts 20 27 2.8 NOTE 2
10 Front engine hanger nuts 40 54 5.5
(12)
Front engine hanger plate
nuts 19 26 2.7
(15)
11 Lower engine hanger nut 40 54 5.5
(14) 12 Cylinder head hanger
(17) bolts 40 54 5.5
13 Cylinder head hanger
plate bolts 24 32 3.3
RIGHT SIDE 14 Rear suspension (upper) 32 44 4.5 NOTE 1
(16)
(lower) 32 44 4.5 NOTE 1
(2) 15 Swingarm pivot nut 65 88 9.0 NOTE 1
(13) (12)
(19) 16 Fork cap 33 45 4.6
(3) 17 Rear shock arm nuts
(swingarm side) 39 53 5.4 NOTE 1, 6
(shock link side) 39 53 5.4 NOTE 1, 6
(9) (7) 18 Rear shock link nut 39 53 5.4 NOTE 1, 6
(8) 19 Rear shock spring lock nut 21 28 2.9
20 Kickstarter arm bolt 28 38 3.9 NOTE 5
21 Fuel pump mounting bolts 8 11 1.1
NOTES: 1. U-nut
2. UBS nut
5. Alock bolt: replace with a new one.
6. Apply molybdenum oil to the threads and flange surface.

(18) (20) (11)

(10)

Technical Information 151

Torque Specifications
LEFT SIDE FRAME
(41) Torque
(46) Item Remarks
(43) lbf•ft N•m kgf•m
(31) (38) 22 Front brake master cylinder
holder bolts 7.3 9.9 1.0
(35) 23 Brake hose oil bolts 25 34 3.5
24 Front brake caliper
(42) mounting bolts 22 30 3.1 NOTE 5
(49) 25 Front brake disc nuts 12 16 1.6 NOTE 1
26 Rear brake disc nuts 12 16 1.6 NOTE 1
(37) 27 Brake pedal pivot bolt 27 36 3.7 NOTE 5
28 Spokes (front) 2.7 3.7 0.4
(48) (rear) 2.7 3.7 0.4
(25)
29 Rim locks 9 12 1.2
30 Drive chain roller (upper) 9 12 1.2 NOTE 4, 5
(lower) 9 12 1.2 NOTE 1
31 Subframe bolts (upper) 24 32 3.3
(lower) 36 49 5.0
(47) 32 Fork center bolt 32 43 4.4 NOTE 3
(30)
(24) 33 Fork damper lock nut 21 29 3.0
34 Disc cover bolts 10 13 1.3
(28) (34) (28) 35 Fork protector socket bolts 5.2 7.0 0.7 NOTE 5
36 Left / right muffler clamp
bolt 15 20 2.0
37 Driven sprocket nuts 24 32 3.3 NOTE 1
RIGHT SIDE (44) 38 Seat mounting bolts 19 26 2.7
(39)
39 Front brake reservoir cap
screws 0.7 1.0 0.1
(22) (23) 40 Rear brake reservoir cap
bolts 0.7 1.0 0.1
(38) (41) 41 PSF air valve assembly 4.1 5.5 0.6
(42) (42) (46)
(31) 42 Right/left muffler mounting
(33) bolt (rear) 19 26 2.7
Left muffler mounting bolt
(front) 19 26 2.7
43 Steering damper mounting
(36) (35) bolts 15 20 2.0 NOTE 5
44 Throttle cable adjuster lock
nuts 3.0 4.0 0.4
45 Rear master cylinder push
rod lock nut 4.4 5.9 0.6
(26) 46 Shroud B bolts (upper) 3.8 5.2 0.5
47 Left engine guard bolt/
washer 7 10 1.0
48 Air bleed bolt 1.2 1.6 0.2
49 Mud guard screws 1.1 1.5 0.2
(36)
NOTES: 1. U-nut
(27) 3. Apply a locking agent to the threads.
(29) 4. SH bolt
5. Alock bolt: replace with a new one.
(29) (40) (45) (32)

152 Technical Information

Oxygenated Fuels

Oxygenated Fuels
Some conventional gasolines are being blended If you notice any undesirable operating symptoms,
with alcohol or an ether compound. These try another service station or switch to another
gasolines are collectively referred to as oxygenated brand of gasoline.
fuels. To meet clean air standards, some areas of
the United States and Canada use oxygenated fuels Fuel system damage or performance problems
to help reduce emissions. resulting from the use of an oxygenated fuel
If you use an oxygenated fuel, be sure it is containing more than the percentages of
unleaded and meets the minimum octane rating oxygenates mentioned above are not covered
requirement. under warranty.

