Honda CRF250R (2017) Manual
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Contents
Contents
MOTORCYCLE SAFETY............................. 1
Important Safety Information ........................... 2
Important Safety Precautions ........................ 2
Accessories & Modifications ........................... 3
Safety Labels .................................................... 4
INSTRUMENTS & CONTROLS .................. 5
Operation Component Locations ...................... 6
MIL (Malfunction Indicator Lamp) ................. 7
MIL Blink Pattern ......................................... 7
Current DTC/Freeze DTC............................. 7
Circuit Inspection .......................................... 8
DTC Index..................................................... 9
Mode Indicator ............................................... 10
BEFORE RIDING......................................... 11
Are You Ready to Ride? ................................ 12
Is Your Motorcycle Ready to Ride? ............... 13
Pre-ride Inspection ...................................... 13
BASIC OPERATING INSTRUCTIONS .... 15
Safe Riding Precautions .............................. 16
Starting & Stopping the Engine ...................... 17
Fast Idle Knob ............................................. 17
Preparation .................................................. 17
Starting Procedure ....................................... 17
How to Stop the Engine .............................. 18
Break-in Guidelines ........................................ 19
SERVICING YOUR HONDA ...................... 21
Before You Service Your Honda
The Importance of Maintenance .....................22
Maintenance Safety .........................................23
Important Safety Precautions.......................23
Maintenance Schedule ....................................24
General Competition Maintenance .................26
Before & After Competition Maintenance .....30
Between Motos & Practice Maintenance..... 30
After Competition Maintenance ..................32
Service Preparations
Maintenance Component Locations ............... 33
Seat ..................................................................34
Fuel Tank ........................................................35
Subframe .........................................................38
Service Procedures
Fluids & Filters
Fuel System .....................................................40
Engine Oil .......................................................49
Transmission Oil .............................................52
Coolant ............................................................54
Air Cleaner ......................................................56
Crankcase Breather .........................................58
Engine
Throttle ............................................................59
Engine Idle Speed ...........................................61
Clutch System .................................................62
Spark Plug .......................................................67
Valve Clearance ..............................................68
Piston/Piston Rings/Piston Pin ........................77
Chassis
Suspension ...................................................... 87
Brakes ........................................................... 111
Wheels .......................................................... 115
Tires & Tubes ............................................... 116
Drive Chain .................................................. 118
Exhaust Pipe/Muffler .................................... 121
Steering Damper ........................................... 125
Additional Maintenance Procedures ............. 128
Appearance Care .......................................... 130
31KRN730 MOM 15799 (1603)CRF250R
Introduction
Introduction
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.
Be aware that motocross is a physically demanding
sport that requires more than just a fine
motorcycle. To do well, you must be in excellent
physical condition and be a skillful rider. For the
best results, work diligently on your physical
conditioning and practice frequently.
Before riding, take time to get acquainted with
your CRF and how it works. To protect your
investment, we urge you to take responsibility for
keeping your CRF well maintained. Scheduled
service is a must, of course. But it’s just as
important to observe the break-in guidelines, and
perform all the pre-ride and other periodic checks
detailed in this manual.
You should also read the owner’s manual before
you ride. It’s full of facts, instructions, safety
information, and helpful tips. To make it easy to
use, the manual contains a table of contents, a
detailed list of topics at the beginning of each
section, and an index at the back of the book.
As you read this manual, you will find information
that is preceded by a symbol. This
information is intended to help you avoid damage
to your CRF, other property, or the environment.
Unless you are mechanically qualified and have
the proper tools, you should see your dealer for the
service and adjustment procedures discussed in
this manual.
An official Honda Service Manual for your CRF is
available (page 174). It is the same manual your
dealer uses. If you plan to do any service on your
CRF beyond the standard maintenance procedures
in this manual, you will find an official Honda
Service Manual a valuable reference.
If you have any questions, or if you ever need a
special service or repairs, remember that your
Honda dealer knows your CRF best and is
dedicated to your complete satisfaction.
Please report any change of address or ownership
to your dealer so we will be able to contact you
concerning important product information.
You may also want to visit our website at
USA: www.powersports.honda.com.
Canada: www.honda.ca.
Happy riding!
California Proposition 65 Warning
WARNING: This product contains or emits
chemicals known to the State of California to cause
cancer and birth defects or other reproductive
harm.
ABBREVIATION
Throughout this manual, the following
abbreviations are used to identify the respective
parts or system.
Abbrev. term Full term
CKP sensor Crankshaft Position sensor
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature
sensor
HPSD Honda Progressive Steering
Damper
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MIL Malfunction Indicator Lamp
PGM-FI Programmed Fuel Injection
TDC Top Dead Center
TP sensor Throttle Position sensor
Motorcycle Safety
Motorcycle Safety 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 safety labels on
your CRF.
Important Safety Information ............................2
Important Safety Precautions.........................2
Accessories & Modifications.............................3
Safety Labels......................................................4
Accessories & Modifications
Motorcycle Safety 3
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.
Accessories & Modifications
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.
Safety Labels
4Motorcycle Safety
Read these labels carefully and don’t remove them.
If a label comes off or becomes hard to read, contact your dealer for replacement.
Safety Labels
Operation Component Locations
6Instruments & Controls
Operation Component Locations
clutch lever
engine stop button
front brake lever
throttle grip
MIL
engine mode select button/
mode indicator
fast idle knob
(engine idle speed)
shift lever
kickstarter
rear brake pedal
MIL (Malfunction Indicator Lamp)
Instruments & Controls 7
MIL (Malfunction Indicator Lamp)
The MIL (1) on your CRF keeps you informed,
alerts you to possible problems, and makes your
riding safer and more enjoyable. Refer to the MIL
frequently.
The MIL flashes when there is any abnormality in
the PGM-FI system. It should also light for a few
seconds and then go off when the engine is started.
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 174).
If the MIL does not come on when it should, have
your dealer check it for problems.
The MIL will blink the appropriate DTC number if
the ECM detects an active problem while the
engine is running at less than 5,500 rpm.
The MIL will stay on when engine speed is over
5,500 rpm.
The MIL has two types of blinks: a long blink and
short blink. The long blinking lasts for 1.2 seconds,
the short blinking lasts for 0.4 seconds.
One long blink is the equivalent of ten short blinks.
For example, when one long blink is followed by
two short blinks, the MIL is 12 (one long blink =
10 blinks, plus two short blinks).
When the ECM stores more than one DTC, the
MIL will indicate them by blinking in the order
from the lowest number to highest number.
The DTC is indicated in two ways according to the
failure status.
– In the case that the ECM detects an active
problem, the MIL will come on and will start to
blink the DTC when the engine is started.
– In the case that the ECM does not detect an
active problem but has recorded a previous
problem in its memory, the MIL will not come
on. If it is necessary to retrieve any past
problems stored in the memory, refer to an
official Honda Service Manual.
(1) MIL
(1)
MIL Blink Pattern Current DTC/Freeze DTC
8Instruments & Controls
MIL (Malfunction Indicator Lamp)
Always clean around the ECM and keep debris
away from the connectors before disconnecting
them.
A faulty PGM-FI system is often related to poorly
connected or corroded connections. Check the
following connections.
Remember, circuit inspection is not a “cure-all” for
other problems in your engine’s PGM-FI system.
Circuit Inspection
(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
(1) (5) (4)
(6)
(2)
(3)
(7)
Instruments & Controls 9
MIL (Malfunction Indicator Lamp)
Refer to MIL Blink Pattern on page 7.
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 and you
need the proper tools to check these codes. Take unit to a dealer.
If the engine does not start, check all connector connections and/or refer to an official Honda Service
Manual (page 174) for troubleshooting of the PGM-FI symptom.
DTC Index
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
12 Injector circuit malfunction • Engine does not start
• Injector, fuel pump and ignition shut down
19 No.1 CKP sensor circuit malfunction • Engine does not start
• Injector, fuel pump and ignition shut down
69 No.2 CKP sensor circuit malfunction • Engine does not start
• Injector, fuel pump and ignition shut down
Mode Indicator
10 Instruments & Controls
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.
The mode indicator indicates a selected mode
when you operate the engine mode select button
(page 134).
