Honda 2004 CRF250R Service Manual. Хонда crf250r мануал


HONDA 2010 CRF250R SERVICE MANUAL Pdf Download.

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Page 1 Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 - General specifications Page 12 Page 13 - Lubrication system specifications Page 14 - Cylinder head/valves specifications Page 15 Page 16 Page 17 Page 18 - Electrical system specifications Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Page 47 Page 48 Page 49 Page 50 Page 51 Page 52 Page 53 Page 54 Page 55 Page 56 Page 57 Page 58 Page 59 Page 60 Page 61 Page 62 Page 63 Page 64 Page 65 Page 66 Page 67 Page 68 - Valve clearance Page 69 - Oil level inspection Page 70 Page 71 Page 72 Page 73 Page 74 Page 75 Page 76 Page 77 Page 78 Page 79 Page 80 Page 81 Page 82 Page 83 Page 84 Page 85 Page 86 Page 87 Page 88 Page 89 Page 90 Page 91 Page 92 Page 93 Page 94 Page 95 Page 96 Page 97 Page 98 Page 99 Page 100 Page 101 Page 102 Page 103 Page 104 Page 105 Page 106 Page 107 Page 108 Page 109 Page 110 Page 111 Page 112 Page 113 Page 114 Page 115 Page 116 Page 117 Page 118 Page 119 Page 120 Page 121 Page 122 Page 123 Page 124 Page 125 Page 126 Page 127 Page 128 Page 129 Page 130 Page 131 Page 132 Page 133 Page 134 Page 135 Page 136 Page 137 Page 138 Page 139 Page 140 Page 141 Page 142 Page 143 Page 144 Page 145 Page 146 Page 147 Page 148 Page 149 Page 150 Page 151 Page 152 Page 153 Page 154 Page 155 Page 156 Page 157 Page 158 Page 159 Page 160 Page 161 Page 162 Page 163 Page 164 Page 165 Page 166 Page 167 Page 168 Page 169 Page 170 Page 171 Page 172 Page 173 Page 174 Page 175 Page 176 Page 177 Page 178 Page 179 Page 180 Page 181 Page 182 Page 183 Page 184 Page 185 Page 186 Page 187 Page 188 Page 189 Page 190 Page 191 Page 192 Page 193 Page 194 Page 195 Page 196 Page 197 Page 198 Page 199 Page 200 Page 201 Page 202 Page 203 Page 204 Page 205 Page 206 Page 207 Page 208 Page 209 Page 210 Page 211 Page 212 Page 213 Page 214 Page 215 Page 216 Page 217 Page 218 Page 219 Page 220 Page 221 Page 222 Page 223 Page 224 Page 225 Page 226 Page 227 Page 228 Page 229 Page 230 Page 231 Page 232 Page 233 Page 234 Page 235 Page 236 Page 237 Page 238 Page 239 Page 240 Page 241 Page 242 Page 243 Page 244 Page 245 Page 246 Page 247 Page 248 Page 249 Page 250 Page 251 Page 252 Page 253 Page 254 Page 255 Page 256 Page 257 Page 258 Page 259 Page 260 Page 261 Page 262 Page 263 Page 264 Page 265 Page 266 Page 267 Page 268 Page 269 Page 270 Page 271 Page 272 Page 273 Page 274 Page 275 Page 276 Page 277 Page 278 Page 279 Page 280 Page 281 Page 282 Page 283 Page 284 Page 285 Page 286 Page 287 Page 288 Page 289 Page 290 Page 291 Page 292 Page 293 Page 294 Page 295 Page 296 Page 297 Page 298 Page 299 Page 300 Page 301 Page 302 Page 303 Page 304 Page 305 Page 306 Page 307 Page 308 Page 309 Page 310 Page 311 Page 312 Page 313 Page 314 Page 315 Page 316 Page 317 Page 318 Page 319 Page 320 Page 321 Page 322 Page 323 Page 324 Page 325 Page 326 Page 327 Page 328 Page 329 Page 330 Page 331 Page 332 Page 333 Page 334 Page 335 Page 336 Page 337 Page 338 Page 339 Page 340 Page 341 Page 342 Page 343 Page 344 Page 345 Page 346 - Rear wheel/suspension Page 347 Page 348 Page 349 Page 350 Page 351 Page 352 Page 353 Page 354 - Assembly Page 355 Page 356 Page 357 Page 358 Page 359 Page 360 Page 361 Page 362 Page 363 Page 364 Page 365 Page 366 Page 367 Page 368 Page 369 Page 370 Page 371 Page 372 Page 373 Page 374 Page 375 Page 376 Page 377 Page 378 Page 379 Page 380 Page 381 Page 382 Page 383 Page 384 Page 385 Page 386 Page 387 Page 388 Page 389 Page 390 Page 391 Page 392 Page 393 Page 394 Page 395 Page 396 Page 397 Page 398 Page 399 Page 400 Page 401 Page 402 Page 403 Page 404 Page 405 Page 406 Page 407 Page 408 Page 409 Page 410 Page 411 Page 412 Page 413 Page 414 Page 415 Page 416 Page 417 Page 418 Page 419 Page 420 Page 421 Page 422 Page 423 Page 424 Page 425 Page 426 Page 427 Page 428 Page 429 Page 430 Page 431 Page 432 Page 433 Page 434 Page 435 Page 436 Page 437 Page 438 Page 439 Page 440 Page 441 Page 442 Page 443 Page 444 Page 445 Page 446

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HONDA CRF250R 2012 OWNER'S MANUAL Pdf Download.

  • Page 2

    2012 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...

  • Page 3

    NOTICE symbol. This information is intended to help you abbreviations are used to identify the respective When you own a Honda, you’re part of a avoid damage to your CRF, other property, or the parts or system. worldwide family of satisfied customers – people environment.

  • Page 4

    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.

  • Page 5: Table Of Contents

    Contents Chassis MOTORCYCLE SAFETY.......1 SERVICING YOUR HONDA......21 Important Safety Information......2 Before You Service Your Honda Suspension............85 Important Safety Precautions......2 The Importance of Maintenance .......22 Brakes..............90 Wheels...............94 Accessories & Modifications ......3 Maintenance Safety...........23 Tires & Tubes ............95 Safety Labels............4 Important Safety Precautions......23 Maintenance Schedule ........24...

