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Contents.qxd 06.5.11 11:51 ページ2 Introduction Congratulations on choosing your Honda CRF motocross motorcycle. When you own a Honda, you’re part of a worldwide family of satisfied customers – people who appreciate Honda’s reputation for building quality into every product. Your CRF is a high performance racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned, closed-course events by experienced riders only.
Contents.qxd 06.5.11 11:51 ページ3 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.
Contents.qxd 06.5.11 11:51 ページ4 Contents MOTORCYCLE SAFETY...............................1 Important Safety Information..............................2 Important Safety Precautions..........................2 Accessories & Modifications ..............................3 Safety Labels.......................................................4 OPERATING CONTROLS .............................5 Operation Component Locations ........................6 BEFORE RIDING ............................................
001-023.qxd 06.5.11 11:53 ページ1 Motorcycle Safety This section presents some of the most important information and recommendations to help you ride your CRF safely. Please take a few moments to read these pages. This section also includes information about the location of the safety labels on your CRF. Important Safety Information...............................2 Important Safety Precautions..........................2 Accessories & Modifications ...............................3 Safety Labels ...............
001-023.qxd 06.5.11 11:53 ページ2 Important Safety Information Important Safety Precautions Your CRF can provide many years of pleasure, if you take responsibility for your own safety and understand the challenges you can meet in competitive racing. As an experienced rider, you know there is much you can do to protect yourself when you ride. The following are a few precautions we consider most important. Never Carry a Passenger. Your CRF is designed for one operator only.
001-023.qxd 06.5.11 11:53 ページ3 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.
001-023.qxd 06.5.11 11:53 ページ4 Safety Labels Read this label carefully and don’t remove it. If the label comes off or becomes hard to read, contact your Honda dealer for replacement.
001-023.qxd 06.5.11 11:53 ページ5 Operating Controls Read this section carefully before you ride. It presents the location of the basic controls on your CRF. Operation Component Locations .........................
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001-023.qxd 06.5.11 11:53 ページ7 Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and what items you should check on your CRF. Are You Ready to Ride?.......................................8 Is Your Motorcycle Ready to Ride?.....................9 Pre-ride Inspection .............................................
001-023.qxd 06.5.11 11:53 ページ8 Are You Ready to Ride? Before riding your CRF for the first time, we strongly recommend that you read this owner’s manual, make sure you understand the safety messages, and know how to operate the controls. Before each ride, it’s also important to make sure you and your CRF are both ready to ride. For information about suspension, carburetor, and other adjustments, see page 95.
001-023.qxd 06.5.11 11:53 ページ9 Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the right): WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed. Always perform a pre-ride inspection before every ride and correct any problems.
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001-023.qxd 06.5.11 11:53 ページ11 Basic Operating Instructions This section gives basic information on how to start and stop your engine as well as break-in guidelines. Safe Riding Precautions .....................................12 Starting & Stopping the Engine .........................13 Preparation ....................................................13 Starting Procedure ........................................13 Flooded Engine .............................................13 How to Stop the Engine......
001-023.qxd 06.5.11 11:53 ページ12 Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precautions beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.
001-023.qxd 06.5.11 11:53 ページ13 Starting & Stopping the Engine Always follow the proper starting procedure described below. Check the engine oil, transmission oil and coolant levels before starting the engine (pages 37,40,41). Your CRF can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter. Cold Engine Starting 1. Turn the fuel valve (1) ON. 2. Shift the transmission into neutral. 3.
001-023.qxd 06.5.11 11:53 ページ14 Starting & Stopping the Engine How to Stop the Engine (1) (2) (1) throttle (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) two or three times, and then close it. 4. Depress and hold the engine stop button (2) until the engine stops completely. Failure to close the fuel valve may cause the carburetor to overflow, result in hard starting.
001-023.qxd 06.5.11 11:53 ページ15 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.
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001-023.qxd 06.5.11 11:53 ページ17 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks.
001-023.qxd 06.5.11 11:53 ページ18 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.
001-023.qxd 06.5.11 11:53 ページ19 Maintenance Safety This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.
001-023.qxd 06.5.11 11:53 ページ20 Maintenance Schedule To maintain the safety and reliability of your CRF, regular inspection and service is required as shown in the Maintenance Schedule that follows. The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment.
001-023.qxd 06.5.11 11:53 ページ21 Maintenance Schedule Perform the Pre-ride Inspection (page 9) at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.
001-023.qxd 06.5.11 11:53 ページ22 General Competition Maintenance Perform maintenance on firm, level ground using optional workstand, or equivalent support. When tightening bolts, nuts or screws, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a crisscross pattern. Use genuine Honda parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
001-023.qxd 06.5.11 11:53 ページ23 General Competition Maintenance Spark Plug Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range. Replace periodically as specified in the Maintenance Schedule. (page 21). Spark Plug Cap Install a small plastic tie-wrap around the spark plug cap to reduce any possibility of it loosening or of water penetration.
024-053.qxd 06.5.11 11:58 ページ24 General Competition Maintenance Handgrips Always use Pro Honda Handgrip Cement when replacing handgrips. Refer to the Service Manual for installation instructions. Throttle Grip Align the index mark on the throttle grip with the index mark of the throttle cable guide. Left handlebar grip: Align the “∆” mark on the left handlebar grip with the paint mark on the handlebar. Gaskets Always use new gaskets when reassembling components.
024-053.qxd 06.5.11 11:58 ページ25 General Competition Maintenance Suspension Linkage Lubrication Disassemble, clean, inspect and lubricate all suspension linkage pivots with grease after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear. Brake Fluid Replacement Refer to Brake Pad Wear in your Owner’s Manual, page 80.
024-053.qxd 06.5.11 11:58 ページ26 Before & After Competition Maintenance Between Motos & Practice Maintenance After Competition Maintenance After practice or between motos you have a chance to make additional checks and adjustments. • Clean accumulated dirt from under the fenders 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 rim lock nut security.
024-053.qxd 06.5.11 11:58 ページ27 Before & After Competition Maintenance Routine Cleaning If your CRF is only slightly dirty, it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags. Take care to prevent catching your fingers between the chain and sprocket. A variety of reasonably priced cleaning brushes are available from variety, drug, food, and hardware stores.
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024-053.qxd 06.5.11 11:58 ページ29 Seat Removal Refer to Safety Precautions on page 19. Removal 1. Remove the seat mounting bolts (1). 2. Remove the seat (2) by sliding it backward. (2) Installation 1. Install the seat while aligning the seat front prong (3) with the seat bracket (4) and seat rear prong (5) with the frame (6). 2. Install and tighten the seat mounting bolts to the specified torque: 19 lbf·ft (26 N·m, 2.