If the mode indicator stays on or does not come on
when it should, have your dealer check it for
problems.
(1) mode indicator
(2) engine mode select button
(2) (1)
Are You Ready to Ride?
12 Before Riding
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, steering
damper, and other adjustments, see page 133.
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.
WARNING
Not wearing a helmet increases the
chance of serious injury or death in a
crash.
Be sure you always wear a helmet, eye
protection and other protective apparel
when you ride.
Is Your Motorcycle Ready to Ride?
Before Riding 13
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): Check the following before each ride:
• Engine oil level ........................................... 50
• Transmission oil level................................. 53
• Fuel line for condition ................................ 40
• Coolant for proper level.............................. 54
• Cooling system and hoses for condition..... 55
• Spark plug for proper heat range, carbon
fouling and spark plug wire terminal for
looseness ..................................................... 67
• Air cleaner for condition and
contamination ............................................. 56
• Clutch lever adjustment and freeplay ......... 62
• Breather drain for cleaning ......................... 58
• Steering head bearing and related parts for
condition ................................................... 128
• Steering damper operation ........................ 125
• Throttle operation ....................................... 59
• Tires for damage or improper inflation
pressure ..................................................... 116
• Spokes for looseness................................. 115
• Rim locks for looseness ............................ 115
• Left fork air pressure................................. 136
• Front and rear suspension for proper
operation ............................................... 87, 88
• Front and rear brakes, check operation..... 111
• Drive chain for correct slack and adequate
lubrication ......................................... 118, 119
• Drive chain sliders and drive chain rollers
for damage or wear ........................... 118, 119
• Exhaust pipe/Muffler for looseness .......... 121
• Every possible part for looseness (such as
cylinder head bolts, engine mounting bolts/
nuts, axle nuts, handlebar holder bolts/nuts,
fork bridge pinch bolts, drive chain adjuster
lock nuts, drive chain roller bolt/nut, wire
harness connectors, kickstarter arm
bolt).................................................... 164-166
• MIL operation ............................................... 7
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.
Pre-ride Inspection
14 Before Riding
BLACK PAGE
Basic Operating Instructions
Basic Operating Instructions 15
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...............................16
Starting & Stopping the Engine .......................17
Fast Idle Knob..............................................17
Preparation...................................................17
Starting Procedure........................................ 17
How to Stop the Engine ...............................18
Break-in Guidelines .........................................19
Basic Operating Instructions
16 Basic Operating Instructions
Basic Operating Instructions
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.
Safe Riding Precautions
WARNING
Running the engine of your vehicle while
in an enclosed or even partially enclosed
area can cause a rapid build-up of toxic
carbon monoxide gas.
Breathing this colorless, odorless gas can
quickly cause unconsciousness and lead
to death.
Only run your vehicle's engine when it is
located in a well ventilated area outdoors.
Starting & Stopping the Engine
Basic Operating Instructions 17
Starting & Stopping the Engine
Always follow the proper starting procedure
described below.
Your CRF can be kickstarted with the transmission
in gear by pulling in the clutch lever before
operating the kickstarter.
The fast idle knob has two functions:
• When pulled out, the fast idle knob assists in
first-time start-up for cold weather starting.
• When pushed in, it acts like an idle adjustment
screw. Refer to Idle Speed Adjustment on
page 61.
Make sure that the transmission is in neutral.
Always follow the proper starting procedure
described as follows.
Check the engine oil, transmission oil and coolant
levels before starting the engine (pages 50, 53, 54).
Cold Engine Starting
1. Shift the transmission into neutral.
2. If the temperature is 95°F (35°C) or below,
pull the fast idle knob (1) fully out.
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.
Warm Engine Starting
1. Shift the transmission into neutral.
2. Kick-start the engine. (Do not open the
throttle.)
If Difficult to Start After Stalling
1. Shift the transmission into neutral.
2. With the throttle fully opened, repeat
kickstarter operation approximately 10 times
to discharge excessive fuel from the engine.
3. Kick-start the engine. (Do not open the
throttle.)
Snapping the throttle or fast idling for more than
about 5 minutes may cause exhaust pipe and
muffler discolorations.
Fast Idle Knob
Preparation
Starting Procedure
(1) fast idle knob
(1)
Break-in Guidelines
Basic Operating Instructions 19
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
The front suspension will feel stiff until after
break-in (approximately 1 hour), this is normal.
Servicing Your Honda
Servicing Your Honda 21
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. You’ll also find important
safety precautions, information on oils, and tips for
keeping your CRF looking good.
An ECM system is used on this motorcycle;
consequently, routine ignition timing adjustment is
unnecessary. If you want to check the ignition
timing, refer to an official Honda Service Manual
(page 174).
An optional tool kit may be available. Check with
your dealer’s parts department.
Before You Service Your Honda
The Importance of Maintenance ......................22
Maintenance Safety..........................................23
Important Safety Precautions.......................23
Maintenance Schedule .....................................24
General Competition Maintenance ..................26
Before & After Competition Maintenance ......30
Between Motos & Practice Maintenance.....30
After Competition Maintenance ..................32
Service Preparations
Maintenance Component Locations ................33
Seat...................................................................34
Fuel Tank .........................................................35
Subframe ..........................................................38
Service Procedures
Fluids & Filters
Fuel System......................................................40
Engine Oil ........................................................49
Transmission Oil.............................................. 52
Coolant.............................................................54
Air Cleaner.......................................................56
Crankcase Breather ..........................................58
Engine
Throttle.............................................................59
Engine Idle Speed ............................................61
Clutch System ..................................................62
Spark Plug........................................................67
Valve Clearance ...............................................68
Piston/Piston Rings/Piston Pin.........................77
Chassis
Suspension....................................................... 87
Front Suspension Inspection ....................... 87
Rear Suspension Inspection......................... 88
Fork Removal .............................................. 89
Recommended Fork Oil .............................. 91
Right Fork Oil Change ................................ 91
Right Fork Disassembly .............................. 93
Damper Oil Change..................................... 95
Right Fork Assembly................................... 97
Left Fork Oil Change ................................ 100
Fork Installation ........................................ 107
Brakes ............................................................ 111
Wheels ........................................................... 115
Tires & Tubes ................................................ 116
Drive Chain ................................................... 118
Exhaust Pipe/Muffler..................................... 121
Steering Damper............................................ 125
Additional Maintenance Procedures.............. 128
Appearance Care ........................................... 130
The Importance of Maintenance
22 Servicing Your Honda
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.
Maintenance Safety
Servicing Your Honda 23
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.
• 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.
• Read the instructions before you begin, and
make sure you have the tools and skills
required.
• To help prevent the motorcycle from falling
over, park it on a firm, level surface, using an
optional workstand or a maintenance stand to
provide support.
• To reduce the possibility of a fire or explosion,
be careful when working around gasoline. Use
only a non-flammable (high flash point)
solvent such as kerosene –not gasoline– to
clean parts. Keep cigarettes, sparks, and flames
away from all fuel-related parts.
WARNING
Failure to properly follow maintenance
instructions and precautions can cause
you to be seriously hurt or killed.
Always follow the procedures and
precautions in this owner’s manual.
Important Safety Precautions
Maintenance Schedule
24 Servicing Your Honda
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.
Therefore, we recommend that you have your
dealer perform these tasks unless you have
advanced mechanical skills and the required tools.
Procedures for items in this schedule are provided
in an official Honda Service Manual available for
purchase from your dealer (page 174).
Service intervals in the maintenance schedule are
expressed in terms of races and riding hours. To
avoid overlooking required service, we urge you to
develop a convenient way to record the number of
races and/or hours you ride.
If you do not feel capable of performing a given
task or need assistance, remember that your Honda
dealer knows your CRF best and is fully equipped
to maintain and repair it. If you decide to do your
own maintenance, use only Honda Genuine Parts
or their equivalents for repair or replacement to
ensure the best quality and reliability.
Perform the (page 13) at each pre-ride inspection
scheduled maintenance period.
Summary of Maintenance Schedule Notes and
Procedures:
Notes:
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.