  • Page 6: Table Of Contents

    Wiring Diagram..........158 Gearing ............137 Tire Selection for Track Conditions....138 CONSUMER INFORMATION ....159 Personal Fit Adjustments ........139 Authorized Manuals ........160 Control Positioning ........139 Contacting Honda..........161 Handlebar Position, Width & Shape...139 Your Dealer .............162 The Honda Rider’s Club (USA only) .....163 Contents...

  • Page 8: Motorcycle Safety

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

  • Page 9: Important Safety Information

    As an experienced rider, you know there is much Keep your Honda in Safe Condition. Maintaining your CRF properly is critical to your you can do to protect yourself when you ride. safety. A loose bolt, for example, can cause a The following are a few precautions we consider to be most important.

  • Page 10: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 11: Safety Labels

    Safety Labels Read these labels carefully and don’t remove them. If the label comes off or becomes hard to read, contact your dealer for replacement. (For Canada) Motorcycle Safety...

  • Page 12: Instruments & Controls

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

  • Page 13: Operation Component Locations

    Operation Component Locations clutch lever front brake lever throttle grip engine stop button fast idle knob (engine idle speed) kickstarter rear brake pedal shift lever Instruments & Controls...

  • Page 14: Indicator

    If the MIL comes on at any other time, reduce speed and refer to an official Honda Service Manual available for purchase from your dealer (page 160). If the MIL does not come on when it should, have your dealer check it for problems.

  • Page 15: Circuit Inspection

    Indicator Circuit Inspection 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. (1) MAP sensor connector (2) ECT sensor connector (3) TP sensor connector (4) IAT sensor connector (5) Injector connector...

  • Page 16: Dtc Index

    The series of 12, 19, and 69 MIL blinks cannot be checked because the engine cannot be started. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 160) for troubleshooting of the PGM-FI symptom.

  • Page 17

    Instruments & Controls...

  • Page 18: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........12 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?....13 you prepared, this section discusses how to Pre-ride Inspection........13...

  • Page 19: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 20: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection 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 Check the following before each ride: right): •...

  • Page 21

    Before Riding...

  • Page 22: Basic Operating Instructions

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

  • Page 23: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 24: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Warm Engine Starting Starting Procedure described below. 1. Shift the transmission into neutral. 2. Kick-start the engine (Do not open the throttle). Your CRF can be kickstarted with the Always follow the proper starting procedure transmission in gear by pulling in the clutch lever described as follows.

  • Page 25: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine (1) throttle (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Lightly open the throttle (1) two or three times, and then close it. 3. Push and hold the engine stop button (2) until the engine stops completely.

  • Page 26: Break-in Guidelines

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

  • Page 27

    Basic Operating Instructions...

  • Page 28: Servicing Your Honda

    You’ll also find Drive Chain ............97 important safety precautions, information on oils, Service Preparations Exhaust Pipe/Muffler ........100 and tips for keeping your Honda looking good. Maintenance Component Locations....32 Steering Damper..........103 Seat ..............33 Additional Maintenance Procedures ....105 An ECM system is used on this motorcycle;...

  • Page 29: The Importance Of Maintenance

    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. Servicing Your Honda...

  • Page 30: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 31: Maintenance Schedule

    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...

  • Page 32

    94-96 STEERING HEAD BEARINGS WE RECOMMENDED THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1.Clean after every moto for dusty riding condition.

  • Page 33: General Competition Maintenance

    Use Honda Genuine Parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.

  • Page 34

    Lithium Grease, or an equivalent, is handy for this because any dirt that penetrates this sealing area will show up clearly (page 56). Use a Honda Genuine air cleaner or an equivalent air cleaner Engine Oil and Filter specified for your model.

  • Page 35

    Remove the nuts, clean remove the nuts, clean the threads, and apply Pro Honda the threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent before torquing the nuts. Hondalock or an equivalent and tighten to the specified torque.

  • Page 36

    If oil leaks through the bleed hole, the oil seal is the throttle operation is perfect after servicing and damaged. See an official Honda Service Manual or consult inspecting. your dealer for replacing the mechanical seal or oil seal.

  • Page 37: Before & After Competition Maintenance

    (1) are in the same position on (2) pressure release screw each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...

  • Page 38

    If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 107). Servicing Your Honda...

  • Page 39: Maintenance Component Locations

    (engine idle speed) rebound damping adjuster drain bolt damping adjuster engine oil filter Servicing Your Honda...

  • Page 40: Seat

    2. Install and tighten the seat mounting bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (1) seat front prong (2) seat bracket (3) seat rear prong (4) ECM bracket Servicing Your Honda...

  • Page 41: Fuel Tank

    Do not support the fuel tank by the fuel feed 5. Pull the breather tube (5) out of steering stem hose (8). nut. 6. Unhook the fuel tank band (6). (12) cushion rubbers Servicing Your Honda...

  • Page 42

    (11) (13) (10) (3) fuel tank (5) fuel tank band (4) collar and fuel tank bolt (9) shrouds (10) shroud tabs (11) air cleaner housing cover tabs (12) shroud B bolts (13) collars and shroud A bolts Servicing Your Honda...

  • Page 43: Subframe

    7. Loosen the screw (15) on the air cleaner (2) seat mounting bolts (4) seat connecting tube clamp (16). 3. Loosen the muffler clamp bolt (5). (16) (11) (15) (11) IAT sensor connector (15) screw (16) air cleaner connecting tube clamp (5) muffler clamp bolt Servicing Your Honda...

  • Page 44

    Be careful not to damage the ECM and wires. (10) right subframe lower bolt (20) (21) (20) subframe (21) crankcase breather tube (2) ECM (5) air cleaner housing cover tabs (3) bracket (6) air cleaner connecting tube (cont’d) (4) shroud tabs (7) throttle body Servicing Your Honda...

  • Page 45

    0.18 ± 0.06 in (4.5 ± 1.5 mm). (23) (18) (21) (13) (17) 0.18 ± 0.06 in (17) IAT sensor connector (22) (4.5 ± 1.5 mm) (18) muffler clamp (22) tab (21) muffler (23) cutout (13) screw Servicing Your Honda...