Before using an oxygenated fuel, try to confirm the Oxygenated fuels can damage paint and plastic.
fuel’s contents. Some states/province require this Be careful not to spill fuel when filling the fuel
information to be posted on the pump. tank. Wipe up any spills immediately.

The following fuel blends are EPA-approved and NOTICE

have been approved for use in your motorcycle:
Oxygenated fuels can damage paint and plastic.
ETHANOL (ethyl or grain alcohol) up to 10% by
Volume
You may use gasoline containing up to 10%
ethanol by volume. Gasoline containing ethanol
may be marketed under the name “Gasohol”.

METHANOL (methyl or wood alcohol) up to 5%

by Volume
You may use gasoline containing up to 5%
methanol by volume as long as it also 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.

Technical Information 153

Competition Logbook

Competition Logbook
Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records
the knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of
racing events. The best way to organize the many worked best at a particular location. These items your logbook may include:
bits of information is to record them in a logbook. include: • Your placing in each moto and overall
• PGM-FI mode finishing position.
Your logbook can include such information as • basic track conditions, altitude, and • Thoughts on what you could do to improve
suspension adjustments, steering damper temperature your performance next time.
adjustments, gearing, and tire selection. This • suspension settings • Notes on any patterns noted in choice of
detailed information, along with your comments, • steering damper settings starting gate positions or in riding portions of
can prove valuable when you compete at the same • chassis adjustments tested and selected the course as the day progressed that may
track or on similar terrain. • gearing prove helpful in future events.
• tire selection • Any places on the course where you chose the
Your logbook can also tell you when maintenance • air pressure wrong line and were passed too easily.
was performed and when it will be necessary • Notes on strategy used by your competition or
again. Your logbook also lets you record any Competition Records by riders in another event that are worth
repairs and lets you keep track of the running time • your placings remembering.
on the engine and suspension components. • thoughts to improve performance next time:
both yours and your CRF’s Maintenance Records
If you choose to sell your CRF, the accurate • strategy notes Regular maintenance items you’ll want to record
maintenance records in your logbook might be the in your logbook should include:
deciding deal-maker for a potential buyer. Maintenance Records • Dates and results of cylinder, piston and ring
• regular interval maintenance examinations
Consider using different color pens or pencils to • repairs • Patterns for frequency of need for
record important information on specific subjects. • running time on engine decarbonization with a particular oil
For example, record results in black, • running time on suspension components • When you last performed shock linkage and
steering damper setting in red, suspension/chassis
swingarm pivot bearing maintenance
settings in blue, and gearing selections in green. Timekeeping • Engine, transmission, and suspension oil
Color codes will help you identify the information This Manual lists maintenance intervals for every- changes
you want with a glance. so-many races or every-so-many hours of running. • Chain, sprocket, chain guide and slider
replacements
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
An official “guesstimate” is close enough for our replacements
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 6 minutes represents one
tenth of an hour).

154 Technical Information

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

(Make several photocopies of this page for future use)

Technical Information 155

Optional Parts List

Optional Parts List

These parts and tools may be ordered from your FRAME Remarks
authorized dealer.
Shock spring 308.3 lbf/in (54 N/mm)
Standard
FRAME Remarks Pink paint
(Medium)
Driven sprocket < >: Drive chain links
Standard 48 Teeth, Aluminum.
<116> Optional 296.9 lbf/in (52 N/mm)

Optional 47 Teeth, Aluminum Soft

Yellow paint
49 Teeth, Aluminum
Drive chain D.I.D 520 DMA4/120RB Stiff 319.8 lbf/in (56 N/mm)
size/link RK520TXZ/120RJ
Handlebar White paint
lower holder
0.1 in (3 mm) offset
Optional no offset