024-053.qxd 06.5.11 11:58 ページ30 Fuel Tank Removal Refer to Safety Precautions on page 19. Removal 1. Turn the fuel valve OFF. 2. Remove the seat (page 29). 3. Remove the shroud A bolts/collars (1). 4. Remove the shroud B bolts (2) and shrouds (3). 5. Pull the breather tube (4) out of steering stem nut. 6. Unhook the fuel tank band (5). 7. Unhook the air cleaner case cover (6) and remove the fuel tank band. 8. Remove the fuel tank bolt/collar (7). WARNING (4) (2) (3) 9.
024-053.qxd 06.5.11 11:58 ページ31 Fuel Tank Removal Installation 1. Install the fuel tank on the frame. 2. Install the fuel valve (1) and tighten the fuel valve bolt (2). 3. Connect the fuel line (3) to the fuel valve. 7. Put the breather tube (7) in the steering stem nut. 9. Install the shroud B bolts (11) and A bolts/ collars (12). (11) (7) (2) (3) (12) (7) breather tube (1) (1) fuel valve (2) fuel valve bolt (11) shroud B bolts (12) shroud A bolts/collars 8.
024-053.qxd 06.5.11 11:58 ページ32 Subframe Removal Refer to Safety Precautions on page 19. Removal 1. Remove the seat (page 29). 2. Remove the side covers (1) by removing the bolts (2). 5. 6. 7. 8. Disconnect the crankcase breather tube (7). Unhook the air cleaner case cover (8). Unhook the fuel tank band (9), and remove it. Loosen the screw (10) on the air cleaner connecting tube clamp (11). (8) (9) (1) (11) Installation 1.
024-053.qxd 06.5.11 11:58 ページ33 Subframe Removal 2. Make sure the carburetor lug (4) align with the air cleaner connecting tube slot (5). 3. Tighten the screw (6) on the air cleaner connecting tube clamp (7). 4. Install and hook the fuel tank band (8). 5. Hook the air cleaner case cover (9). 6. Connect the crankcase breather tube (10). (9) (5) 9. Install the muffler (13). 10. Install the muffler clamp (14) by aligning the tab (15) of the muffler clamp with the cut-out (16) of the muffler. (13) 13.
024-053.qxd 06.5.11 11:58 ページ34 Fuel System Refer to Safety Precautions on page 19. Fuel Recommendation Type Pump Octane Number Refueling Procedure Fuel Valve and Hose Fuel Tank Capacity: 1.90 US gal (7.2R) Unleaded (3) 91 (or higher) (2) We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components. Your engine is designed to use any gasoline that has a pump octane number of 91 or higher.
024-053.qxd 06.5.11 11:58 ページ35 Fuel System Fuel Filter The fuel filter is mounted on the bottom the fuel tank. Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor. Therefore, the fuel filter should be serviced frequently. 4. Wash the fuel filter (3) in high flash-point cleaning solvent. 5. Check that the O-ring (4) is in good condition. Install the fuel joint in the fuel tank by tightening the bolts securely. Refill the fuel tank.
024-053.qxd 06.5.11 11:58 ページ36 Engine Oil Refer to Safety Precautions on page 19. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the engine. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine.
024-053.qxd 06.5.11 11:58 ページ37 Engine Oil JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification.
024-053.qxd 06.5.11 11:58 ページ38 Engine Oil 8. Remove the left engine guard bolt (4) and left engine guard (5). (4) NOTICE (5) If the oil filter is not installed properly, it will cause serious engine damage. (4) left engine guard bolt (5) left engine guard 9. Remove the oil filter cover bolts (6) and oil filter cover (7). 10. Remove the oil filter (8) from the oil filter cover. 11. Check that the oil filter cover O-ring (9) is in good condition. Replace it if necessary.
024-053.qxd 06.5.11 11:58 ページ39 Transmission Oil Refer to Safety Precautions on page 19. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the transmission and clutch. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine and transmission.
024-053.qxd 06.5.11 11:58 ページ40 Transmission Oil JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification.
024-053.qxd 06.5.11 11:58 ページ41 Coolant Your CRF’s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head. Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion. Coolant Recommendation Use Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines.
024-053.qxd 06.5.11 11:58 ページ42 Coolant Cooling System Inspection Coolant Replacement 1. Check the cooling system for leaks (see the Honda Service Manual for troubleshooting of leaks). 2. Check the water hoses (1) for cracks, deterioration, and radiator hose clamp for looseness. 3. Check the radiator mount for looseness. 4. Make sure the overflow tube (2) is connected and not clogged. 5. Check the radiator fins for clogging. 6.
024-053.qxd 06.5.11 11:58 ページ43 Air Cleaner Refer to Safety Precautions on page 19. The air cleaner uses polyurethane inner and outer pieces which can’t be separated. A dirty air cleaner will reduce engine power. Proper air cleaner maintenance is very important for off-road vehicles. A dirty, water-soaked, worn-out, or defective air cleaner will allow dirt, dust, mud, and other impurities to pass into the engine.
024-053.qxd 06.5.11 11:58 ページ44 Air Cleaner 5. Remove the air cleaner element (5) out from the air cleaner holder (6). (7) (8) (5) (9) (6) 9. Apply a thin coat of Pro Honda White Lithium Grease or equivalent to the sealing surface. 10. Assemble the air cleaner element and holder. Install the tab (7) of the holder in the hole (8) of the air cleaner tab (9). 11. Install the air cleaner assembly into the air cleaner housing keeping the two access top tabs (2) up. 12.
024-053.qxd 06.5.11 11:58 ページ45 Crankcase Breather Refer to Safety Precautions on page 19. Service more frequently if your CRF is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube. Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits. 2. Reinstall the crankcase breather tube plug.
024-053.qxd 06.5.11 11:58 ページ46 Throttle Refer to Safety Precautions on page 19. Throttle Freeplay (1) (1) freeplay Inspection Check freeplay (1). Freeplay: 1/8 - 3/16 in (3 - 5 mm) If necessary, adjust to the specified range. Upper Adjustment Minor adjustments are generally made with the upper adjuster. (2) (3) (+) (–) (4) (2) dust cover (3) lock nut (4) adjuster 46 Servicing Your Honda (+) increase (–) decrease 1. Pull the dust cover (2) back. 2. Loosen the lock nut (3). 3.
024-053.qxd 06.5.11 11:58 ページ47 Throttle Throttle Inspection (1) (1) throttle 1. Check that the throttle assembly is positioned properly and the securing bolts are tight. 2. Check for smooth rotation of the throttle (1) from fully open to fully closed in all steering positions. If there is a problem, see your Honda dealer. 3. Inspect the condition of the throttle cables from the throttle grip down to the carburetor. If the cable is kinked or chafed, have it replaced. 4.
024-053.qxd 06.5.11 11:58 ページ48 Engine Idle Speed Refer to Safety Precautions on page 19. Remember, idle speed adjustment in not a “cure-all” for other problems in your engine’s fuel-delivery system. Adjusting the idle will not compensate for a fault elsewhere. The engine must be at normal operating temperature for accurate idle speed adjustment. 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.