Maintenance Procedures:
I : inspect and clean, adjust, lubricate or replace if
necessary
C: clean
A: adjust
L : lubricate
R: replace
General Competition Maintenance
26 Servicing Your Honda
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 specied 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.
General Competition Maintenance
Servicing Your Honda 27
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 25).
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.
Air Cleaner
Clean and oil your air cleaner regularly because the volume
of air able to pass through it has a great effect on
performance. Both engine performance and long term
durability may be affected by an air cleaner that has
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 56).
Use the Honda Genuine air cleaner or an equivalent air
cleaner specified for your model.
Using the wrong Honda air cleaner or a non-Honda air
cleaner which is not of equivalent quality may cause
premature engine wear or performance problems.
Engine Oil and Filter
Drain and replace engine oil often to ensure the greatest
service life of the piston, cylinder and crankshaft.
Also replace engine oil lter often to ensure the greatest
service life. Frequent changes will also assure consistent
performance of power and response (page 50).
Air Cleaner Housing Sealing
Remove and reseal the air cleaner connecting tube where it
connects to the air cleaner housing with Pro Honda Handgrip
Cement or an equivalent if there is any doubt to its sealing
integrity. Inspect the air cleaner and air intake tract regularly
for signs of deterioration or dirt penetration.
Transmission Oil
Drain and replace transmission oil often to ensure the greatest
service life of the transmission and clutch. Frequent changes
will also assure consistent performance of both shifting and
clutch action (page 53).
Left Fork Air Pressure
Set the left fork air pressure within the specified range
(page 136).
General Competition Maintenance
Servicing Your Honda 29
Brake Fluid Replacement
Refer to Brake Pad Wear on page 114.
Brake Caliper Inspection: Be sure both the front and rear
calipers are able to move freely on the caliper pin and caliper
bracket pins. Check pad thickness periodically and replace the
pads when minimum thickness is reached. If the brakes fade
when they are hot, inspect the pads for glazing or damage, and
replace if necessary.
Brake Fluid Replacement: Refer to an official Honda Service
Manual (page 174) for brake fluid replacement instructions.
Replace the brake fluid in the brake system every 2 years.
Replace the fluid more frequently if you subject your brakes to
severe use. Heavy braking heats the brake fluid and it may
deteriorate sooner than expected. Any type of riding, that
requires frequent use of the brakes, such as in tight woods, can
shorten the service life of brake fluid.
Bleed Hole
After every race, check the bleed hole below the water pump
cover for leakage. Clean away any clogged dirt or sand, if
necessary. Check the bleed hole of the water pump for signs
of seal leakage. If water leaks through the bleed hole, replace
the mechanical seal. If oil leaks through the bleed hole, replace
the oil seal. Make sure that there is no continuous coolant
leakage from the bleed hole while operating the engine. A
small amount of coolant weeping from the bleed hole is
normal. See an official Honda Service Manual or consult your
dealer for replacing the mechanical seal or oil seal. Both seals
should be replaced at the same time.
Suspension Linkage Lubrication
Disassemble, clean, inspect and lubricate all suspension linkage
pivot bearings with molybdenum disulfide grease (containing
more than 3% molybdenum disulfide additive) after each 7.5
hours of running time in order to maintain proper suspension
performance and minimize component wear.
Footpegs
Worn footpeg teeth can be repaired by filing the grooves
between the teeth with a triangular shaped file.
Be aware that ling them too sharp will reduce boot sole
lifespan. Sharpen only the points of the teeth. Filing the
grooves deeper will weaken the footpegs. Be sure the pegs
are free to pivot freely and that the pivot pin retaining cotter
pins are in good condition.
Swingarm
Do not attempt to weld or otherwise repair a damaged
swingarm. Welding will weaken the swingarm.
Swingarm Pivot Lubrication
Clean, inspect and lubricate the swingarm and suspension
linkage pivots with molybdenum disulde grease (containing
more than 3% molybdenum disulfide additive) after each 7.5
hours of running time in order to maintain proper suspension
performance and minimize component wear. Be sure all of the
dust seals are in good condition.
Handgrips
Always use Pro Honda Handgrip Cement or an equivalent
when replacing handgrips.
Refer to an official Honda Service Manual (page 174) for
installation instructions.
Throttle Grip
Right throttle grip: Align the index mark on the throttle grip
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.
For added security, you may choose to bind the handgrips to
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.
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
sure there is no cable interference. Make certain the throttle
operation is perfect after servicing and inspecting.
32 Servicing Your Honda
Before & After Competition Maintenance
It is important to the long term performance of
your CRF to practice a consistent maintenance
program. Right after the event is a good time to
begin your next maintenance cycle.
After Race Lubrication
Apply a light coating of rust-inhibiting oil to the
drive sprocket and any steel portions of the chassis
or engine where the paint has worn away.
This will prevent rusting of the exposed metal.
Apply rust-inhibiting oil more heavily if the event
was particularly wet or muddy. Take care to avoid
spraying any oil near the brake pads or the brake
discs.
Take care to prevent catching your fingers between
the chain and sprocket.
Remove the drive chain, clean and lubricate it
(pages 119, 120). Be sure the chain is wiped clean
and is dry before lubricating the chain.
Routine Cleaning
If your CRF is only slightly dirty, it is best to clean
it by hand with the aid of a stiff bristled nylon
brush and some clean rags.
Take care to prevent catching your fingers between
the chain and sprocket.
A variety of reasonably priced cleaning brushes
are available from variety, drug, food, and
hardware stores. Some of these brushes are
extremely useful in removing dirt from the many
tight contours of the metal pieces of your CRF.
Avoid using sti, abrasive brushes on the plastic or
rubber parts.
If your CRF was exposed to sea air or salt water,
rinse it as soon as possible after the event, dry it,
and apply a spray lubricant to all metal parts.
If you decide to wash your CRF or use cleaners,
refer to (page 130).Appearance Care
After Competition Maintenance
Maintenance Component Locations
Servicing Your Honda 33
Maintenance Component Locations
clutch lever
front brake fluid reservoir
front brake lever
throttle grip
radiator cap
fuel fill cap
air bleed bolt
spark plug
fast idle knob
(engine idle speed)
air cleaner
crankcase
breather
tube B
drive chain
transmission oil
drain bolt
engine oil filter
front brake
caliper
engine oil fill cap/dipstick rear suspension
spring pre-load
adjuster
crankcase breather tube A
left front suspension balance chamber air valve
• left front suspension inner chamber air valve
• left front suspension outer chamber air valve
right front suspension
compression damping adjuster
steering damper
adjuster
right front suspension
rebound damping
adjuster
transmission oil
check bolt
engine oil
drain bolt
rear brake
pedal
rear brake fluid
reservoir
rear brake
caliper
rear suspension rebound
damping adjuster
• rear suspension high speed
compression damping
adjuster
• rear suspension low speed
compression damping
adjuster
transmission
oil fill cap
Seat
34 Servicing Your Honda
Seat
Refer to Important Safety Precautions on page 23.
Removal
1. Remove the seat mounting bolts (1).
2. Remove the seat (2) by sliding it backward.
Installation
1. Install the seat while aligning the seat front slit
(1) with the front seat bracket (2) and seat
prong (3) with the seat stopper plate (4).
2. Install and tighten the seat mounting bolts (5)
to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
(1) seat mounting bolts (2) seat
(2)
(1)
(1) seat front slit (4) seat stopper plate
(2) front seat bracket (5) seat mounting bolts
(3) seat prong
(1) (3)
(2)
(4) (5)
Fuel Tank
(cont’d)
Servicing Your Honda 35
Fuel Tank
Refer to Important Safety Precautions on page 23.
Removal
1. Remove the seat (page 34).
2. Remove the shroud A bolts and collars (1).
3. Remove the shroud B bolts (2).
4. Slide the shrouds (3) toward the front to
separate them from the air cleaner housing
covers (4).
5. Slide the shrouds toward the rear until their
hooks (5) are aligned with the recesses (6) of
the fuel tank.
6. Turn the shrouds as shown in the figure, and
then remove them.
The right and left shrouds can be removed in the
same manner.
7. Install a hose clamp (7) to the breather tube (8)
and shut the hose clamp securely.
8. Pull the breather tube (8) out of steering stem
nut.