  • Page 46

    15 lbf·ft (21 N·m, 2.1 kgf·m) (30) (32) (27) (26) muffler mounting B bolt (27) muffler mounting A bolt (28) (29) seat (30) side covers (31) seat mounting bolts (32) bolts (28) muffler clamp bolt Servicing Your Honda...

  • Page 47: Fuel System

    91 (or higher) and flame away. • Handle fuel only outdoors. Use only unleaded fuel in your Honda. If you • Wipe up spills immediately. ride your Honda in a country where leaded fuel might be available, take precautions to use only 3.

  • Page 48

    Fuel Pump side: (1) fuel quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting 5. Remove the bolt (4), clamp and setting rubber (5). (8) shop towel (cont’d) (4) bolt (5) clamp and setting rubber Servicing Your Honda...

  • Page 49

    • Handle fuel only outdoors. • Wipe up spills immediately. Injector side: Fuel Pump side: Align (1) retainer (new) (3) locking pawls (2) connector (4) connector grooves (10) (10) (9) retainer tabs (10) locking pawls Servicing Your Honda...

  • Page 50

    (11) with the groove (16) rubber cover (12) of the stay. 7. Install the fuel tank (page 35). (11) 8. Increase the fuel pressure (page 48). (10) (12) (8) rubber (11) clamp tab (9) clamp (12) groove (10) bolt Servicing Your Honda...

  • Page 51

    (10) (11) (1) fuel pump mounting bolts (2) stopper cable guide (10) fuel pump wire terminals (3) stopper cable (11) fuel pump base (4) washers (5) collars (6) conical spring washers (7) fuel pump plate Servicing Your Honda...

  • Page 52

    13. Remove the fuel pump filter from the fuel pump assembly (20). (12) hooks (14) grooves (13) tabs (17) (19) (18) (20) (17) fuel pump stopper (18) damper rubber (19) fuel pump assembly (20) fuel pump filter Servicing Your Honda...

  • Page 53

    (12) O-ring (new) pump filter as shown. (13) fuel pump base Install the fuel pump stopper (11). (14) fuel pump unit holder assembly (15) hooks (16) grooves (17) tabs (11) (10) (10) new damper rubber (11) fuel pump stopper Servicing Your Honda...

  • Page 54

    (19) black wire terminal (20) fuel pump base terminals (26) fuel pump plate (27) identification mark (21) O-ring (new) (22) fuel pump unit 15. Connect the fuel line (page 42). 16. Increase the fuel pressure (page 48). Servicing Your Honda...

  • Page 55

    (3) between the main and sub-harness as shown. Connect the battery harness positive (+) cable first, then connect the battery harness negative (–) cable to a 12V battery terminals. • Battery harness 070MZ-MEN0100 • Battery harness adapter 070MZ-KRN0100 Servicing Your Honda...

  • Page 56: Engine Oil

    SAE 10W–30 (weight) JASO T 903 standard MA suggested oil* Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil* * Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label.

  • Page 57

    Improper disposal of drained fluids is harmful to the environment. (1) engine oil fill cap/dipstick (1) engine oil fill cap/dipstick (2) upper level mark (2) engine oil drain bolt (3) lower level mark (3) sealing washer (new) Servicing Your Honda...

  • Page 58

    (9) facing out, away from the engine. You should see the “OUT-SIDE” mark (10) on the filter body, near the rubber seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Servicing Your Honda...

  • Page 59: Transmission Oil

    Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil* JASO T 903 standard The JASO T 903 standard is an index for engine * Suggested 4-stroke engine oils are equal oils for 4-stroke motorcycle engines.

  • Page 60

    1– 4. 12 lbf·ft (16 N·m, 1.6 kgf·m) 5. After inspecting the oil level or adding oil, tighten the oil check bolt to the specified torque: Oil Check Bolt: 9 lbf·ft (12 N·m, 1.2 kgf·m). Servicing Your Honda...

  • Page 61: Coolant

    Coolant Recommendation Checking & Adding Coolant 1.09 US qt (1.03R) after draining 3. Install the radiator cap securely. Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 23. quality ethylene glycol antifreeze containing NOTICE corrosion protection inhibitors specifically 1.

  • Page 62

    2. Check the water hoses (1) for cracks, through the bleed hole, the oil seal is are mechanically qualified. Refer to the Honda deterioration, and hose clamp for looseness. Service Manual (page 160).

  • Page 63: Air Cleaner

    Your CRF’s air cleaner has very specific performance requirements. Use a new Honda (1) air cleaner retaining bolt Genuine air cleaner specified for your model or (2) air cleaner assembly an air cleaner of equal quality.

  • Page 64

    Install the holder tab (5) in the hole (6) of the air cleaner element. NOTICE 8. Apply 0.1 – 0.2 oz (3 – 5 g) of Pro Honda (3) air cleaner element (5) holder tab White Lithium Grease or equivalent to the air...

  • Page 65: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) crankcase breather tube Servicing Your Honda...

  • Page 66

    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. (–) (2) dust cover (+) increase (3) lock nut (–) decrease (4) upper adjuster Servicing Your Honda...

  • Page 67

    (1) throttle housing (2) paint mark 2. Check for smooth rotation of the throttle (3) from fully open to fully closed in all steering positions. If there is a problem, see your dealer. (3) throttle Servicing Your Honda...

  • Page 68: Engine Idle Speed

    3. Shift the transmission into neutral. Start the engine. 4. Keep the motorcycle in an upright position. 5. Adjust idle speed with the fast idle knob (1). Idle speed: 2,000 ± 100 rpm (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 69: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. Servicing Your Honda...

  • Page 70

    If you can’t get proper adjustment, or the clutch 2. Check the clutch cable for deterioration, does not work properly, the cable may be kinked kinks, or damage. or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 65). Servicing Your Honda...

  • Page 71

    3. Remove the five clutch spring bolts and clutch clutch lifter if the bearing plate does not turn springs (4). smoothly. Loosen the bolts in a crisscross pattern in two or three progressive steps. (6) clutch lifter (7) clutch lifter rod Servicing Your Honda...