024-053.qxd 06.5.11 11:58 ページ49 Clutch System Refer to Safety Precautions on page 19. Clutch Lever Adjustment 4. Turn the cable end adjuster (3) in direction (+) until it seats lightly and then turn it out 5 turns. Clutch Lever Freeplay (1) Cable end adjuster: The distance between the tip of the clutch lever and the grip may be adjusted. (–) Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable disconnected.
024-053.qxd 06.5.11 11:58 ページ50 Clutch System Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster. Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit — or the correct freeplay cannot be obtained.
024-053.qxd 06.5.11 11:58 ページ51 Clutch System 5. Remove the clutch pressure plate (6). Clutch Cover/Disc/Plate Removal Clutch Disc/Plate Inspection (5) 1. Drain the transmission oil (page 40). 2. Remove the rear brake pedal (1) by removing its pivot bolt (2). Replace the clutch discs (1) if they show signs of scoring or discoloration. Measure the thickness of each clutch disc. Service Limit: 0.112 in (2.85 mm) (2) Replace the clutch discs and clutch plates as an assembly.
024-053.qxd 06.5.11 11:58 ページ52 Clutch System Clutch Spring Inspection (1) 3. Apply grease to the clutch lifter rod (3). 4. Insert the clutch lifter rod into the mainshaft. 5. Apply engine oil to the needle bearing (4) and washer (5) and install them onto the clutch lifter (6). 6. Install the clutch lifter onto the rod. 10. Install a new O-ring (9) in the groove of the clutch cover (10). 11. Install the clutch cover by tightening the six cover bolts to the specified torque: 7 lbf·ft (10 N·m, 1.
024-053.qxd 06.5.11 11:58 ページ53 Hot Start Lever Refer to Safety Precautions on page 19. Hot Start Lever Freeplay left handlebar (1) (2) Adjustment Adjustments can be made with the cable end adjuster. Loosen the lock nut (3) and turn the adjuster (4). Turning the adjuster clockwise (+) will increase freeplay and turning it counterclockwise (–) will decrease freeplay. After adjustment, tighten the lock nut.
054-075.qxd 06.5.11 13:02 ページ54 Spark Plug Refer to Safety Precautions on page 19. Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions. Standard IFR8H11 (NGK) or VK24PRZ11 (DENSO) Optional IFR9H11 (NGK) or VK27PRZ11 (DENSO) Spark Plug Replacement & Inspection 1. 2. 3. 4. Remove the seat and fuel tank (pages 29,30). Disconnect the spark plug cap (1). Clean any dirt from around the spark plug base. Remove the spark plug (2).
054-075.qxd 06.5.11 13:03 ページ55 Valve Clearance Refer to Safety Precautions on page 19. Excessive valve clearance will cause noise and eventual engine damage. Little or no clearance will prevent the valve from closing and cause valve damage and power loss. Check valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule (page 21). The checking or adjusting of the valve clearance should be performed while the engine is cold.
054-075.qxd 06.5.11 13:03 ページ56 Valve Clearance 3. Rotate the crankshaft by turning the primary drive gear bolt (3) clockwise until aligning the punch mark (4) on the primary drive gear with the “∆” mark (5) on the right crankcase cover. In this position, the piston may either be on the compression or exhaust stroke. If the crankshaft passed the punch mark, rotate the primary drive gear bolt clockwise again and align the punch mark with the “∆” mark.
054-075.qxd 06.5.11 13:03 ページ57 Valve Clearance Camshaft Holder Assembly Removal 1. Record the intake valve and exhaust valve clearances. Make sure the piston is at TDC (Top Dead Center) on the compression stroke (page 55). 2. Remove the cam chain tensioner lifter cover bolt (1) and sealing washer (2). Use the tensioner stopper tool. • Tensioner stopper 070MG-0010100 3. Turn the tensioner shaft clockwise with the stopper tool (3) until it stops, in order to retract the tensioner fully.
054-075.qxd 06.5.11 13:03 ページ58 Valve Clearance 6. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. Loosen the camshaft holder assembly bolts (7) in a crisscross pattern in two or three steps. Remove the camshaft holder assembly bolts, camshaft holder assembly (8), intake valve lifters (9) and shims. 7. Remove the valve lifters (9), decompressor shaft (10) and plunger (11).
054-075.qxd 06.5.11 13:03 ページ59 Valve Clearance Shim Selection 1. Clean the valve shim contact area in the valve lifter (1) with compressed air. 2. Measure the shim thickness with a micrometer and record it. Seventy-three different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (3.000 mm thickness) in intervals of 0.025 mm. (1) (2) 3. Calculate the new shim thickness using the equation below.
054-075.qxd 06.5.11 13:03 ページ60 Valve Clearance Camshaft Holder Assembly 1. Install the newly selected shims (1) on the valve spring retainers (2). NOTICE Do not let the shims fall into the crankcase. 3. Install the plunger (3) into the camshaft (4) with its rounded surface facing up and groove (5) side toward the decompressor shaft (6). Install the decompressor shaft while aligning its tab (7) with the groove of the plunger shown.
054-075.qxd 06.5.11 13:03 ページ61 Valve Clearance 6. While holding the cam chain, rotate the primary drive gear bolt (12) (crankshaft) clockwise and align the punch mark (13) with the “∆” mark (14). Make sure the piston is at TDC (Top Dead Center) on the compression stroke. 8. Set the decompressor weight (20) by aligning its hole (21) with out side weight pin (22) as shown. (15) (19) (22) (14) (21) (12) (20) (17) (13) (12) primary drive gear bolt (13) punch mark (14) “∆” mark 7.
054-075.qxd 06.5.11 13:03 ページ62 Valve Clearance 11.Check the operation of the plunger (3) by pushing the decompressor weight (20) with your finger and then pushing the plunger down. Release the decompressor weight and pull up the plunger. 13.Rotate the primary drive gear bolt (crankshaft) clockwise two turns and align the punch mark (13) with the index mark (14). Make sure that the timing mark (17) on the sprocket align with the “∆” mark (18) on the camshaft holder assembly.
054-075.qxd 06.5.11 13:03 ページ63 Valve Clearance Spark Plug Installation Tighten the spark plug (1): • If the old plug is good: 1/8 turn after it seats. • If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 3/4 turn after it seats. DENSO: 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats.
054-075.qxd 06.5.11 13:03 ページ64 Valve Clearance 3. Check the rubber seals (5) are in good condition, replace them if necessary. Install the rubber seals onto the cylinder head cover with the “UP” marks (7) facing up. 6. Connect the spark plug cap (10) and breather tube (11). (10) (7) (5) (11) (7) (10) spark plug cap (11) breather tube (5) rubber seal (7) “UP” marks 7. Install the fuel tank and seat (page 29, 31). 4. Install the cylinder head cover (6). 5.