9. Unhook the fuel tank band (9) and air cleaner
rubber (10).
10. Remove the fuel tank bolt and collar (11).
11. Remove the clamp A (12) from the throttle
cable (13) and fuel pump wire (14).
12. Unhook the fuel feed hose (15) from the clamp
B (16).
(1) shroud A bolts and collars
(2) shroud B bolts
(3) shrouds
(4) air cleaner housing covers
(4)
(3)
(1)
(2)
(5) hooks (6) recesses
(7) hose clamp (8) breather tube
(6)
(5)
(8)
(7)
(8) breather tube
(9) fuel tank band
(10) air cleaner rubber
(11) fuel tank bolt and collar
(12) clamp A (15) fuel feed hose
(13) throttle cable (16) clamp B
(14) fuel pump wire
(8)
(11)
(10)
(9)
(12)
(14) (13)
(15)
(16)
36 Servicing Your Honda
Fuel Tank
13. Pull the fuel tank (17) out of the frame and
hang it to the left of the frame.
Check the fuel tank stopper cable (18) for
deterioration, kinks or other damage.
Do not support the fuel tank by the fuel feed hose
(15).
14. Check for interference between the frame and
tank and adjust the cushion rubbers (19) if
necessary.
Installation
1. Install the fuel feed hose (1) to the clamp B (2).
2. Attach the clamp A (3) to the white tape (4) on
the throttle cable (5) and fuel pump wire (6).
3. Install the fuel tank (7) on the frame.
4. Install the collar and fuel tank bolt (8).
5. Hook the air cleaner rubber (9) and the fuel
tank band (10).
WARNING
Gasoline is highly flammable and
explosive.You can be burned or seriously
injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
(15) fuel feed hose (18) fuel tank stopper cable
(17) fuel tank
(17)
(18)(15)
(19) cushion rubbers
7.1 – 7.5 in
(180 – 190 mm)
0 – 0.4 in
(0 – 10 mm)
(19)
(19)
(1) fuel feed hose (4) white tape
(2) clamp B (5) throttle cable
(3) clamp A (6) fuel pump wire
(7) fuel tank
(8) collar and fuel tank bolt
(9) air cleaner rubber
(10) fuel tank band
(3)
(6) (5)
(1)
(2)
(4)
(8)
(7)
(10)
(9)
Servicing Your Honda 37
Fuel Tank
6. Put the breather tube (11) in the steering stem
nut (12).
7. Remove the hose clamp (13) from the breather
tube.
8. Align the shroud hooks (14) with the recesses
(15) of the fuel tank.
9. Turn the shrouds (16) and hook them onto the
frame (17).
10. Slide the shrouds (16) toward the rear so that
the shrouds and the tabs (18) on the air cleaner
housing covers are aligned.
11. Install the shroud B bolts (19), collars and
shroud A bolts (20).
Tighten the shroud B bolts to the specified
torque:
3.8 lbf·ft (5.2 N·m, 0.5 kgf·m)
12. Install the seat (page 34).
(11) breather tube (13) hose clamp
(12) steering stem nut
(14) shroud hooks
(15) recesses
(16) shrouds
(17) frame
(12) (11)
(13)
(15)
(14)
(17)
(16)
(16) shrouds
(18) air cleaner housing cover tabs
(19) shroud B bolts
(20) collars and shroud A bolts
(16)
(18)
(19)
(20)
Subframe
38 Servicing Your Honda
Subframe
Refer to Important Safety Precautions on page 23.
Removal
1. Remove the seat (page 34).
2. Remove the right and left mufflers (page 121).
3. Remove the rear fender mounting bolts, nuts
(1) and rear fender (2) backward.
4. Remove the air cleaner case (3) from the
bosses (4) of the subframe.
5. Remove the air cleaner mounting bolts (5) and
unhook the fuel tank band (6).
6. Remove the subframe lower bolts (7) and
subframe upper bolts (8).
Remove the subframe (9).
Installation
1. Loosely attach the upper and lower ends of the
subframe to the main frame and loosely install
all subframe bolts.
2. Tighten the subframe upper bolts (1) and
subframe lower bolts (2) to the specified
torque:
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)
(1) rear fender mounting bolts and nuts
(2) rear fender
(3) air cleaner case (4) subframe bosses
(1) (2)
(3)
(3)
(4)
(5) air cleaner mounting bolts
(6) fuel tank band
(7) subframe lower bolts
(8) subframe upper bolts
(9) subframe
(6)
(5)
Left side:
(8)
(7)
(9) (9)
(8)
(7)
Right side:
(1) subframe upper bolts
(2) subframe lower bolts
(1)
(2) (2)
(1)
Left side: Right side:
Servicing Your Honda 39
Subframe
3. Install the air cleaner case (3) to the bosses (4)
of the subframe.
4. Install the rear fender (5) and align the hole in
the rear fender with the hole in the subframe,
and then install the rear fender mounting bolts
and nuts (6).
5. Hook the fuel tank band (7).
6. Install the air cleaner mounting bolts (8).
7. Install the left and right mufflers (page 122).
8. Install the seat (page 34).
(3) air cleaner case (4) subframe bosses
(5) rear fender
(6) rear fender mounting bolts and nuts
(4)
(3)
(3)
(6) (5)
(7) fuel tank band
(8) air cleaner mounting bolts
(7)
(8)
Fuel System
40 Servicing Your Honda
Fuel System
Refer to Important Safety Precautions on page 23.
Use only unleaded fuel in your CRF. If you ride
your CRF in a country where leaded fuel might be
available, take precautions to use only unleaded
fuel.
Your engine is designed to use any unleaded
gasoline that has a pump octane number of 91 or
higher. Gasoline pumps at service stations
normally display the pump octane number.
For information on the use of oxygenated fuels, see
page 167.
Use of lower octane gasoline can cause persistent
“pinging” or “spark knock” (a louder rapping
noise) which, if severe, can lead to engine damage.
(Light pinging experienced while operating under
a heavy load, such as climbing a hill, is no cause
for concern.)
If pinging or spark knock occurs at a steady engine
speed under normal load, change brands of
gasoline. If pinging or spark knock persists,
consult your dealer.
Never use stale or contaminated gasoline. Avoid
getting dirt, dust or water in the fuel tank.
1. To open the fuel fill cap (1), pull the breather
tube (2) out of the steering stem nut (3). Turn
the fuel fill cap counterclockwise and remove
it.
2. Add fuel until the level reaches the bottom of
the filler neck (4).
Fuel Tank Capacity: 1.66 US gal (6.3 ℓ)
• Be careful not to damage the fuel pump while
filling the fuel tank.
• Avoid overfilling the tank. There should be no
fuel in the filler neck.
3. Close the fuel fill cap and insert the breather
tube in the steering stem nut.
1. Hang the fuel tank to the left side of the frame
(page 35).
2. Remove the fuel quick connect fitting cover
(1).
3. Check the fuel line (2) for cracks,
deterioration, damage or leakage. Replace the
fuel line, if necessary.
4. Install the fuel quick connect fitting cover.
5. Install the fuel tank (page 36).
Fuel
Type Unleaded
Pump Octane Number 91 (or higher)
Refueling Procedure
(1) fuel fill cap (3) steering stem nut
(2) breather tube (4) filler neck bottom
(1)
(2)(3)
(4)
WARNING
Gasoline is highly flammable and
explosive. You can be burned or seriously
injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
Fuel Line Inspection
(1) fuel quick connect fitting cover
(2) fuel line
(2)
(1)
Fuel System
(cont’d)
Servicing Your Honda 41
1. Hang the fuel tank to the left side of the frame
(page 35).
2. Release the fuel pump connector A (1) from
the stay (2) and disconnect it.
3. Reposition the fuel tank and start the engine
and let it idle until the engine stalls.
Disconnection
1. Relieve the fuel pressure (this page).
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.
5. Remove the bolt (4), clamp and setting rubber
(5).
6. Place a shop towel (6) over the fuel quick
connect fitting.