TOOLS Remarks
Pin spanner A To adjust spring preload.
(two spanners required)
Workstand For maintenance

Air gauge For checking tire air pressure and

PSF air pressure

156 Technical Information

Spare Parts & Equipment

Spare Parts & Equipment

There are numerous spare parts you can take to an
event to help ensure you get in a full day of riding. General Tools Chemical Products
In addition to the usual nuts and bolts, consider the
following: sockets (3/8 in drive) Pro Honda GN4 4-stroke Oil
screwdrivers: blade & Phillips No. 1, 2, 3 (Engine and Transmission Oil)
wrench, large adjustable KHL15-11 (KYB)
Spare Parts wrenches: open end & box Pro Honda DOT 4 Brake Fluid
spark plugs wrenches: hex (Allen) Pro Honda HP Chain Lube
air cleaner (clean & oiled, sealed in a plastic bag) wrench, spoke Pro Honda Foam Filter Oil
chain & masterlinks torque wrench (metric scale, click-stop style) Pro Honda Hondabrite
chain guide slider pliers: standard, needle-nose, channel-lock set Pro Honda Dielectric Grease
chain guide hammer, plastic head Pro Honda Handgrip Cement
chain rollers syringe with adjustable stop Pro Honda Hondalock
tire tubes (front & rear) air pressure gauge Molybdenum disulfide grease (containing more
fenders tire irons
than 3% molybdenum disulfide additive)
footpegs tire pump or air tank
Pro Honda White Lithium Grease
fuel feed hose and retainers feeler gauge set
Vernier caliper (metric) Multi-Purpose Grease
fuel pump filter Rust-inhibiting oil
number plate & side covers pressure/vacuum testing equipment
Open end wrench 9/16 in (15 mm) Cable lubricant
handlebar Pro Honda HP Coolant
grips Urea based multi-purpose grease designed for high
levers (brake & clutch) Honda Special Tools temperature, high pressure performance
clutch lever handlebar mount (example: EXCELITE EP2 manufactured by
clutch cable Any special tools for your CRF purchased from KYODO YUSHI, Japan or equivalent)
throttle assembly your dealer.
throttle cable • Tensioner stopper 07AMG-001A100
shift lever • Fork damper holder 07TMB-001010A Other Products
brake pedal • Fork damper attachment 070MB-MEN0200
spokes (front & rear, each side) • Spoke Wrench 07JMA-MR60100 pliers-safety wire
sprockets (larger & smaller than standard) • Spoke Wrench 070MA-KZ30100 safety wire
assorted nuts, bolts, washers, screws, cotter pins • Battery harness 070MZ-MENA100 mechanic’s wire
Additional Spares • Battery harness adaptor 070MZ-KRN0100 duct tape
fuel pump • Air fork pump, 0-60 psi 07AMJ-MENA300 plastic tie-wraps
front brake master cylinder hose clamps
rear brake assembly You can purchase the PGM-FI setting tools [1], [2] drop light
wheels & tires (front & rear, mounted) and [3] from your CRF dealer. electrical tape
clutch discs and plates [1] Serial-USB unit assy 38880-N1C-770 Scotch-Brite Hand Pad #7447 (maroon)
engine & transmission oil [2] Data Setting Tool Application CD-ROM Teflon tape
seat 38772-NX7-020
ignition components [3] Data Setting Tool Manual CD-ROM
radiator hoses 38773-N1C-C00
radiator shrouds (L & R)
brake hoses (front & rear)

Technical Information 157

Wiring Diagram

Wiring Diagram
ENGINE STOP BUTTON/ REGULATOR/ ENGINE MODE SELECT BUTTON/
MIL RECTIFIER CONDENSOR FUEL PUMP ECM MODE INDICATOR

MODE LED
ENG STOP
LED LED

MODE SW
CHARGE
CHARGE

K-LINE

WARN
PCP2

PCP1
EARTH

INJ-V

VCC
SCS

IGP
BATT

TW

INJ
SG

PG
TH
PB

LG
TA
WPC

IG
5P

IG

IG
E

E
(BI)

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-11
A-10
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
6P