054-075.qxd 06.5.11 13:03 ページ65 Piston/Piston Rings/Piston Pin Cylinder Head Removal 1. Clean the area above the engine before disassembly to prevent dirt falling into the engine. 2. Drain the radiator coolant after cooling the motorcycle (page 42). 3. Remove the seat and fuel tank (page 29, 30). 4. Remove the muffler (page 87) and subframe (page 32). 5. Remove the carburetor (page 119). 6. Remove the exhaust pipe (page 89). 7.
054-075.qxd 06.5.11 13:03 ページ66 Piston/Piston Rings/Piston Pin 13.Remove the engine hanger nut (9), engine hanger A bolt (10) and fuel hose guide (11). Remove the engine hanger B bolts (12), left engine hanger plate (13) and right engine hanger plate (14). 14.Remove the cylinder head bolts (15). 15.Loosen the cylinder bolt (16). 17.Remove the dowel pins (19), cylinder head gasket (20) and cam chain guide (21). NOTICE (15) Do not let the dowel pins and cam chain fall into the crankcase.
054-075.qxd 06.5.11 13:03 ページ67 Piston/Piston Rings/Piston Pin Cylinder Removal 4. Spread each piston ring (4) and remove by lifting it up at a point just opposite the gap. Piston Removal 1. Remove the cylinder bolt (1) and cylinder (2). NOTICE Do not let the cam chain fall into the crankcase. Do not pry on or strike the cylinder. 1. Place clean shop towels in the crankcase to keep the piston pin clips, or other parts, from falling into the crankcase. 2.
054-075.qxd 06.5.11 13:03 ページ68 Piston/Piston Rings/Piston Pin Piston/Piston Pin/ Piston Ring Inspection We recommend you consult the Service Manual or your authorized Honda dealer for correct Service Limit measurements. Piston Ring Installation 1. Remove the carbon deposits from the piston head and piston ring grooves with the removed ring (1). • To install the oil ring, install the spacer first, then install the side rails. • Install the top ring on the piston with the marking side facing up. 3.
054-075.qxd 06.5.11 13:03 ページ69 Piston/Piston Rings/Piston Pin Piston Installation 1. Place clean shop towels over the crankcase opening to keep the piston pin clips from falling into the crankcase. 2. 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 connecting rod small end inner surface. 3.
054-075.qxd 06.5.11 13:03 ページ70 Piston/Piston Rings/Piston Pin 5. Apply engine oil to the cylinder wall, piston outer surface and piston rings. Route the cam chain (4) through the cylinder (5). Install the cylinder over the piston rings by hand while compressing the piston rings (6). 6. Install the cam chain guide (7) and fit the cam chain guide tabs (8) in the cylinder cut-outs (9). Push the guide until it bottoms in the crankcase guide hole. Cylinder Head Installation 1.
054-075.qxd 06.5.11 13:03 ページ71 Piston/Piston Rings/Piston Pin 2. Route the cam chain through the cylinder head (3). Install the cylinder head. 4. Install the cylinder bolt (5), cylinder head bolts (6) and tighten them to the specified torque: 7 lbf·ft (10 N·m, 1.0 kgf·m) NOTICE (9) (6) Do not damage mating surfaces when installing the cylinder head. (11) (7) 3. Apply engine oil to all cylinder head nut (4) threads and seating surface.
054-075.qxd 06.5.11 13:03 ページ72 Piston/Piston Rings/Piston Pin 6. Connect the radiator hose (13) to the cylinder head. (13) 10.Install the crankshaft hole cap (page 63). 11.Install the cylinder head cover (page 63). 12.Install the ignition coil (15), ground terminal (16), bolts (17) and nut (18). Connect the primary wire connector (19). (16) (19) (17) (18) (15) (13) radiator hose 7. Tighten the radiator hose clamp screw (14) as illustrated below.
054-075.qxd 06.5.11 13:03 ページ73 Suspension Refer to Safety Precautions on page 19. Loose, worn, or damaged suspension components may adversely affect the handling and stability of your CRF. If any suspension components appear worn or damaged, see your Honda dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts or repairs are needed.
054-075.qxd 06.5.11 13:03 ページ74 Suspension Rear Suspension Inspection 1. Bounce the rear of the motorcycle up and down and check for smooth suspension action. The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure. The gas pressure in the reservoir is contained within a rubber bladder.
054-075.qxd 06.5.11 13:03 ページ75 Suspension NOTICE Recommended Fork Oil viscosity (weight) 5 W suggested oil Pro Honda HP Fork Oil or equivalent The outer tube (1) can drop on the slider (7) and damage the fork dust seal (5) and guide bushing (6) when the fork damper is removed. To avoid damage hold both the outer tube and slider when removing the fork damper. Fork Oil Change (5) 5. Drain the fork oil by turning the outer tube (1) upside down.
076-093.qxd 06.5.11 13:07 ページ76 Suspension 6. Pour the recommended fork oil into the outer tube. Fork Oil Capacity: Optional Stiffer (0.48 kgf/mm) Fork Spring Standard (0.46 kgf/mm) Fork Spring No mark (factory products) 4 scribe marks 2 scribe marks (aftermarket parts) Standard oil capacity 13.0 US oz (384 cm3) Maximum oil capacity 13.8 US oz (407 cm3) Slightly stiffer as it nears full compression. Minimum oil capacity 10.5 US oz (311 cm3) Slightly softer as it nears full compression.
076-093.qxd 06.5.11 13:07 ページ77 Brakes Refer to Safety Precautions on page 19. Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop. Front Brake Lever Adjustment (3) The rear brake pedal height should be approximately level with the right footpeg. (2) Frequently inspect the system to ensure there are no fluid leaks.
076-093.qxd 06.5.11 13:07 ページ78 Brakes Rear Brake Fluid Level Check Fluid Level Inspection Front Brake Fluid Level Check (2) (1) (1) LWR mark With the motorcycle in an upright position, check the fluid level. It should be above the LWR mark (1). If the level is at or below the LWR mark, check the brake pads for wear (page 80). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks.
076-093.qxd 06.5.11 13:07 ページ79 Brakes Adding Front Brake Fluid Adding Rear Brake Fluid NOTICE NOTICE Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first. Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts.
076-093.qxd 06.5.11 13:07 ページ80 Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions. (Generally, the pads will wear faster on wet and dirty tracks) Inspect the pads at each regular maintenance interval (page 21). Rear Brake Pads Inspect the brake pads (4) from the rear side of the caliper to determine the pad wear. If either pad is worn anywhere to a thickness of 0.04 in (1 mm), both pads must be replaced.