Fuel Pressure Relieving
(1) fuel pump connector A (2) stay
(2)
(1)
Fuel Line Replacement
(1) fuel quick connect fitting cover
(2) fuel pump
(3) fuel quick connect fitting
(4) bolt
(5) clamp and setting rubber
(4)
Fuel pump side: Injector side:
(2)(3)
(1) (3) (5)
(6) shop towel
(6)
Fuel pump side: Injector side:
42 Servicing Your Honda
Fuel System
7. Unlock the slide retainer (7) of the quick
connect fitting by completely pulling it up.
Release the fuel quick connect fitting from the
fuel joint (8) while holding the connector
housing (9).
• Use a shop towel to absorb the remaining
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.
8. Remove the rubber cover (10) from the fuel
joint of the fuel pump.
9. To prevent damage and keep foreign matter
out, cover the disconnected connectors (11)
and fuel joints (8) with plastic bags (12).
Connection
1. Install the rubber cover (1) onto the fuel joint
(2) of the fuel pump as shown.
2. Be sure that the slide retainer (3) is completely
pulled up before connecting the quick connect
fitting.
• Do not bend or twist the fuel feed hose.
• Do not reuse the kinked or damaged fuel
hose.
• Do not use gloves or a shop towel while
installing the quick connect fitting.
WARNING
Gasoline is highly flammable and
explosive. You can be burned or seriously
injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
(7) slide retainer
(8) fuel joint
(9) connector housing
(9)
(7)
(8)
(10) rubber cover
(8) fuel joint
(11) disconnected connectors
(12) plastic bags
(10)
(11)
(12)
(8)
(1) rubber cover (2) fuel joint
(3) slide retainer
(2)(1)
(3)
Servicing Your Honda 43
Fuel System
3. Connect the quick connect fitting to the fuel
joint (2) until you hear the “click” while
holding the connector housing (4).
Lock the slide retainer (3) by pushing it until
you hear the “click”.
If it is hard to connect, put a small amount of
engine oil on the pipe end of the fuel joint.
4. Make sure the connection is secure and that the
slide retainer is firmly locked into place; check
visually and by pulling the connector housing.
5. Install the setting rubber (5), clamp (6) and bolt
(7) by aligning the clamp tab (8) with the
groove (9) of the stay.
6. Install the fuel quick connect fitting cover (10).
Be sure the rubber cover (1) is properly installed
between the fuel quick connect fitting cover and
fuel pump.
7. Increase the fuel pressure (page 48).
(2) fuel joint
(3) slide retainer
(4) connector housing
(3)
(4) (2) (5) setting rubber (8) clamp tab
(6) clamp (9) groove
(7) bolt
(9)
(5)
(8)
(7) (6)
(1) rubber cover
(10) fuel quick connect fitting cover
(1)
(10)
44 Servicing Your Honda
Fuel System
Empty the fuel tank into an approved gasoline
container using a commercially available hand
siphon or an equivalent method.
Be careful not to damage the fuel pump while
draining the fuel in the fuel tank.
Removal
1. Relieve the fuel pressure (page 41).
2. Disconnect the fuel line from the fuel pump
(page 41).
3. Remove the fuel tank (1) by releasing the
stopper cable (2) from the hook (3) of the frame.
4. Disconnect the fuel pump connector B (4).
5. Remove the fuel pump mounting bolts (5),
stopper cable guide (6), stopper cable (2),
washers (7), collars (8), conical spring washers
(9) and fuel pump plate (10).
6. Remove the fuel pump unit (11) and O-rings
(12).
Be careful not to damage the fuel pump unit.
7. Disconnect the fuel pump wire terminals (13)
from the fuel pump base (14).
Be careful not to damage the wires when
disconnecting the fuel pump wire terminals.
Fuel Pump Filter Replacement
WARNING
Gasoline is highly flammable and
explosive. You can be burned or seriously
injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
(1) fuel tank (3) frame hook
(2) stopper cable
(1)
(3)
(2)
(2) stopper cable
(4) fuel pump connector B
(5) fuel pump mounting bolts
(6) stopper cable guide
(7) washers
(8) collars
(9) conical spring washers
(10) fuel pump plate
(2)(6)
(5)
(7)
(8)
(9)
(10)
(4)
(11) fuel pump unit (12) O-rings
(13) fuel pump wire terminals
(14) fuel pump base
(12)
(11)
(13)
(14)
Servicing Your Honda 45
Fuel System
8. Check the hooks (15) of the fuel pump unit
holder and tabs (16) on the fuel pump base for
damage or discoloration.
If the hooks and tabs are damaged or
discolored, replace the fuel pump unit as an
assembly.
9. Release the hooks of the fuel pump unit holder
from the grooves (17) in the fuel pump base
tabs while pushing the holder against the base
and slightly spreading the base tabs.
Be careful not to damage the hooks and tabs.
10. Remove the fuel pump unit holder assembly
(18) from the fuel pump base (14) and remove
the O-ring (19).
Wipe the spilled out fuel immediately.
11. Remove the fuel pump stopper (20) and
damper rubber (21).
12. Remove the fuel pump assembly (22) with fuel
pump filter (23), O-ring (24) from the fuel
pump unit holder (25).
13. Check the fuel pump filter (23) for clog,
damage or deterioration and replace it if
necessary.
14. Remove the fuel pump filter from the fuel
pump assembly (22).
(15) hooks (17) grooves
(16) tabs
(15)
(16)
(17)
(16) (17)
(14) fuel pump base
(18) fuel pump unit holder assembly
(19) O-ring
(20) fuel pump stopper
(21) damper rubber
(18)
(19)
(14)
(20)
(21)
(22) fuel pump assembly
(23) fuel pump filter
(24) O-ring
(25) fuel pump unit holder
(22) fuel pump assembly (23) fuel pump filter
(22)
(23)
(24)
(25)
(22)
(23)
46 Servicing Your Honda
Fuel System
Installation
1. Install a new fuel pump lter (1) onto the fuel
pump assembly (2) aligning its hook (3) with
the joint boss (4) completely.
Be careful not to damage the hook.
2. Apply small amount of engine oil to a new
O-ring (5).
Install a new O-ring to the fuel pump assembly
(6).
3. Install the fuel pump assembly with fuel pump
filter into the fuel pump unit holder (7) while
routing the fuel pump red (8) and black (9)
wires through the holder grooves (10) as
shown.
4. Install a new damper rubber (11) to the fuel
pump filter as shown.
Install the fuel pump stopper (12).
5. Apply small amount of engine oil to a new
O-ring (13).
Install a new O-ring to the fuel pump base (14).
6. Install the fuel pump unit holder assembly (15) into
the fuel pump base while aligning its hooks (16) with
the grooves (17) in the fuel pump base tabs (18).
If the gap between the hooks and tabs is more
than 0.04 in (1.0 mm), replace the fuel pump
unit.
Be sure that the hooks are completely seated.
7. Connect the fuel pump red (19) and black (20)
wire terminals to the fuel pump base terminals
(21). Push the wire terminals until they stop as
shown.
Be careful not to damage the wires.
8. Apply 0.02 oz (0.5 g) maximum of engine oil
to a new O-ring (22).
Install a new O-ring onto the fuel pump unit (23).
(1) fuel pump filter (new) (3) hook
(2) fuel pump assembly (4) joint boss
(1)
(2)
(3)
(4) (5) O-ring (new) (8) red wire
(6) fuel pump assembly (9) black wire
(7) fuel pump unit holder (10) grooves
(11) damper rubber (new) (12) fuel pump stopper
(8)
(6)
(7) (5)
(9)
(8)
(9)
(10)
(10)
(10)
(12)
(11)
(13) O-ring (new) (16) hooks
(14) fuel pump base (17) grooves
(15) fuel pump unit holder assembly (18) tabs
(19) red wire terminal (22) O-ring (new)
(20) black wire terminal (23) fuel pump unit
(21) fuel pump base terminals
(15)
(16)
(18)(17) (17) (18)
(13)
(14)
(23)
(22)
(19) (20)
(21)
(19) (20)
(21)
Servicing Your Honda 47
Fuel System
9. Apply small amount of engine oil to a new
O-ring (24).
Install a new O-ring into the fuel tank
groove.
10. Install the fuel pump unit (25) into the fuel tank
(26).
Be careful not to damage the wires.