  • Page 72

    Service Limit: 0.112 in (2.85 mm) Replace the clutch discs and clutch plates as an assembly. (2) clutch plate If you feel the clutch slippage when replacing the clutch discs and plates, replace the clutch springs. (1) clutch disc Servicing Your Honda...

  • Page 73

    (1) spring seat (4) clutch plates 9 lbf·ft (12 N·m, 1.2 kgf·m) (2) judder spring (5) clutch disc A (3) clutch discs (8) clutch pressure plate (9) clutch spring bolts/clutch springs Servicing Your Honda...

  • Page 74: Spark Plug

    10. Connect the direct ignition coil. Take care to avoid pinching any cables or wires. (3) sealing gasket 11. Install the fuel tank and seat (pages 33, 35). (4) spark plug gap Servicing Your Honda...

  • Page 75: Valve Clearance

    (1) breather tube (2) spark plug cap 3. Remove the cylinder head cover bolts/rubber seals (3) and cylinder head cover (4). (3) cylinder head cover bolts/rubber seals (4) cylinder head cover 4. Remove the spark plug hole packing. Servicing Your Honda...

  • Page 76

    If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 70) and select the correct shim for each valve. (2) primary drive gear bolt (4) “∆” mark (3) punch mark (5) exhaust rocker arm Servicing Your Honda...

  • Page 77

    (3) until it stops, in order to retract the tensioner fully. Then insert the tensioner stopper fully to hold the stopper in the fully retracted position. (1) cam chain tensioner lifter cover bolt (2) sealing washer (3) tensioner stopper Servicing Your Honda...

  • Page 78

    Do not let the set rings fall into the crankcase. NOTICE If the set rings are remained on the camshaft holder, remove the set rings carefully. Do not let the valve lifters or shims fall into the crankcase. (10) (10) valve lifters Servicing Your Honda...

  • Page 79

    2. Measure the shim thickness with a micrometer and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...

  • Page 80

    (3). Install the valve lifters to the proper position. (15) (13) set rings (15) camshaft bearing grooves (12) (7) cam shaft (12) cam chain (8) intake cam lobes (cont’d) (3) valve lifters Servicing Your Honda...

  • Page 81

    11 lbf·ft (15 N·m, 1.5 kgf·m) (14) (20) sealing washer (24) (21) cam chain tensioner lifter cover bolt (14) (23) (18) (14) camshaft holders (17) camshaft holder bolts A (23) O-ring (new) (18) camshaft holder bolts B (24) crankshaft hole cap Servicing Your Honda...

  • Page 82

    5. Connect the spark plug cap (7) and breather tube (8). (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (7) spark plug cap (8) breather tube 6. Install the fuel tank and the seat (pages 33, 35). Servicing Your Honda...

  • Page 83: Piston/piston Rings/piston Pin

    (7) out from the insulator (8). Do not hang the throttle body and support it with a suitable strap. (2) radiator hose clamp screw (3) radiator hose (6) insulator band screw (7) throttle body (8) insulator Servicing Your Honda...

  • Page 84

    (14) cylinder bolt (10) (12) (15) cylinder head stud bolts/washers (16) cylinder head (9) cylinder head hanger bolts (10) cylinder head hanger plate bolts (11) left cylinder head hanger plate (12) right cylinder head hanger plate (cont’d) Servicing Your Honda...

  • Page 85

    18. Remove the dowel pins (17), cylinder head gasket (18) and cam chain guide (19). NOTICE Do not let the dowel pins and cam chain fall into the crankcase. (19) (17) (18) (17) dowel pins (19) cam chain guide (18) cylinder head gasket Servicing Your Honda...

  • Page 86

    2. Remove the dowel pins (3) and cylinder (1) piston ring gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...

  • Page 87

    Space the ring end gaps 180 degrees apart between the top ring and the upper side rail. spacer ring Space the ring end gaps 90 degrees apart side rail between the upper side rail, spacer, and the lower side rail. Servicing Your Honda...

  • Page 88

    (6). (1) dowel pins (2) cylinder gasket 5. Clean any gasket material off the cylinder. (1) piston (4) piston pin (2) “O” mark (5) piston pin clip (3) large valve recess (6) piston cut-out (cont’d) Servicing Your Honda...

  • Page 89

    Do not let the dowel pins fall into the crankcase. Do not damage the piston rings and cylinder walls. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (5) piston rings (4) cylinder Servicing Your Honda...

  • Page 90

    Do not let the washers and nuts fall into the crankcase. (10) (10) (3) cylinder head (4) cylinder head stud bolts/washers (7) left cylinder head hanger plate (8) right cylinder head hanger plate (9) cylinder head hanger plate bolts (10) cylinder head hanger bolts (cont’d) Servicing Your Honda...

  • Page 91

    – secondary air leaks (16) – coolant leaks 0 – 0.04 in – oil leaks (0 – 1.0 mm) (19) radiator hose clamp screw (15) (14) (14) rear shock absorber (16) nut (15) rear shock absorber upper bolt Servicing Your Honda...

  • Page 92: Suspension

    Replace the wear ring if it is 0.06 in (1.5 mm) materials. Check the oil for any or flat with the outer tube (4). contamination. When replacing the wear ring, remove the fork leg (page 112). Install the wear ring with its end gap (5) facing rearward. Servicing Your Honda...

  • Page 93

    If there is, have the adjustment.) bearings replaced by your dealer. • If you have a problem finding an acceptable adjustment, return to the standard position and begin again. Servicing Your Honda...

  • Page 94

    10/50 18.9 16.5 14.8 13.7 12.5 11.4 0/32 18.4 15.9 14.5 13.7 11.7 10°C/50°F (1) outer tube (3) lock nut wrench 0°C/32°F 20°C/68°F (2) fork damper (4) axle holder 30°C/86°F (1) outer tube (7) oil hole (cont’d) Servicing Your Honda...

  • Page 95

    Standard oil 12.8 US oz capacity (377 cm Maximum oil 13.0 US oz Slightly stiffer as capacity (385 cm it nears full compression. Minimum oil 10.2 US oz Slightly softer as capacity (301 cm it nears full compression. Servicing Your Honda...