076-093.qxd 06.5.11 13:07 ページ81 Wheels Refer to Safety Precautions on page 19. Maintenance of spoke tension and wheel trueness (roundness) is critical to safe motorcycle operation. During the first few rides, spokes will loosen more rapidly due to the initial seating of the parts. Excessively loose spokes may result in instability at high speeds and the possible loss of control. It’s also important that the rim locks are secure to prevent tire slippage.
076-093.qxd 06.5.11 13:07 ページ82 Tires & Tubes Refer to Safety Precautions on page 19. To safely operate your CRF, the tires must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated. WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding tire inflation and maintenance.
076-093.qxd 06.5.11 13:07 ページ83 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.
076-093.qxd 06.5.11 13:07 ページ84 Drive Chain Refer to Safety Precautions on page 19. The service life of the chain depends on proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain or sprockets. (4) (1) When the motorcycle is ridden on unusually dusty or muddy tracks, more frequent maintenance will be necessary. (3) (2) Before servicing your drive chain, turn the engine OFF and check that your transmission is in neutral.
076-093.qxd 06.5.11 13:07 ページ85 Drive Chain Replace the roller if necessary as follows. Install the upper drive chain roller (Green) with the “/” mark (9) facing toward the frame and lower drive chain rollar (Black) with the “/” mark (9) side facing out. (7) (9) (5) (2) (4) For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each outing.
076-093.qxd 06.5.11 13:07 ページ86 Drive Chain 4. Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. Both chain and sprockets must be in good condition, or the new replacement chain or sprocket(s) will wear rapidly. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any sprocket which is damaged or excessively worn. 5. Measure a section of the drive chain to determine whether the chain is worn beyond its service limit.
076-093.qxd 06.5.11 13:07 ページ87 Exhaust Pipe/Muffler Exhaust Pipe/Muffler Inspection 1. Check the flange bolts and exhaust pipe joint nuts for tightness. 2. Check the exhaust pipe and muffler for cracks or deformation. A damaged exhaust pipe and muffler may reduce engine performance. 2. Loosen the muffler clamp bolt (4). 3. Remove the muffler A bolt (5), muffler B bolt/washers (6) and muffler (7). (6) (5) (4) Muffler Removal 1.
076-093.qxd 06.5.11 13:07 ページ88 Exhaust Pipe/Muffler Muffler Installation 1. Remove the gasket (1). 2. Install the muffler clamp (2) and new gasket onto the exhaust pipe (3). 5. Tighten the muffler B bolt/washers (8) and muffler A bolt (9) to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) 6. Tighten the muffler clamp bolt (10) to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) 7. Install the right side cover (11) and side cover bolt (12). 8.
076-093.qxd 06.5.11 13:07 ページ89 Exhaust Pipe/Muffler Exhaust Pipe Removal Exhaust Pipe Installation 1. Remove the muffler (page 87). 2. Remove the exhaust pipe joint nuts (1), exhaust pipe (2) and exhaust pipe gasket (3). (2) 1. Install a new exhaust pipe gasket (1), exhaust pipe (2) and exhaust pipe joint nuts (3) and tighten to the specified torque: 15 lbf·ft (21 N·m, 2.
076-093.qxd 06.5.11 13:07 ページ90 Additional Maintenance Procedures Refer to Safety Precautions on page 19. Steering Head Bearing Inspection 1. With your CRF on a box or workstand (front wheel elevated), turn the handlebar to the right and left to check for roughness in the steering head bearings. Handlebar Inspection 1. Check the handlebar (1) for bends or cracks. 2. Check that the handlebar has not moved from its proper position (by inspecting the paint mark (2)). 3.
076-093.qxd 06.5.11 13:07 ページ91 Additional Maintenance Procedures LEFT SIDE Nuts, Bolts, Fasteners (1) (8) Check and tighten nuts, bolts, and fasteners before every outing. ENGINE Torque Item 1 2 3 4 5 6 7 8 9 10 Cylinder head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap Oil filter cover bolts Cylinder bolt Cylinder head bolts Exhaust pipe joint nuts Drive sprocket bolt lbf•ft 7 7 7 N•m 10 10 10 kgf•m 1.0 1.0 1.
076-093.qxd 06.5.11 13:07 ページ92 Appearance Care Refer to Safety Precautions on page 19. Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values his motorcycle. A clean CRF is also easier to inspect and service. While you’re cleaning, be sure to look for damage, wear, and gasoline or oil leaks.
076-093.qxd 06.5.11 13:07 ページ93 Appearance Care Condensation Control Some condensation can form within the transmission cavity as well. This is natural and just one more reason you should change the engine and transmission oil often. After Cleaning Lubrication There are some things you should do just after washing your CRF to help prevent rust and corrosion. Once your CRF is clean and dry, you should protect any bare steel from rusting by applying a light coating of a rust-inhibitor.
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094-117.qxd 06.5.11 13:09 ページ95 Adjustments for Competition This section tells you how to fine tune your CRF for maximum competition performance. Initial suspension adjustments should be performed after a minimum of two hours of easy break-in time. Optional front and rear suspension springs are available in both stiffer and softer than standard rates, in order to tailor your CRF specifically for your weight, riding style and course conditions.
094-117.qxd 06.5.11 13:09 ページ96 Front Suspension Adjustments The front suspension can be adjusted for the rider’s weight and riding conditions by using one or more of the following methods: • Oil volume — The effects of higher or lower fork oil level are only felt during the final 3.9 in (100 mm) of fork travel. • Compression damping — Turning the compression damping screw adjusts how quickly the fork compresses. • Rebound damping — Turning the rebound damping screw adjusts how quickly the fork extends.
094-117.qxd 06.5.11 13:09 ページ97 Front Suspension Adjustments Both compression and rebound damping can be increased by turning the adjuster clockwise. NOTICE Always start with full hard when adjusting damping. Do not turn the adjuster screw more than the given positions or the adjuster may be damaged. Be sure that the rebound and compression adjusters are firmly located in a detent, and not between positions.
094-117.qxd 06.5.11 13:09 ページ98 Front Suspension Adjustments 1. Place your CRF on the optional workstand or equivalent support with the front wheel off the ground. 2. Unlock the number plate tab (3) from the handlebar pad (4). 3. Remove the handlebar pad. (4) 5. Loosen the upper pinch bolts (8). 6. Loosen the fork damper (7), but do not remove them yet. NOTICE 8. Remove the front axle nut (11) and loosen the front axle pinch bolts (12) on both forks.
094-117.qxd 06.5.11 13:09 ページ99 Front Suspension Adjustments 11.Loosen the fork leg lower pinch bolts (19), then pull the fork legs down and out. 15.Hold the outer tube, then remove the fork damper (23) from the outer tube using a lock nut wrench (24). Gently slide the outer tube down onto the lower end (axle holder) (25). 16.Drain the fork oil from the outer tube (28). Drain the fork oil from the oil hole (29) of the fork damper.