Bl
G
WPC
33P

G
R
Bl/W WPC (BI)

W/G
R/Y

Lg
W
Bl

Bl
R
2P
(BI)

Bl
G

Y
WPC 2P WPC

Gr/Bu
W/Bu

Bl/Bu
Bu/Y

Y/Bu
Bl/W
Lg/Y

G/W

W/G
G/W
O/Bl
W/Y

G/R
Bl

Y/G

R/Y
P/Y
G

Lg
Br

Bl
4P

P
4P MINI
(BI) (Bl) (BI)
WPC
W/Bu
Bl/W

W/G
R/Y
R/Y

4P

Lg

Bl
Bl

(R)

O/Bl
Bl
G

Br
Bl
G

Y/Bu

Bu/Y
G/W

G/W

G/W
W/Y
W
Bl
G

Y
WPC
6P
(BI)
IGNITION

Gr/Bu
Bl/Bu

Bu/Y

Lg/Y
COIL

G/W

W/Y

G/R

G/R
P/Y

G/R

G/R
Y/G

R/Y

R/Y
W

P
Y
WPC WPC
SPARK 2P 2P WPC
(Gr) (BI) WPC 3P
ENGINE STOP BUTTON PLUG WPC 3P
FRAME 2P (Bu)
E IG GROUND (BI)
PUSH
FREE
COLOR Bl/W R/Y NO.1 CKP SENSOR NO.2 CKP SENSOR
COLOR COMB : GROUND/MARKING INJECTOR ECT IAT TP MAP
ALTERNATOR
Bl BLACK Br BROWN SENSOR SENSOR SENSOR SENSOR
ENGINE MODE SELECT BUTTON Y YELLOW O ORANGE
E IG Bu BLUE Lb LIGHT BLUE
PUSH G GREEN Lg LIGHT GREEN
FREE R RED P PINK
COLOR Lg R W WHITE Gr GRAY

158 Technical Information

Consumer Information

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

Consumer Information 159

Authorized Manuals

Authorized Manuals
The Service Manual used by your authorized dealer is available from your
Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order
authorized manuals.)

Also available but not necessary to service your model is the Honda Common
Service Manual which explains theory of operation and basic service
information for various systems on Honda motorcycles, scooters, ATVs,
MUVs, and PWCs.

These Honda manuals are written for the professional technician, but most
mechanically-capable owners should find them helpful if they have the proper
tools and skills. Special Honda tools are necessary for some procedures.

Publication Item No. Description

61MEN76 2015 CRF450R Service Manual
61CSM00 Common Service Manual
31MEN710 2015 CRF450R Owner’s Manual

Order On-Line: www.helminc.com

Order Toll Free: 1-888-CYCLE93 (1-888-292-5393)
(NOTE: For Credit Card Orders Only)
Monday - Friday 8:00 AM - 6:00 PM EST

160 Consumer Information

Contacting Honda

Contacting Honda
Your owner’s manual was written to cover most of
the questions you might ask about your CRF.
Any questions not answered in the owner’s manual
can be answered by your dealer. If your dealer
doesn’t have the answer right away, they 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 CRF or with your dealer, please send your
comments to the following address:

Motorcycle Division, American Honda Motor Co.,

Inc., P.O. Box 2200, Torrance CA 90509- 2200,
Mailstop: 100-4C-7B,
Telephone: (866) 784-1870.

Canada: Honda Canada Inc., Customer Relations

Dept, 180 Honda Boulevard, Markham, Ontario
L6C 0H9, telephone: (888) 946 – 6329,
facsimile: (877) 939 – 0909.
E-mail: [email protected]

Please include the following information in your

letter:

• name, address, and telephone number

• product model, year, and VIN
• date of purchase
• dealer name and address

We will likely ask your dealer to respond, or

possibly acknowledge your comments directly.