  • Page 96

    When using the lock nut wrench, use a 20 in (500 mm) long deflecting beam type torque wrench The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the fork damper. Servicing Your Honda...

  • Page 97: Brakes

    (page 93), (1) lock nut there is probably air in the brake system. (2) adjuster Refer to an official Honda Service Manual or see your dealer to have the air 1. Loosen the lock nut (1). (–) 2.

  • Page 98

    Honda recommends using Honda DOT 4 system and it must be bled. brake fluid from a scaled container, or an Refer to an official Honda Service Manual or see equivalent. your dealer for brake bleeding. Honda recommends using Honda DOT 4...

  • Page 99

    Do not mix different types of fluid as they may not be compatible. may not be compatible. • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent.

  • Page 100

    0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) front brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 101: Wheels

    3. Check wheel rim runout. If runout is possible loss of control. It’s also important that noticeable, see the Honda Service Manual for the rim locks are secure to prevent tire slippage. inspection instructions.

  • Page 102: Tires & Tubes

    Underinflated tires can also cause wheel damage on hard terrain. Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...

  • Page 103

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

  • Page 104: Drive Chain

    Lubricate the drive chain (page 98) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed (page 98). (2) chain guide slider (3) wear limit Servicing Your Honda...

  • Page 105

    2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda HP Chain Lube or an equivalent is rollers and replace them if below the service Align the index marks (4) of the axle plates recommended.

  • Page 106

    17 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 107: Exhaust Pipe/muffler

    B bolt (6), washe A (7), washer B (8) and muffler (9). (1) seat mounting bolt (3) right side cover (2) side cover bolt (5) muffler mounting A bolt (8) washer B (6) muffler mounting B bolt (9) muffler (7) washer A Servicing Your Honda...

  • Page 108

    4. Install the muffler clamp (2) by aligning the tab (5) of the muffler clamp with the cutout (6) of the muffler. (11) (11) muffler clamp bolt (2) muffler clamp (5) tab (4) muffler (6) cutout (cont’d) Servicing Your Honda...

  • Page 109

    4. Tighten the exhaust pipe joint nuts to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) 5. Tighten the muffler clamp bolt, muffler mounting A bolt and B bolt (page 101). 6. Installation can be done in the reverse order of removal. Servicing Your Honda...

  • Page 110: Steering Damper

    (9) as shown. steering damper at the standard setting before Refer to the Honda Service Manual or see making any adjustments. your Honda dealer for steering damper • Check the spherical bearings and dust seal for disassembly.

  • Page 111

    (1), collar (2) and steering damper (3). Replace the spherical bearing if it does not move smoothly and quietly. Refer to the Honda Service Manual or see your dealer. (1) steering damper (2) “UP” mark (3) stopper ring...

  • Page 112: Additional Maintenance Procedures

    (1) handlebar (2) handlebar holders the fork bushings may be worn. Refer to the (3) paint mark Honda Service Manual for replacement or (4) handlebar upper holder bolts adjustment procedures, or see your dealer. Control Cables Periodically, disconnect the throttle, clutch and hot start cables at their upper ends.

  • Page 113

    (12) drive sprocket bolt Transmission oil drain bolt (6) clutch cover bolts (13) transmission oil drain bolt Cylinder head stud bolts (7) coolant drain bolt (14) cylinder head stud bolts (8) engine oil drainbolt Servicing Your Honda Servicing Your Honda...

  • Page 114: Appearance Care

    Wet any heavy deposits with water first. Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge. Servicing Your Honda...

  • Page 115

    #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda Servicing Your Honda...

  • Page 116: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments ......110 for maximum competition performance. Rear Suspension Adjustments ......125 Suspension Adjustments for Track Initial suspension adjustments should be Conditions...........129 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....130 break-in time.

  • Page 117: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Compression Damping Adjustment as it is worked (such as in a fork).

  • Page 118: Fork Springs

    Front Suspension Adjustments Both compression and rebound damping can be Fork Springs increased by turning the adjuster clockwise. The fork springs in CRF’s are about right for NOTICE riders weighing between 170 lb (77 kg) and 200 Always start with full hard when adjusting lb (91 kg) (less riding gear).

  • Page 119: Front Suspension Disassembly

    NOTICE disassembled and cleaned after the first 3 hours of riding. See an official Honda Keep the master cylinder upright to prevent air Service Manual or your dealer for this service. from entering system.

  • Page 120

    Front Suspension Adjustments 7. Remove the front axle nut (9) and loosen the 11. Loosen the fork bridge lower pinch bolts (19), then pull the fork legs down and out. axle pinch bolts (10) on both forks. (15) (14) Pull the front axle shaft (11) out of the wheel hub and remove the front wheel with disc cover/collar.

  • Page 121

    Front Suspension Adjustments 14. Hold the outer tube, then remove the fork 15. Drain the fork oil from the outer tube/slider 18. Make the mechanic's stopper tool out of a thin damper (6) from the outer tube using a lock (26) and oil holes (27) of the fork damper.

  • Page 122: Damper Oil Change

    Front Suspension Adjustments 23. Remove the fork damper assembly (32) from Damper Oil Change (23) the fork assembly (33). (30) Remove the fork from the vise. Remove the fork spring (34), spring retainer 1. Place the fork damper (1) in a vise with a (29) (35) and collar/washer (36) from the fork piece of wood or soft jaws to avoid damage.

  • Page 123

    Front Suspension Adjustments 3. Remove the fork cap assembly (2) from the 6. Clean the fork cap and fork damper threads 8. Pump the fork damper piston rod (4) slowly several times to bleed the air from the fork fork damper threads and then pop it out by (6).

  • Page 124

    Front Suspension Adjustments 10. Extend the fork damper piston rod (4) to 11. Place the fork damper (1) in a vise with a 13. Check the fork damper piston rod sliding maximum length, holding it, install the fork surface for damage. piece of wood or soft jaws to avoid damage.

  • Page 125: Fork Assembly

    Front Suspension Adjustments 15. Drain the extra oil from the oil holes (12) of NOTICE Fork Assembly the fork damper oil chamber (5). Improper disposal of drained fluids is harmful to By doing this procedure, about 0.2 US oz (5 cm 1.