094-117.qxd 06.5.11 13:09 ページ100 Front Suspension Adjustments 20.Push out the fork center bolt from the axle holder of the slider by pushing the fork damper. 21.Make the mechanic's stopper tool out of a thin piece of steel (1.0 mm thick) as shown if you do not have the special tool. 24.Remove the push rod (33) from the fork damper. 25.Remove the special tool or mechanic's stopper tool (31) between the axle holder (25) and lock nut (32) while applying pressure to the fork cap.
094-117.qxd 06.5.11 13:09 ページ101 Front Suspension Adjustments 3. Remove the fork cap assembly (2) from the fork damper (1). Be careful not to damage the fork cap bushing. Do not disassemble the fork cap assembly. Replace the fork cap as an assembly if it is damaged. 6. Extend the fork damper piston rod to maximum. Pour the recommended fork oil into the fork damper. Recommended Oil: Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount: 6.5 US oz (192 cc, 6.8 Imp oz) 8.
094-117.qxd 06.5.11 13:09 ページ102 Front Suspension Adjustments 10. Tighten the fork cap assembly (2) while holding the cut out of the fork damper (1) using the lock nut wrench (3) to the specified torque: 22 Ibf·ft (30 N·m, 3.1 kgf·m) 12. Screw in the lock nut (8) to the fork damper piston rod (5) fully. (5) (8) (2) (1) 14. Drain the extra oil from the oil hole (5) of the fork damper (1). By doing this procedure, about 0.
094-117.qxd 06.5.11 13:09 ページ103 Front Suspension Adjustments Fork Assembly 1. Drain the fork oil from the outer tube/slider (1) by placing it upside down. (About 7 cc of fork oil will be left in the outer tube/slider when it is left inverted for about 20 minutes at 20°C) 2. Tighten the lock nut (2) fully and measure the thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) Wipe the oil completely off the fork damper. (2) (1) (A) (2) lock nut (1) outer tube/slider (A) thread length 3.
094-117.qxd 06.5.11 13:09 ページ104 Front Suspension Adjustments 4. Place the lower end (axle holder) of the slider in a vise with a piece of wood or soft jaws to avoid to damage. NOTICE Overtightening the vise can damage the axle holder. 5. Temporarily install the fork damper to the fork. Push out the fork damper piston rod from the axle holder of the slider by pushing the fork damper.
094-117.qxd 06.5.11 13:09 ページ105 Front Suspension Adjustments 13.Pour the recommended fork oil (11) into the outer tube/slider (1). Optional Stiffer (0.48 kgf/mm) Fork Spring Fork Oil Capacity: Standard (0.46 kgf/mm) Fork Spring No mark (factory products) Recommended Oil: Pro Honda HP Fork Oil 5 W or equivalent. 4 scribe marks 2 scribe marks (aftermarket parts) (11) (1) Standard oil capacity 13.0 US oz (384 cm3) Maximum oil capacity 13.
094-117.qxd 06.5.11 13:09 ページ106 Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper assembly (4) is in good condition. Apply the recommended fork oil to the O-ring. 15.Pull up the outer tube/slider (1) slowly and install the fork damper assembly (4) into the outer tube. (4) (12) 17.Tighten the fork damper assembly (4) to the specified torque using the lock nut wrench (14). Actual: 25 lbf·ft (34 N·m, 3.5 kgf·m) Torque wrench scale reading: 23 Ibf·ft (31 N·m, 3.
094-117.qxd 06.5.11 13:09 ページ107 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts (18) and axle holder thoroughly. Apply locking agent to the bolt threads. Install the fork protectors (19), fork protector bolts and brake hose clamp bolts (20). Tighten the fork protector bolts to the specified torque: 5.2 Ibf·ft (7 N·m, 0.7 kgf·m) 22.Align the brake caliper (22) and hose with the left fork leg, making sure that the brake hose is not twisted.
094-117.qxd 06.5.11 13:09 ページ108 Front Suspension Adjustments 26.Route the number plate tab (27) around the handlebar pad (28) as shown. 28.While keeping the forks parallel, alternately tighten the right axle pinch bolts (29) to the specified torque: 15 Ibf·ft (20 N·m, 2.0 kgf·m) 30.Turn the rebound damping (32) and compression damping (33) adjuster screws back to their original settings.
094-117.qxd 06.5.11 13:09 ページ109 Rear Suspension Adjustments The rear suspension can be adjusted for the rider’s weight and riding conditions by changing the spring pre-load and the rebound and compression damping. The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assembly only.
094-117.qxd 06.5.11 13:09 ページ110 Rear Suspension Adjustments Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjusters. The high speed damping adjuster (1) is effective when damping adjustment is desired for high speed operation. The low speed damping adjuster (2) should be used when damping adjustment is desired at relatively low speeds.
094-117.qxd 06.5.11 13:09 ページ111 Rear Suspension Adjustments REAR FENDER MOUNTING BOLT Rear Suspension Race Sag Setting the proper race sag (ride height) is very important for competition use. UNLOADED MEASUREMENT (without rider) EXAMPLE: 23.6 in (600 mm) Race sag refers to the amount of rear wheel travel used by your CRF at rest, ready to ride, with you on the seat. As a general rule of thumb, the race sag dimension should be about one-third of the maximum travel.
094-117.qxd 06.5.11 13:09 ページ112 Rear Suspension Adjustments 6. Calculate the free sag dimension. To do this, subtract the loaded without rider dimension (step 5) from the unloaded dimension (step 2). Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF. With the spring pre-load set to obtain the proper race sag, the rear suspension should sag 0.4 to 1.0 in (10 to 25 mm). If the rear of your CRF sags less than 0.
094-117.qxd 06.5.11 13:09 ページ113 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.
094-117.qxd 06.5.11 13:09 ページ114 Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 96 – 113. 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.
094-117.qxd 06.5.11 13:09 ページ115 Suspension Adjustment Guidelines Symptom Stiff suspension Action Initial travel too stiff: • Stiff on small bumps while riding at full throttle in a straight line. • Stiff on small cornering bumps. • Front end wanders while riding at full throttle in a straight line. – Test softer compression damping adjustments in one-click increments. – Reduce the rebound damping adjustments in one-click increments. – Check for dirt in the dust seals.
094-117.qxd 06.5.11 13:09 ページ116 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.
094-117.qxd 06.5.11 13:09 ページ117 Carburetor Adjustments & Tuning Tips The carburetor on your CRF should perform suitably with the standard recommended settings under average load, climatic, and barometric conditions. However, to fine tune the engine’s power output, the carburetor may require adjustments for specific competition needs. Optional main jets, slow jets and leak jets are available for your CRF. See your Honda dealer.