11. Install the fuel pump plate (27) with its
identification mark (28) facing toward the
front side and facing up.
12. Install the conical spring washers (29), collars
(30), washers (31), stopper cable (32), stopper
cable guide (33) and fuel pump mounting bolts
(34).
Make sure that the convex surfaces of the conical
spring washers are upside.
13. Tighten the fuel pump mounting bolts to the
specified torque in the specified sequence as
shown:
8 lbf·ft (11 N·m, 1.1 kgf·m)
14. Connect the fuel pump connector B (35).
15. Install the stopper cable (32) to the hook (36)
of the frame while holding the fuel tank (26).
16. Connect the fuel line (page 42).
17. Increase the fuel pressure (page 48).
(24) O-ring (new) (26) fuel tank
(25) fuel pump unit
(27) fuel pump plate (28) identification mark
(26) (25)
(24)
(27)
(28)
(29) conical spring washers
(30) collars
(31) washers
(32) stopper cable
(33) stopper cable guide
(34) fuel pump mounting bolts
(34)(30)(29)
(32)
(29)
(33)
(30)
(31) (34)
(26) fuel tank (35) fuel pump connector B
(32) stopper cable (36) frame hook
1
3
5
2
4
6
(35)
(26)
(36)
(32)
Engine Oil
Servicing Your Honda 49
Engine Oil
Refer to Important Safety Precautions on page 23.
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.
*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.
• Your CRF does not need oil additives.
Use the recommended oil.
• Do not use API SH or higher 4-stroke engine oils
displaying a circular API “energy conserving” or
“resource conserving” service label on the
container. They may affect lubrication.
Other viscosities shown in the following chart may
be used when the average temperature in your
riding area is within the indicated range.
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.
Oil Recommendation
API
classification
SG or higher except oils
labeled as energy
conserving or resource
conserving on the circular
API service label
Viscosity
(weight)
SAE 10W-30
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
NOT RECOMMENDED OK
(1) oil code
(2) oil classification
(1)
(2)
50 Servicing Your Honda
Engine Oil
1. Run the engine at idle for 3 minutes, then shut
it off.
2. Wait 3 minutes after shutting off the engine to
allow the oil to properly distribute itself in the
engine.
3. Support the CRF in an upright position on a
level surface.
4. Remove the engine oil ll cap/dipstick (1),
wipe it clean, and insert it without screwing it
in. Remove the oil fill cap/dipstick.
5. Check that the oil level is between the upper
(2) and lower (3) level marks on the engine oil
fill cap/dipstick.
• If the oil is at or near the upper level mark,
you do not have to add oil.
• If the oil is below or near the lower level
mark, add the recommended oil until it
reaches the upper level mark. (Do not
overfill.)
Reinstall the engine oil fill cap/dipstick.
Repeat steps 1 – 5.
6. Check that the O-ring (4) is in good condition
and replace it if necessary.
7. Reinstall the engine oil fill cap/dipstick (1).
8. Check for oil leaks.
1. Run the engine at idle for 3 minutes, then shut it off.
2. Support the CRF in an upright position on a
level surface.
3. Remove the engine oil fill cap/dipstick (1)
from the left crankcase cover.
4. Place an oil drain pan under the engine to catch
the oil. Then remove the engine oil drain bolt
(2) and sealing washer (3).
5. With the engine stop button pushed, repeat
kickstarter operation approximately five times
to drain the engine oil completely.
6. After the oil has drained, apply engine oil to
the drain bolt threads and seating surface, then
tighten it with a new sealing washer to the
specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 158).
NOTICE
Improper disposal of drained fluids is harmful to
the environment.
Checking & Adding Oil
(1) engine oil fill cap/dipstick
(2) upper level mark
(3) lower level mark
(1)
(1)
(2)
(3)
(1) engine oil fill cap/dipstick
(4) O-ring
(4)
(1)
Changing Engine Oil & Filter
(1) engine oil fill cap/dipstick
(2) engine oil drain bolt
(3) sealing washer (new)
(1) (3)
(2)
Servicing Your Honda 53
Transmission Oil
1. Run the engine at idle for 3 minutes, then shut
it off.
2. Wait 3 minutes after shutting off the engine to
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
right crankcase cover. A small amount of oil
should flow out of the oil check bolt hole.
Allow any excess oil to flow out of the oil
check bolt hole.
If no oil flows out of the oil check bolt hole,
add oil slowly through the transmission oil fill
hole until oil starts to flow out of the oil check
bolt hole.
Install the oil check bolt with the sealing
washer and transmission oil fill cap. Repeat
steps 1 – 4.
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)
6. Check that the O-ring (4) is in good condition
and replace it if necessary.
7. Reinstall the transmission oil fill cap (1).
8. Check for oil leaks.
1. Run the engine at idle for 3 minutes, then shut
it off.
2. Support the CRF in an upright position on a
level surface.
3. Remove the transmission oil fill cap (1) from
the right crankcase cover.
4. Place an oil drain pan under the engine to catch
the oil. Then remove the transmission oil drain
bolt (2) and sealing washer (3).
5. After the oil has drained, apply engine oil to
the drain bolt threads and seating surface, then
tighten it with a new sealing washer to the
specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
6. Fill the crankcase with recommended oil.
Capacity:
0.72 US qt (0.68 ℓ) after draining
7. Install the transmission oil fill cap.
8. Check the transmission oil level by following
the steps in Checking & Adding Oil (this page).
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 158).
NOTICE
Improper disposal of drained fluids is harmful to
the environment.
Checking & Adding Oil
(1) transmission oil fill cap (3) sealing washer (new)
(2) oil check bolt
(1)
(2)
(3)
(1) transmission oil fill cap
(4) O-ring
Replacing Transmission Oil
(4)
(1)
(1) transmission oil fill cap
(2) transmission oil drain bolt
(3) sealing washer (new)
(1)
(2)
(3)
Servicing Your Honda 55
Coolant
1. Check the cooling system for leaks (see an
official Honda Service Manual for
troubleshooting of leaks).
2. Check the radiator hoses (1) for cracks,
deterioration, and radiator hose clamps for
looseness.
3. Check the radiator mount for looseness.
4. Make sure the overflow hose (2) is connected
and not clogged.
5. Check the radiator fins (3) for clogging.
6. Check the air bleed bolt (4) for looseness.
7. Check the bleed hole (5) below the water pump
cover (6) for leakage. Clean away any clogged
dirt or sand, if necessary. Check the bleed hole
of the water pump for signs of seal leakage. If
water leaks through the bleed hole, replace the
mechanical seal. If oil leaks through the bleed
hole, replace the oil seal. Make sure that there
is no continuous coolant leakage from the
bleed hole while operating the engine.
A small amount of coolant weeping from the
bleed hole is normal. See an official Honda
Service Manual or consult your dealer for
replacing the mechanical seal or oil seal.
Both seals should be replaced at the same time.
Refer to Important Safety Precautions on page 23.
Coolant should be replaced by your dealer, unless
you have the proper tools and service data and are
mechanically qualified. Refer to an official Honda
Service Manual (page 174).
To properly dispose of drained coolant, refer to
You & the Environment on page 158.
NOTICE
Improper disposal of drained fluids is harmful to
the environment.
Cooling System Inspection
(1) radiator hoses (3) radiator fins
(2) overflow hose (4) air bleed bolt
(2)(4)
(3) (3)
(1)
(1)
(5) bleed hole
(6) water pump cover
(5)
(6)
Coolant Replacement
WARNING
Removing the radiator cap while the
engine is hot can cause the coolant to
spray out, seriously scalding you.
Always let the engine and radiator cool
down before removing the radiator cap.
Air Cleaner
56 Servicing Your Honda
Air Cleaner
Refer to Important Safety Precautions on page 23.
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.
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
performance requirements. Use a new Honda
Genuine air cleaner specified for your model or an
air cleaner of equal quality.
NOTICE
Using the wrong air cleaner may result in
premature engine wear.
Proper air cleaner maintenance can prevent
premature engine wear or damage, expensive
repairs, low engine power, poor gas mileage, and
spark plug fouling.
NOTICE
Improper or lack of proper air cleaner
maintenance can cause poor performance and
premature engine wear.