  • Page 126

    Front Suspension Adjustments 3. Install the collar (3) to the C-ring (4) of the 4. Blow out the oil completely off the fork 5. Place the lower end (axle holder) of the slider fork damper assembly (5) as shown. in a vise with a piece of wood or soft jaws to spring (8) using compressed air.

  • Page 127

    Front Suspension Adjustments 9. Measure the length of the fork center bolt lock 11. Remove the piston base or mechanic's stopper 14. Remove the fork damper from the fork. nut (2) and fork center bolt (12) clearance. tool while pushing the fork damper. 15.

  • Page 128

    Front Suspension Adjustments 16. Install a new O-ring (15) on the fork damper Fork Oil Capacity: Optional Stiffer 26.20 lbf/in (4.59 N/mm) Fork Spring assembly (4). Apply the recommended fork Standard 25.12 lbf/in (4.4 N/mm) Fork Spring oil to the O-ring. 17.

  • Page 129

    Front Suspension Adjustments 19. Tighten the fork damper (17) to the specified 23. Clean the threads of the fork protector socket torque using the lock nut wrench (18). bolts (22) and axle holder thoroughly. Actual: Apply locking agent to the bolt threads. 25 lbf·ft (34 N·m, 3.5 kgf·m) Install the fork protectors (23), fork protector Torque wrench scale reading:...

  • Page 130

    Front Suspension Adjustments 26. Clean the threads of the brake caliper 30. Install the handlebar (34), mounting rubbers, mounting bolts (29) and brake caliper washers and handlebar lower holder nuts (35) (30) (31) thoroughly. and tighten the handlebar holder nuts to the Apply locking agent to the bolt threads.

  • Page 131

    Front Suspension Adjustments 32. With the front brake applied, pump the fork 34. Install and tighten the disc cover socket bolt up and down several times to seat the axle and (37) to the specified torque: check front brake operation. 10 Ibf·ft (13 N·m, 1.3 kgf·m) (37) (37) disc cover socket bolt...

  • Page 132: Rear Suspension Adjustments

    Service or disposal should only be done by your dealer or a qualified mechanic, equipped with the proper tools, safety equipment and the Honda Service Manual. If your CRF is new, put enough part-throttle break-in time (about one hour) on it to ensure that the suspension has worked in.

  • Page 133: Rear Suspension Damping

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

  • Page 134: Rear Suspension Race Sag

    Rear Suspension Adjustments unloaded: motorcycle on an optional workstand Ask the other helper to measure the loaded Rear Suspension Race Sag with rear suspension fully extended, no rider. with rider dimension. loaded with rider: motorcycle on ground, with REAR FENDER MOUNTING BOLT Setting the proper race sag (ride height) is very rider.

  • Page 135

    Rear Suspension Adjustments 5. Measure the loaded without rider dimension. Spring Rates A spring that is too stiff for your weight will not Do this with your CRF set at the standard race If you are lighter or heavier than the average allow the rear tire to hook up under acceleration rider and cannot set the proper ride height and will pass more bumps on to you.

  • Page 136: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 137: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 110 – 129. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.

  • Page 138

    Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...

  • Page 139

    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: –...

  • Page 140: Tuning Tips

    Tuning Tips An optional PGM-FI setting tool can change the NOTICE NOTICE ignition timing and amount of the fuel injection (page 157). Using spark plugs with an improper heat range An improperly tightened spark plug can damage Be sure to observe the PGM-FI setting by or incorrect reach can cause engine damage.

  • Page 141: Steering Damper Adjustment

    Steering Damper Adjustment The steering damper can be adjusted for riding Steering Damper Adjustment conditions by using following method: • Damping – Turning the steering damper adjuster adjusts how quickly the steering The steering damper adjuster (1) has 13 positions damper extends and retracts.

  • Page 142: Steering Damper Adjustment Guidelines

    Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods decribed on this page. Symptoms and Adjustment • Always begin with the standard settings. • Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment. Test ride after each adjustment.

  • Page 143: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle not adjustable. Align the groove in the outer tube changes in overall handling.

  • Page 144: Gearing

    Unless you have the required mechanical • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate knowhow, tools, and Honda Service Manual, higher gear (less teeth) to keep engine rpm appraisal of the gearing change. “Seat-of-the- sprocket changing should be done by your dealer.

  • Page 145: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 146: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to Handlebar Position, Width & Shape the threads of these bolts prior to adjustment to help ensure the correct torque is retained.

  • Page 147

    Adjustments for Competition...

  • Page 148

    Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ......142 Storing Your Honda..........143 You & the Environment ........144 Troubleshooting..........145 Tips...

  • Page 149: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 150: Removal From Storage

    If you won’t be riding for an extended period, Removal from Storage such as during the winter, thoroughly inspect your Honda and correct any problem before storing it. That way, needed repairs won’t be 1. Uncover and clean your CRF.

  • Page 151: You & The Environment

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

  • Page 152: Troubleshooting

    The items that require use of an CORRECT • Worn cylinder and • Brake dragging 1. Check the wheel INCORRECT official Honda Service Manual are followed by piston ring • Worn or damaged spin smoothly • Damaged cylinder head wheel bearings an asterisk (*).

  • Page 153

    Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy • Faulty ECM • Incorrect spark plug 1. Check the ignition INCORRECT 1. Check the spark INCORRECT •...

  • Page 154: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........148 other technical data. Specifications ...........149 Torque Specifications........150 Oxygenated Fuels..........153 Competition Logbook ........154 Optional Parts List ...........156 Spare Parts & Equipment.........157 Wiring Diagram..........158 Technical Information...

  • Page 155: Vehicle Identification

    Vehicle Identification The VIN (vehicle identification number) (1) is Serial Numbers stamped on the right side of the steering head. RIGHT SIDE The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of this manual.

  • Page 156: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85.9 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,181 mm Overall width Single 5˚ inclined from Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement vertical...

  • Page 157: Torque Specifications

    Torque Specifications Torque Nuts, Bolts, Fasteners Remarks Item lbf•ft N•m kgf•m ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts (14) RIGHT SIDE Water pump cover bolts Crankshaft hole cap NOTE 1 Transmission oil check bolt...