118-133.qxd 06.5.11 13:13 ページ118 Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit The accelerator pump circuit operates when the throttle is opened. As the throttle valve (1) opens, the pump rod (2) depresses the diaphragm (3). At this time, the inlet check valve (4) is shut resulting in a sharp increase in pressure in the pump chamber (5). The outlet check valve (6) then opens, supplying fuel to the main bore via the accelerator nozzle (7).
118-133.qxd 06.5.11 13:13 ページ119 Carburetor Adjustments & Tuning Tips Carburetor Circuit Functions The carburetor has several major circuits, each providing the fuel/air mixture over a given portion of throttle valve opening. Jet Needle The jet needle controls fuel/air mixture over fully closed to 3/4 throttle. The straight section (1) affects throttle response at smaller throttle openings. By changing the position of the clip (2) in its groove, you can improve acceleration at medium low and medium speed.
118-133.qxd 06.5.11 13:13 ページ120 Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 30). 5. Remove the subframe (page 32). 6. Remove the fuel hose (2) from the fuel hose guide (3). 7. Loosen the insulator band screw (4). 10. Remove the hot start cable holder (6). (6) 12. Loosen the throttle cable lock nut (9), adjuster (10), throttle cable bolt (11) and disconnect the throttle cables (12) from the throttle drum (13). (9) (10) (2) (13) (4) (11) (6) hot start cable holder (3) 11.
118-133.qxd 06.5.11 13:13 ページ121 Carburetor Adjustments & Tuning Tips Carburetor Disassembly 1. Remove the carbretor top cover bolts (1) clamp (2) and carburetor top cover (3). (2) 3. Remove the link arm set torx screw (6). When installing the link arm set torx screw, apply a locking agent to the link arm set torx screw threads. 4. Remove the throttle valve (5), throttle valve roller (7) and floating valve (8).
118-133.qxd 06.5.11 13:13 ページ122 Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws (10) and accelerator pump cover (11). 7. Remove the holder screw (17), throttle stop screw holder (18), float bowl screws (19), tube guides (20) and float bowl (16). (10) (17) (19) (18) 9. Measure the float level (24) with the float level gauge (25) while the float tab is just contacting the float valve with the carburetor intake (26) is facing up. The float level should be 0.24 in (6.
118-133.qxd 06.5.11 13:13 ページ123 Carburetor Adjustments & Tuning Tips Carburetor Assembly To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. (4) Tighten the following parts to the specified torque. float bowl screws: 1.5 lbf·ft (2.1 N·m, 0.2 kgf·m) accelerator pump cover screws: 1.5 lbf·ft (2.1 N·m, 0.2 kgf·m) carburetor top cover bolts: 1.5 lbf·ft (2.1 N·m, 0.2 kgf·m) jet needle/holder assembly: 1.5 lbf·ft (2.1 N·m, 0.
118-133.qxd 06.5.11 13:13 ページ124 Carburetor Adjustments & Tuning Tips Standard Tuning Recommendations For the following recommendations to be accurate, you must use the standard settings as a baseline. Also, don’t change any of the settings until you’ve determined what changes are necessary. Adjustment Standard settings Pilot screw opening 1 3/4 turns out Slow jet #42 Jet needle NJYR Needle clip position 3rd groove Main jet #178 Float level 0.24 in (6.
118-133.qxd 06.5.11 13:13 ページ125 Carburetor Adjustments & Tuning Tips Special Tuning Conditions There are some unique atmospheric conditions or situations that may require additional adjustments. It should not be necessary to go more than one jet size richer or leaner to fine tune your CRF. If larger jetting changes are necessary, check for air leaks, blocked or restricted exhaust or fuel systems, or a dirty air cleaner.
118-133.qxd 06.5.11 13:13 ページ126 Carburetor Adjustments & Tuning Tips WARNING Carburetor Minor Adjustments The standard carburetor settings are ideal for the following conditions: sea level altitude, and 68°F (20°C ) air temperature. If your conditions are different, you may need to adjust the carburetor settings, using the tuning information on pages 124 and 125. Confirm your settings are correct before proceeding. Minor Adjustments 1.
118-133.qxd 06.5.11 13:13 ページ127 Carburetor Adjustments & Tuning Tips 7. Change the main jet (4) and slow jet (5) as required. 10. Remove the fuel tank (page 30). 11. Remove the carburetor top cover bolts (9), clamp (10) and carburetor top cover (11). 12. Remove the jet needle/holder assembly (12). (4) (11) (10) (12) (5) (9) (4) main jet (5) slow jet 8. Reinstall the float bowl plug. 9.
118-133.qxd 06.5.11 13:13 ページ128 Carburetor Adjustments & Tuning Tips Spark Plug Reading Refer to Spark Plug on page 54. Check any jetting change by reading the spark plug. The following procedure is recommended. You may not get an accurate reading if you simply turn off the engine and pull the plug for inspection. Use a new spark plug. Inspect the plug before installing it. NOTICE Using spark plugs with an improper heat range or incorrect reach can cause engine damage.
118-133.qxd 06.5.11 13:13 ページ129 Chassis Adjustments The following suggestions may improve a specific concern. Subtle changes in overall handling may also be noted. Rear End If you have a problem with rear wheel traction, raise the rear end of your CRF by increasing the rear spring pre-load. Instead of running 3.9 in (100 mm) of sag, you can run 3.5 in (90 mm) so the rear of the bike will sit a little higher.
118-133.qxd 06.5.11 13:13 ページ130 Gearing You can “adjust” the power delivery of the standard engine to suit track conditions by changing gearing. This allows you to utilize a different portion of the engine’s power range at a given throttle setting. New gearing may provide the change you are looking for without the need to consider further modifications. The portion of your engine’s power range you use can be adjusted by changing the final drive ratio with different sized rear sprockets.
118-133.qxd 06.5.11 13:13 ページ131 Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber compound can affect your placing in competition. The tires on your CRF offer a “happy medium” for the variety of soil conditions the majority of riders are likely to encounter. Experienced competitors often switch to tires developed for specific terrain conditions. If you do switch, stay with the factory recommended sizes. Other tires may affect handling or acceleration.
118-133.qxd 06.5.11 13:13 ページ132 Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input. • Position the shift lever and rear brake pedal so they are close to your boot for rapid access, but not so close that either is depressed when sitting or standing comfortably on your CRF. Control Positioning • Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference.
118-133.qxd 06.5.11 13:13 ページ133 Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle .........................134 Storing Your Honda..........................................135 Preparation for Storage ................................135 Removal from Storage.................................135 You & the Environment ...................................136 Troubleshooting................................................
134-164.qxd 06.5.11 13:15 ページ134 Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda, we recommend that you follow these guidelines: • Use a loading ramp. • Make sure the fuel valve is off. • Secure the motorcycle in an upright position, using motorcycle tie-down straps. Avoid using rope, which can loosen and allow the motorcycle to fall over. To secure your CRF, brace the front wheel against the front of the truck bed or trailer rail.