1. Remove the seat (page 34).
2. Remove the air cleaner retaining bolt (1) and
air cleaner assembly (2).
Cleaning
(1) air cleaner retaining bolt
(2) air cleaner assembly
(2)
(1)
Servicing Your Honda 57
Air Cleaner
3. Remove the air cleaner element (3) from the air
cleaner holder (4) by releasing the holder tabs
(5) from the holes (6) of the air cleaner
element.
4. Wash the air cleaner in clean non-flammable
cleaning solvent. Then wash in hot, soapy
water, rinse well, and allow to dry thoroughly.
The air cleaner element is made in two pieces:
inner and outer, which cannot be separated.
5. Clean the inside of the air cleaner housing.
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.
7. Assemble the air cleaner element and holder.
Install the holder tabs in the holes of the air
cleaner element.
8. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda
White Lithium Grease or equivalent to the air
cleaner housing contact area of the air cleaner
element.
9. Install the air cleaner assembly (2) into the air
cleaner housing by aligning its tabs (8) with the
stay (9) of the air cleaner housing.
10. Carefully position the sealing flange of the
element to prevent dirt intrusion.
11. Install and tighten the air cleaner retaining bolt
(1) securely.
NOTICE
Improper installation of the air cleaner assembly
may allow dirt and dust to enter the engine and
cause rapid wear of the piston rings and cylinder.
12. Install the seat (page 34).
(3) air cleaner element (5) holder tabs
(4) air cleaner holder (6) holes
(5)
(6) (3)
(4)
(5)
(6)
(7) plastic bag
(2) air cleaner assembly
(8) air cleaner assembly tabs
(9) air cleaner housing stay
(7)
(9)
(8)
(2)
(1) air cleaner retaining bolt
(1)
Crankcase Breather
58 Servicing Your Honda
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 crankcase breather tubes.
If the drain tube overflows, the air filter may
become contaminated with engine oil causing poor
engine performance.
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.
Draining
(1) crankcase breather tube plugs
(2) crankcase breather tubes
(2)
(1)
Throttle
Servicing Your Honda 59
Throttle
Refer to Important Safety Precautions on page 23.
Inspection
Check freeplay (1).
Freeplay: 1/16 – 1/4 in (2 – 6 mm)
If necessary, adjust to the specified range.
Upper Adjustment
Minor adjustments are generally made with the
upper adjuster.
1. Pull the dust cover (1) back.
2. Loosen the lock nut (2).
3. Turn the adjuster (3).
Turning the adjuster in direction (–) will
decrease freeplay and turning it in direction (+)
will increase freeplay.
4. Tighten the lock nut to the specified torque:
3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
Return the dust cover to its normal position.
5. After adjustment, check for smooth rotation of
the throttle grip from fully closed to fully open
in all steering positions.
If the adjuster is threaded out near its limit or
the correct freeplay cannot be reached, turn the
adjuster all the way in and back out one turn.
Tighten the lock nut to the specified torque:
3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
Install the dust cover and make the adjustment
with the lower adjuster.
Lower Adjustment
The lower adjuster is used for major freeplay
adjustment, such as after replacing the throttle
cables or removing the throttle body. It is also used
if you cannot get the proper adjustment with the
upper adjuster.
1. Loosen the lock nut (1).
2. Turn the adjuster (2) in direction (–) to
decrease freeplay, and in direction (+) to
increase freeplay.
3. Tighten the lock nut to the specified torque:
3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
4. Operate the throttle grip to ensure that it
functions smoothly and returns completely.
If you can’t get the freeplay within the specified
range, contact your dealer.
Throttle Freeplay
(1) freeplay
(1)
(1) dust cover (+) increase freeplay
(2) lock nut (–) decrease freeplay
(3) adjuster
(1) (2)
(3)
(–)
(+)
(1) lock nut (+) increase freeplay
(2) adjuster (–) decrease freeplay
(2)
(1)
(–)
(+)
60 Servicing Your Honda
Throttle
1. Check that the throttle assembly is positioned
properly (the end of the throttle housing (1) is
aligned with the paint mark (2) on the
handlebar) and the securing bolts are tight.
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. Inspect the condition of the throttle cables
from the throttle grip down to the throttle body.
If the cable is kinked or chafed, have it
replaced.
4. Check the cables for tension or stress in all
steering positions.
5. Lubricate the cables with a commercially
available cable lubricant to prevent premature
rust and corrosion.
Throttle Inspection
(1) throttle housing (2) paint mark
(3) throttle
(2)
(1)
(3)
Engine Idle Speed
Servicing Your Honda 61
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 speed 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
adjustment screw.
Turning it counterclockwise results in a faster/
higher idle speed.
Turning it clockwise results in a slower/lower idle
speed.
1. If the engine is cold, start it and warm it up 3
minutes. Then shut it o.
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
Idle Speed Adjustment
(1) fast idle knob
(+) increase
(–) decrease
(1)
(–)
(+)
Clutch System
62 Servicing Your Honda
Clutch System
Refer to Important Safety Precautions on page 23.
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 is adjusted or clutch cable
is disconnected.
1. Loosen the lock nut (1).
2. To position the clutch lever farther away from
the handgrip, turn the adjuster (2)
counterclockwise. To position the clutch lever
closer to the handgrip, turn the adjuster
clockwise.
3. Tighten the lock nut.
4. Turn the cable end adjuster (3) in direction (+)
until it seats lightly and then turn it out five
turns.
5. Loosen the lock nut (4) and turn the integral
cable adjuster (5) to adjust the clutch lever
freeplay at the tip of lever.
Freeplay: 3/8 – 13/16 in (10 – 20 mm)
Tighten the lock nut.
6. Adjust the cable end adjuster for minor
adjustment (page 63).
Inspection
Check freeplay (1).
Freeplay: 3/8 – 13/16 in (10 – 20 mm)
If necessary, adjust to the specified range.
Improper freeplay adjustment can cause premature
clutch wear.
Make sure to adjust the clutch lever freeplay after
the clutch cable is disconnected.
Clutch Lever Adjustment
(1) lock nut (2) adjuster
(1) (2)
(3) cable end adjuster
(+) increase freeplay
(–) decrease freeplay
(4) lock nut
(5) integral cable adjuster
(+) increase freeplay
(–) decrease freeplay
(3)
(–)
(+)
(5)
(4) (–)
(+)
Clutch Lever Freeplay
(1) freeplay
(1)
Clutch System
(cont’d)
Servicing Your Honda 65
• 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)
Replace the clutch discs and clutch plates as a
set.
• Check the clutch plates (2) for excessive
warpage or discoloration.
Check the plate warpage on a surface plate using
a feeler gauge.
Service Limit: 0.004 in (0.10 mm)
Replace the clutch discs and clutch plates as a
set.
• If you feel the clutch slippage when replacing the
clutch discs and plates, replace the clutch
springs.
1. Install the spring seat (1) and judder spring (2)
onto the clutch center as shown.
Coat the clutch discs with engine oil.
2. Install the clutch disc A (larger I.D. disc) (3)
onto the clutch outer.
Stack the seven clutch plates (4) and seven
clutch discs B (5) alternately.
3. Apply engine oil to the needle bearing (6).
Install the needle bearing and washer (7) onto
the clutch lifter (8). Then, install a new clip (9)
by fitting it into the groove in the clutch lifter.
Clutch Disc/Plate Inspection
(1) clutch discs
(2) clutch plates
(1)
(2)
Clutch Disc/Plate Installation
(1) spring seat (4) clutch plates
(2) judder spring (5) clutch discs B
(3) clutch disc A
(5)
(1)
(2) (3)
(4)
(6) needle bearing (8) clutch lifter
(7) washer (9) clip (new)
(7)
(9)
(6)
(8)
Spark Plug
Servicing Your Honda 67
Spark Plug
Refer to Important Safety Precautions on page 23.
The recommended standard spark plug is
satisfactory for most racing conditions.
Use only the recommended type of spark plugs in
the recommended heat range.
NOTICE
Using a spark plug with an improper heat range or
incorrect reach can cause engine damage.
Using a non-resistor spark plug may cause
ignition problems.