  • Page 158

    Torque Specifications Frame Torque Item Remarks lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch (14) bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1...

  • Page 159

    Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (40) FRAME Caliper mounting bolts NOTE 4 (44) (41) (29) (37) Front brake disc nuts NOTE 1 (48) Rear brake disc nuts NOTE 1 Brake pedal pivot bolt NOTE 5 (33) Spoke (front) (rear)

  • Page 160: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions.

  • Page 161: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.

  • Page 162

    Competition Logbook Date Running Location/Event Comments (Suspension Settings, Steering Damper Settings, Gearing, Chassis Adjustments, Time Maintenance Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 163: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks authorized dealer. Shock spring 296.9 lbf/in (52.0 N/mm) Standard FRAME Remarks No mark Driven sprocket < >: Drive chain links (factory products) Standard 49 Teeth, Aluminum. Blue <116>...

  • Page 164: Spare Parts & Equipment

    In addition to the usual nuts and bolts, radiator hoses Chemical Products consider the following: radiator shrouds (L & R) brake hoses (front & rear) Pro Honda GN4 4-stroke Oil Spare Parts (Engine and Transmission Oil) General Tools SAE80 or 90 gear oil spark plugs HP Fork Oil, SS-19 air cleaner (clean &...

  • Page 165: Wiring Diagram

    Wiring Diagram Technical Information...

  • Page 166: Consumer Information

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

  • Page 167: Authorized Manuals

    Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized manuals) Also available but not necessary to service your model is the Honda Common...

  • Page 168: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 169: Your Dealer

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

  • Page 170: The Honda Rider's Club (usa Only)

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

  • Page 171

    ..........134 competition logbook........154 stop button............18 suspension, front ........110 consumer information ........159 stopping ............18 suspension, rear..........125 contacting Honda ..........161 won’t start ..........145 suspension, track conditions ......129 controls ..............5 environment, protecting ........144 tire selection ..........138 coolant ...............54 after competition maintenance ......30 customer service..........162...

  • Page 172

    Index gap, spark plug ..........67 maintenance, rear suspension maintenance......125 gasohol ............153 after competition ..........30 Rider’s Club Honda (USA only).....163 gasoline..............40 before & after competition......30 riding, gearing.............137 between motos & practice......30 apparel ............2 guidelines, component locations ........32 basic operation ..........15 steering damper ..........135 general competition........26...

  • Page 173

    Index stopping engine ..........18 storage .............143 subframe ............36 suspension, front ..............85 rear..............86 suspension adjustment, front ............110 rear..............125 for track conditions ........129 guidelines ...........130 transmission oil ..........52 tuning tips............133 throttle, freeplay............59 inspection .............60 tires, air pressure ...........95 flat ..............95 selection............138 tools ...............157 torque specifications engine ............150 frame ...........151-152...

  • Page 174

    MEMO...

  • Page 175

    MEMO...

  • Page 176

    MEMO...

  • Page 177: Quick Reference

    Engine No. important notes. Owner’s: Name How To Avoid Costly Repairs Address City/State The engine of your Honda can be the most Phone expensive component to repair. Proper Dealer’s: maintenance, especially the use of the Name recommended fluids and filters, prevents Address premature wear and damage.

  • www.manualslib.com

    HONDA CRF250R 2006 OWNER'S MANUAL Pdf Download.

  • Page 1

    2006 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...

  • Page 2

    CRF and how it works. To protect your Please report any change of address or ownership investment, we urge you to take to your Honda dealer so we will be able to responsibility for keeping your CRF well contact you concerning important production maintained.

  • Page 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.

  • Page 4: Table Of Contents

    Is Your Motorcycle Ready to Ride?....9 Contacting Honda..........155 Pre-ride Inspection..........9 Chassis Your Honda Dealer..........156 Suspension............72 The Honda Rider’s Club (USA only) .....157 BASIC OPERATING INSTRUCTIONS ..11 Brakes..............77 Safe Riding Precautions........12 Wheels...............81 TABLE OF CONTENTS ......158 Starting & Stopping the Engine ......13 Tires &...

  • Page 5: Motorcycle Safety, Motorcycle Safety

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

  • Page 6: Important Safety Information, Important Safety Precautions

    As an experienced rider, you know there is much Keep your Honda in Safe Condition. you can do to protect yourself when you ride. Maintaining your CRF properly is critical to your safety. A loose bolt, for example, can cause a...

  • Page 7: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 8: Safety Labels

    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. Motorcycle Safety...

  • Page 9: Operating Controls

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

  • Page 10: Operation Component Locations

    Operation Component Locations hot start lever clutch lever front brake lever throttle grip engine stop button choke knob kickstarter fuel valve shift lever rear brake pedal Operating Controls...

  • Page 11: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....9 you prepared, this section discusses how to Pre-ride Inspection ..........9...

  • Page 12: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 13: Is Your Motorcycle Ready To Ride, Pre-ride Inspection

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection 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 Check the following before each ride: right): •...

  • Page 14

    Before Riding...

  • Page 15: Basic Operating Instructions

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

  • Page 16: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 17: Starting & Stopping The Engine, Starting Procedure, Flooded Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting described below. levels before starting the engine (pages 37,40,41). 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. Your CRF can be kickstarted with the Cold Engine Starting 3.

  • Page 18

    Starting & Stopping the Engine How to Stop the Engine (1) throttle grip (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) 2 – 3 times, and then close it.

  • Page 19: Break-in Guidelines

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

  • Page 20

    Basic Operating Instructions...

  • Page 21: Servicing Your Honda, Before You Service Your Honda The Importance Of Maintenance

    You’ll also find Exhaust Pipe/Muffler .........87 important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ....91 and tips for keeping your Honda looking good. Maintenance Component Locations....28 Seat Removal .............29 Appearance Care ..........93 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30...

  • Page 22: The Importance Of Maintenance

    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. Servicing Your Honda...

  • Page 23: Maintenance Safety, Important Safety Precautions

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 24: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine...