Consumer Information 161

Your Honda Dealer

Your Honda Dealer

Once you purchase your new Honda, get familiar Your Honda dealer can inform you about
with the organization of your Honda dealer so you competition events in your area. You’ll also find
can utilize the full range of services available. that your dealer is a source of information on the
Honda Rider’s Club of America (USA only).
The service department is there to perform regular
maintenance and unexpected repairs. It has the We’re sure you’ll be as pleased with the service
latest available service information from Honda. your Honda dealer continues to provide after the
sale as you are with the quality and dependability
The parts department offers Honda Genuine Parts, of your Honda.
Pro Honda products, Honda Genuine Accessories
(USA only), and Honda accessories and products
(Canada only). The same quality that went into
your Honda can be found in Honda Genuine
replacement parts. You’ll also find comparable
quality in the accessories and products available
from the parts department.

162 Consumer Information

The Honda Rider's Club (USA only)

The Honda Rider's Club (USA only)

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

Consumer Information 163

Index

Index
A C E
accessories ......................................................... 3 capacity, fuel ....................................................39 engine,
adjustments, care, appearance .............................................107 flooded........................................................ 17
chassis....................................................... 137 chain drive........................................................95 idle speed.................................................... 60
control freeplay .............................. 58, 61, 88 chassis adjustments ........................................137 lacks power............................................... 145
for competition ......................................... 109 cleaner, air........................................................55 number...................................................... 148
gearing...................................................... 138 cleaning, appearance care ..............................107 mode select button.................................... 110
personal fit................................................ 140 clutch system, adjustment ................................61 oil................................................................ 48
steering damper ........................................ 135 competition logbook ......................................154 pinging........................................................ 39
suspension, front....................................... 111 consumer information ....................................159 starting ........................................................ 17
suspension, rear ........................................ 126 contacting Honda ...........................................161 stop button .................................................. 18
suspension, track conditions..................... 130 controls...............................................................5 stopping ...................................................... 18
tire selection, track condition ................... 139 coolant..............................................................53 won’t start................................................. 145
after competition maintenance ........................ 31 customer service.............................................162 environment, protecting................................. 144
air cleaner ........................................................ 55 cylinder system ................................................78
air pressure,
PSF ........................................................... 113 F
tires ............................................................. 95 D
apparel, protective ............................................. 2 filter,
appearance care ............................................. 107 damping adjustments, air................................................................ 55
authorized manuals........................................ 160 front...........................................................110 oil................................................................ 49
rear ............................................................127 flooded engine, starting ................................... 17
steering damper.........................................135 fork,
B dealer, your Honda.........................................162 front suspension adjustment ..................... 111
diagram, wiring ..............................................158 front suspension inspection ........................ 86
basic operation................................................. 15 drive chain........................................................95 oil recommendation.................................... 87
before riding .................................................... 11 front brake lever adjustment............................ 88
between motos & practice maintenance .......... 30 front suspension maintenance........................ 111
brakes, fuel................................................................... 39
fluid level.................................................... 89 fuel,
lever, front adjustment................................ 88 line inspection............................................. 39
pad wear ..................................................... 91 line replacement ......................................... 40
pedal height ................................................ 88 oxygenated................................................ 153
break-in guidelines .......................................... 19 pump filter .................................................. 43
refueling...................................................... 39
system......................................................... 39
tank capacity............................................... 39