134-164.qxd 06.5.11 13:15 ページ135 Storing Your Honda If you won’t be riding for an extended period, such as during the winter, thoroughly inspect your Honda and correct any problem before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your CRF running again. To reduce or prevent deterioration that can occur during storage, also follow the following procedures. 6. Remove the radiator cap and coolant drain bolt (3) at the water pump (4) to drain coolant.
134-164.qxd 06.5.11 13:15 ページ136 You & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally-responsible motorcycle owner. • Choose Sensible Cleaners. Use a biodegradable detergent when you wash your CRF.
134-164.qxd 06.5.11 13:15 ページ137 Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis. The items that require use of the Honda Service Manual are followed by an asterisk. ENGINE DOES NOT START OR IS HAND TO START CHECK 1. Check the fuel flow to carburetor GOOD SPARK 3. Test cylinder compression* WEAK OR NO SPARK LOW CORRECT 4. Start by following normal starting procedure ENGINE STARTS BUT SOON STOPS ENGINE DOES NOT FIRE 5.
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134-164.qxd 06.5.11 13:15 ページ139 Technical Information This section contains dimensions, capacities, and other technical data. Vehicle Identification .......................................140 Specifications ...................................................141 Torque Specifications.......................................142 Oxygenated Fuels.............................................145 Competition Logbook ......................................146 Optional Parts List ....................................
134-164.qxd 06.5.11 13:15 ページ140 Vehicle Identification The engine number (2) is stamped on the left crankcase. Serial Numbers The VIN and engine serial numbers 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 streering head.
134-164.qxd 06.5.11 13:15 ページ141 Specifications Item English 86.3 in Overall width 32.5 in 825 mm Overall height 49.7 in 1,262 mm 2,191 mm Wheelbase 58.9 in 1,495 mm Seat height 37.6 in 955 mm Footpeg height 17.0 in 432 mm Ground clearance 13.3 in 339 mm F. suspension R. suspension Tire size, front Tire size, rear Twin tube Telescopic fork, travel 11.0 in (280 mm) stroke 12.4 in (315 mm) Pro-link, travel 12.
134-164.qxd 06.5.11 13:15 ページ142 Torque Specifications Nuts, Bolts, Fasteners Check and tighten nuts, bolts, and fasteners before every outing.
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134-164.qxd 06.5.11 13:15 ページ145 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel’s contents.
134-164.qxd 06.5.11 13:15 ページ146 Competition Logbook Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events. The best way to organize the many bits of information is to record them in a logbook. Your logbook can include such information as suspension adjustments, carburetor adjustments, gearing, and tire selection. This detailed information, along with your comments, can prove valuable when you compete at the same track or on similar terrain.
134-164.qxd 06.5.11 13:15 ページ147 Competition Logbook Date Running Time Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.
134-164.qxd 06.5.11 13:15 ページ148 Optional Parts List These parts and tools may be ordered from your authorized Honda dealer. CARBURETOR Main jet (Standard: #178) Remarks #168 – #188 (in increments of 2 or 3) FRAME Driven sprocket Standard Optional 168 Size Slow jet (Standard: #42) #38 – #48 (in increments of 2 or 3) Jet Needles Standard needle: NJYR Straight diameter: ø2.755 mm Drive chain size/link Handlebar lower holder Optional Remarks < >: Drive chain links 48 Teeth, Aluminum.
134-164.qxd 06.5.11 13:15 ページ149 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.
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134-164.qxd 06.5.11 13:15 ページ151 Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual. Authorized Manuals .........................................152 Contacting Honda.............................................153 Your Honda Dealer...........................................154 The Honda Rider’s Club ..................................
134-164.qxd 06.5.11 13:15 ページ152 Authorized Manuals The Service Manual used by your authorized Honda dealer is available from Helm, Inc. 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 common to all Honda motorcycles, motor scooters and ATVs.
134-164.qxd 06.5.11 13:15 ページ153 Contacting Honda Your owner’s manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner’s manual can be answered by your Honda dealer. If he doesn’t have the answer right away, he will get it for you. If you have a difference of opinion with your dealer, please remember that each dealership is independently owned and operated. That’s why it’s important to work to resolve any differences at the dealership level.
134-164.qxd 06.5.11 13:15 ページ154 Your Honda Dealer Once you purchase your new Honda, get familiar with the organization of your Honda dealer so you can utilize the full range of services available. Your dealer can inform you about competition events in your area. You’ll also find that your dealer is a source of information the Honda Rider’s Club of America. The service department is there to perform regular maintenance and unexpected repairs. It has the latest available service information from Honda.
134-164.qxd 06.5.11 13:15 ページ155 The Honda Rider’s Club One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider’s Club of America. Your purchase of a new motorcycle, scooter, ATV or PWC from a participating U.S. Honda dealer entitles you to a complimentary one-year membership in the Club. There are hundreds of HRCA Chapter-sponsoring dealers across the USA with events and activities almost every weekend.
134-164.qxd 06.5.11 13:15 ページ156 Table of Contents The following presents the contents of each section of your owner’s manual. MOTORCYCLE SAFETY...............................1 Important Safety Information..............................2 Important Safety Precautions..........................2 Accessories & Modifications ..............................3 Safety Labels.......................................................4 OPERATING CONTROLS .............................5 Operation Component Locations ........
134-164.qxd 06.5.11 13:15 ページ157 Table of Contents ADJUSTMENTS FOR COMPETITION .....95 Front Suspension Adjustments..........................96 Front Suspension Air Pressure......................96 Front Suspension Damping ..........................96 Fork Springs..................................................97 Front Suspension Disassembly .....................97 Damper Oil Change ....................................100 Fork Assembly ............................................
134-164.qxd 06.5.11 13:15 ページ158 Index A C accessories...........................................................3 adjustments, altitude and temperature.............................124 carburetor ...................................................126 chassis ........................................................129 control freeplay .............................44,49,53,77 for competition.............................................95 gearing........................................................
134-164.qxd 06.5.11 13:15 ページ159 Index G gap, spark plug ..................................................54 gasohol ............................................................145 gasoline..............................................................34 gearing.............................................................130 guidelines, suspension adjustment ..................114 H handlebar inspection..........................................90 Honda, contacting ..........................................
134-164.qxd 06.5.11 13:15 ページ160 Index suspension, front ..............................................................73 rear................................................................74 suspension adjustment, front ..............................................................96 rear..............................................................109 for track conditions ....................................113 guidelines ...................................................114 T transmission oil .......
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134-164.qxd 06.5.11 13:15 ページ164 Quick Reference The following is a brief, but important collection of information you need to know about your Honda. You’ll also find space to record important notes. Record important information here: VIN Engine No. Owner’s: Name How To Avoid Costly Repairs Address City/State The engine of your Honda can be the most expensive component to repair. Proper maintenance, especially the use of the recommended fluids and filters, prevents premature wear and damage.