This motorcycle uses a spark plug that has an
iridium tip in the center electrode and a platinum
tip in the side electrode.
Be sure to observe the following when servicing
the spark plug.
• Do not clean the spark plug. If an electrode is
contaminated with accumulated objects or dirt,
replace the spark plug with a new one.
• To check the spark plug gap, use only a “wire-
type feeler gauge.” To prevent damaging the
iridium tip of the center electrode and platinum
tip of the side electrode, never use a “leaf-type
feeler gauge.”
• Do not adjust the spark plug gap. If the gap is out
of specification, replace the spark plug with a
new one.
1. Remove the seat and hang the fuel tank to the
left of the frame (pages 34, 35).
2. Disconnect the spark plug cap (1).
3. Clean any dirt from around the spark plug
base.
4. Remove the spark plug (2).
5. Check the electrodes for wear or deposits, the
sealing gasket (3) for damage, and the insulator
for cracks. Replace if you detect them.
6. Check the spark plug gap (4), using a wire-type
feeler gauge. If the gap is out of specifications,
replace the plug with a new one.
The recommended spark plug gap is:
0.024 – 0.028 in (0.60 – 0.70 mm)
7. To obtain accurate spark plug readings,
accelerate up to speed on a straightaway.
Press and hold the engine stop button and
disengage the clutch by pulling the lever in.
Coast to a stop, then remove and inspect the
spark plug. The porcelain insulator around the
center electrode should appear tan or medium
gray.
If you’re using a new plug, ride for at least 10
minutes before taking a plug reading; a brand-new
plug will not color initially.
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
problem elsewhere (page 148).
Check the PGM-FI system and ignition timing.
8. With the sealing gasket attached, thread the
spark plug in by hand to prevent cross-
threading.
9. Tighten the spark plug.
• 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:
1/2 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
NOTICE
An improperly tightened spark plug can damage
the engine. If a plug is too loose, the piston may be
damaged. If a plug is too tight, the threads may be
damaged.
10. Connect the spark plug cap. Take care to avoid
pinching any cables or wires.
11. Install the fuel tank and seat (pages 34, 36).
Spark Plug Recommendation
Standard R0451B-8 (NGK)
Spark Plug Inspection & Replacement
(1) spark plug cap (2) spark plug
(3) sealing gasket
(4) spark plug gap
(1)
(2)
(4) (3)
Valve Clearance
(cont’d)
Servicing Your Honda 69
4. Rotate the crankshaft by turning the primary
drive gear bolt (2) clockwise until the punch
mark (3) on the primary drive gear aligns with
the index mark (4) on the right crankcase
cover. In this position, the piston may either be
on the compression or exhaust stroke at TDC.
If the crankshaft passed the punch mark, rotate
the primary drive gear bolt clockwise again
and align the punch mark with the index mark.
The inspection must be made when the piston
is at the top of the compression stroke when
both the intake and exhaust valves are closed.
This condition can be determined by moving
the exhaust rocker arm (5). If it is free, an
indication that the valves are closed and that
the piston is on the compression stroke. If it is
tight and the valves are open, rotate the
primary drive gear bolt 360° and realign the
punch mark with the index mark.
1. Set the piston at TDC on the compression
stroke (page 68).
2. Measure the intake valve clearance by
inserting a feeler gauge (1) between the valve
lifters (2) and intake cam lobes (3).
Valve Clearance:
(2) primary drive gear bolt (4) index mark
(3) punch mark
(3) (4)
(2)
(5) exhaust rocker arm
(5) Valve Clearance Inspection
(1) feeler gauge
(2) valve lifters
(3) intake cam lobes
IN: 0.005 ± 0.001 in (0.12 ± 0.03 mm)
(1)
(1) (2)
(3)
Servicing Your Honda 71
Valve Clearance
5. Make sure the piston is at TDC on the
compression stroke (page 68).
Loosen the camshaft holder bolts A (7), B (8)
in a crisscross pattern in two or three steps.
Remove the camshaft holder bolts, set rings
and camshaft holders (9).
As you remove the camshaft holders, set rings may
be sticking in the camshaft holders.
NOTICE
Do not let the set rings fall into the crankcase.
If the set rings are remained on the camshaft
holders, remove the set rings carefully.
6. Slide the left camshaft bearing (10) and
remove the camshaft (11) by removing the cam
chain (12).
Suspend the cam chain with a piece of wire to
prevent the chain from falling into the crankcase.
NOTICE
Do not let the cam chain fall into the crankcase.
7. Remove the intake valve lifters (13).
Keep the intake valve lifters and shims separate so
you can easily identify the originally installed
location such as intake or exhaust, right or left.
8. Remove the valve shims (14).
(7) camshaft holder bolts A
(8) camshaft holder bolts B
(9) set rings and camshaft holders
(7) (9)
(8)
(9)
(10) left camshaft bearing
(11) camshaft
(12) cam chain
(12)
(10) (11)
(13) intake valve lifters
(14) valve shims
(13)
(14)
(14)
72 Servicing Your Honda
Valve Clearance
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.
Sixty-nine different shims (2) are available in
0.025 mm thickness intervals, from 1.200 mm
(the thinnest) to 2.900 mm (the thickest).
3. Calculate the new shim thickness using the
equation below.
A = (B – C) + D
A: New shim thickness
B: Recorded valve clearance
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 2.900
mm.
NOTICE
Do not lap the intake and exhaust valves. They are
titanium and have a thin oxide coating. Lapping
will damage this coating.
If required shim size is outside the available range,
have your motorcycle inspected by your dealer.
Shim Selection
(1) valve lifter
(1)
(2) shim
(2)
1.80 mm 1.825 mm 1.85 mm 1.875 mm
74 Servicing Your Honda
Valve Clearance
7. Make sure that the dowel pins (12) are installed
into the camshaft holders (13).
8. Install the set rings (14) on the camshaft
bearing grooves (15).
NOTICE
Do not let the set rings fall into the crankcase.
Each camshaft holder has an identification mark
(16).
9. Install the camshaft holders (13) in their proper
position by aligning the camshaft holder
grooves with the set rings.
10. Apply engine oil to the camshaft holder bolt
threads and seating surface.
Tighten the camshaft holder bolts A (17) and B
(18) to the specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
Tighten the camshaft holder bolts in a crisscross
pattern in two or three steps.
11. Remove the tensioner stopper (19) from the
cam chain tensioner lifter.
12. Install a new sealing washer (20) and tighten
the cam chain tensioner lifter cover bolt (21).
(12) dowel pins
(13) camshaft holders
(14) set rings
(15) camshaft bearing grooves
(14)
(12)(13)
(12)
(14) (15)
(16) identification marks
(13) camshaft holders
(17) camshaft holder bolts A
(18) camshaft holder bolts B
(16)
(17)
(18) (13)
(13)
(19) tensioner stopper
(20) sealing washer (new)
(21) cam chain tensioner lifter cover bolt
(19)
(20)
(21)
Servicing Your Honda 75
Valve Clearance
13. Install the condenser stay (22) and tighten the
condenser stay mounting bolts (23).
14. Rotate the camshaft by rotating the crankshaft
clockwise several times and make sure that the
piston is at TDC on the compression stroke
(page 68).
15. Measure the intake valve and exhaust valve
clearances by inserting a feeler gauge (24).
Valve Clearance:
1. Install the spark plug (page 67).
2. Coat a new O-ring (1) with engine oil and
install it onto the crankshaft hole cap (2).
Apply grease to the crankshaft hole cap
threads. Install and tighten the crankshaft hole
cap to the specified torque:
11 lbf·ft (15 N·m, 1.5 kgf·m)
(22) condenser stay
(23) condenser stay mounting bolts
IN: 0.005 ± 0.001 in (0.12 ± 0.03 mm)
EX: 0.008 ± 0.001 in (0.21 ± 0.03 mm)
(24) feeler gauge
(22)
(23)
(24) (24)
Crankshaft Hole Cap Installation
(1) O-ring (new)
(2) crankshaft hole cap
(2)
(1)
Produkt Specifikationer
| Mærke: | Honda |
| Kategori: | Motor |
| Model: | CRF250R (2017) |
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