164 Index
 Index
G M R
gap, spark plug ................................................ 66 maintenance, rear suspension maintenance ......................... 126
gasohol........................................................... 153 after competition .........................................31 Rider’s Club Honda (USA only) ................... 163
gasoline............................................................ 39 before & after competition..........................30 riding,
gearing ........................................................... 138 between motos & practice...........................30 apparel .......................................................... 2
guidelines, component locations ...................................32 basic operation............................................ 15
steering damper ........................................ 136 general competition.....................................26 before.......................................................... 11
suspension adjustment.............................. 131 importance ..................................................22 important safety information ........................ 2
safety...........................................................23 safety precautions ......................................... 2
schedule ......................................................24
H manual, service ..............................................160
handlebar inspection...................................... 105
mode indicator .........................................10, 110 S
modifications......................................................3
Honda, safety,
contacting ................................................. 161 a few words about.................Safety Messages
Rider’s Club ............................................. 163 O important information................................... 2
service manual.......................................... 160 important precautions ................................... 2
your dealer................................................ 162 oil, labels............................................................. 4
engine..........................................................48 maintenance................................................ 23
fork..............................................................87 riding precautions ....................................... 16
I transmission ................................................51 schedule, maintenance..................................... 24
operating instructions.......................................15 seat................................................................... 33
identification, vehicle .................................... 148 operation component locations ..........................6 serial numbers................................................ 148
idle knob, fast ............................................ 17, 60 optional, service,
idle speed, engine ............................................ 60 parts list.....................................................156 customer ................................................... 162
indicator, sprockets ...................................................138 manuals..................................................... 160
circuit inspection .......................................... 8 oxygenated fuels ............................................153 spare parts ...................................................... 157
DTC index .................................................... 9 spark knock...................................................... 39
MIL blink ..................................................... 7 spark plug,
mode ................................................... 10, 110 P maintenance................................................ 66
inspection, pre-ride .......................................... 13 reading ...................................................... 134
instruments ........................................................ 5 pads, brake .......................................................91 specifications ................................................. 149
parts, optional.................................................156 spring pre-load, rear suspension .................... 126
personal fit adjustments .................................140 starting,
L pinging, engine.................................................39 engine ......................................................... 17
plug, spark........................................................66 troubleshooting......................................... 145
labels, safety ...................................................... 4 pre-load, rear suspension ...............................125
logbook, competition..................................... 154 steering damper,
pre-ride inspection ...........................................13 adjustment ................................................ 135
protective apparel...............................................2 guidelines.................................................. 136
PSF.................................................................113 operation inspection ................................. 102
(cont’d)

Index 165
Index
steering stem inspection ................................ 105
stopping engine................................................ 18 W
storage ........................................................... 143 washing your motorcycle ...............................107
subframe .......................................................... 37 wheels ..............................................................92
suspension, wiring diagram ...............................................158
front ............................................................ 86
rear.............................................................. 87
suspension adjustment,
for track conditions................................... 130
front .......................................................... 111
guidelines ................................................. 131
rear............................................................ 126

T
throttle,
freeplay....................................................... 58
inspection ................................................... 59
tires,
air pressure ................................................. 93
flat............................................................... 93
selection...................................................... 94
tools ............................................................... 157
torque specifications
engine ....................................................... 150
frame.................................................. 151-152
transmission oil................................................ 51
transporting.................................................... 142
troubleshooting .............................................. 145
tubes, replacing................................................ 93
tuning tips ...................................................... 134

V
valve clearance ................................................ 67
vehicle identification no. (VIN) .................... 148

166 Index
Quick Reference

Quick Reference
The following is a brief, but important collection Record important information here:
of information you need to know about your CRF. VIN
You'll also find space to record important notes.
Engine No.
Owner's:
How To Avoid Costly Repairs Name

The engine of your CRF can be the most expensive Address

component to repair. Proper maintenance, City/State
especially the use of the recommended fluids and Phone
filters, prevents premature wear and damage.
Dealer's:
Frequent causes of costly engine repairs are: Name
• Transmission oil & engine oil: insufficient Address
quantity, improper oil.
City/State
• Air cleaner: dirty, leaking because of improper
installation (poor seal) Phone
Service Mgr.

Maintenance The maintenance schedule (page 25) lists service frequencies for:
each race or about 2.5 hours,
every 3 races or about 7.5 hours, every 6 races or about 15.0 hours,
every 9 races or about 22.5 hours and 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 13):
Fuel/Tank Capacity unleaded gasoline, pump octane number of 91 or higher
tank: 1.66 US gal (6.3 ℓ)
Engine oil Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil.
Transmission oil Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil.
Tires Front 80/100 – 21 51M Rear 120/80 – 19 63M
DUNLOP MX52F DUNLOP MX52
Type bias-ply, tube
Tire Pressure (cold) Front: 15 psi (100 kPa, 1.0 kgf/cm2)
Rear: 15 psi (100 kPa, 1.0 kgf/cm2)
Spark Plug standard: SILMAR9A-9S (NGK)
optional: SILMAR10A-9S (NGK)
Coolant ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50 solution with
Pro Honda HP Coolant or an equivalent distilled water.
Drive Chain Size/Link D.I.D 520DMA4/116RB
RK 520TXZ/116RJ

Quick Reference