  • Page 25

    NOTE: 1.Clean after every heat for dusty riding conditions. 2.Replace every 2 years. Replacement requires mechanical skill. 3.Replace after the first break-in ride. 4.Inspect after the first break-in ride. 5.Replace the transmission oil, if the clutch discs and plates are replaced. Servicing Your Honda...

  • Page 26: General Competition Maintenance

    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.

  • Page 27

    Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium...

  • Page 28

    For added peace of mind, carburetor is screwed on tight. Make certain the throttle remove the nuts, clean the threads, and apply Honda Thread operation is perfect after servicing and inspecting. Lock or an equivalent prior to torquing the nuts.

  • Page 29

    If replacement is necessary, both seals offers added assurance and security. Remove the nuts, clean should be replaced. the threads of both the nuts and bolts, apply Honda Thread Lock or an equivalent and tighten to the specified torque. Servicing Your Honda...

  • Page 30: Before & After Competition Maintenance, Between Motos & Practice Maintenance, After Competition Maintenance

    (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...

  • Page 31

    If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 93). Servicing Your Honda...

  • Page 32: Maintenance Component Locations

    Servicing Your Honda...

  • Page 33: Seat Removal

    2. Remove the seat (2) by sliding it backward. 2. Install and tighten the seat bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat bolts (2) seat (3) front prong (4) seat bracket (5) rear prong (6) tab Servicing Your Honda...

  • Page 34: Fuel Tank Removal

    3. Remove the shroud A bolts/collars (2). (7) air cleaner cover rubber 4. Remove the shroud B bolts (3) and shrouds (4). (8) fuel tank bolt (9) fuel line (10) fuel valve bolt (2) shroud A bolts/collars (3) shroud B bolts (4) shroud Servicing Your Honda...

  • Page 35

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

  • Page 36: Subframe Removal

    3. Remove the seat (page 29). (6) lower mounting bolts (1) crankcase breather tube (7) upper mounting bolt (8) subframe (2) fuel tank band (3) air cleaner cover rubber (4) screw (5) air cleaner connecting tube clamp Servicing Your Honda...

  • Page 37

    36 lbf·ft (49 N·m, 5.0 kgf·m) (4) screw (5) air cleaner connecting tube clamp (6) air cleaner cover rubber (7) fuel tank band (8) crankcase breather tube (1) subframe (2) upper mounting bolt (3) lower mounting bolts Servicing Your Honda...

  • Page 38: Fuel System

    (2) fuel filter of gasoline. If pinging or spark knock persists, WARNING consult your Honda dealer. 1. Check the fuel valve (1) and fuel filter (2) for Gasoline is highly flammable and contamination.

  • Page 39

    5. Install the fuel joint in the fuel tank. 6. Install the fuel tank (page 31) and refill the fuel. Turn the fuel valve to ON; check for leaks. (1) fuel joint (3) fuel filter (2) bolts (4) O-ring Servicing Your Honda...

  • Page 40: Engine Oil

    JASO T 903 MA or MB NOT RECOMMENDED suggested oil* Pro Honda GN4, HP4 (without molybdenum additives) or HP4M (with Other viscosities shown in the following chart molybdenum additives) may be used when the average temperature in 4-stroke oil or an equivalent* your riding area is within the indicated range.

  • Page 41

    6 races or about every 15.0 hours. Repeat steps 1–5. However, if you replace only the oil before 6. Reinsert the engine oil filler cap/dipstick. the recommended interval, see page 21. 7. Check for oil leaks. (cont’d) Servicing Your Honda...

  • Page 42

    (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage.

  • Page 43: Transmission Oil

    Other viscosities shown in the following chart suggested oil* Pro Honda HP Trans oil, may be used when the average temperature in Pro Honda GN4 or HP4 your riding area is within the indicated range.

  • Page 44

    5. After inspection the oil level or adding oil, (3) sealing washer tighten the oil check bolt to the specified torque: Oil Check Bolt: 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Install the transmission oil filler cap securely. Servicing Your Honda...

  • Page 45: Coolant

    Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is low. Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing.

  • Page 46

    Refer to Safety Precautions on page 19. Honda Service Manual for troubleshooting of leaks). Coolant should be replaced by your Honda 2. Check the water hoses (1) for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.

  • Page 47: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.

  • Page 48

    Install and tighten the retaining bolt (1) securely. (10) (1) air cleaner retaining bolt (2) two access top tabs (3) air cleaner assembly (4) “ ” mark (10) groove Servicing Your Honda...

  • Page 49: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...

  • Page 50

    5. Operate the throttle grip to ensure that it functions smoothly and returns completely. 6. Install the fuel tank (page 31). If you can’t get the freeplay within the specified range, contact your Honda dealer. (–) (2) dust cover (+) increase (3) lock nut (–) decrease...

  • Page 51

    If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commercially- available cable lubricant to prevent premature rust and corrosion. Servicing Your Honda...

  • Page 52: Engine Idle Speed

    Refer to Safety Precautions on page 19. Idle Speed Adjustment The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled 1. Turn the pilot screw (1) in until it is lightly servicing, including carburetor adjustment.

  • Page 53: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. (cont’d) Servicing Your Honda...

  • Page 54

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the Honda Service Manual (page 154). Servicing Your Honda...

  • Page 55

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

  • Page 56

    7 lbf·ft (10 N·m, 1.0 kgf·m) 5. Apply engine oil to the needle bearing of the clutch lifter. 6. Install the clutch lifter (4) onto the rod. (7) O-ring (8) clutch cover (3) clutch lifter rod (4) clutch lifter Servicing Your Honda...

  • Page 57

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

  • Page 58: Hot Start Lever

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

  • Page 59: Spark Plug

    “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. (3) sealing gasket (4) spark plug gap Servicing Your Honda...

  • Page 60: Valve Clearance

    2. Remove the spark plug (page 55). (1) breather tube (2) direct ignition coil 3. Remove the cylinder head cover bolts (3), and cylinder head cover (4). (3) cylinder head cover bolts (4) cylinder head cover 4. Remove the plug hole packing. Servicing Your Honda...

  • Page 61

    If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 58) and select the correct shim for each valve. (3) primary drive gear lock bolt (5) index mark (4) “punch” mark (6) exhaust rocker arm Servicing Your Honda...

  • Page 62

    (3) until it stops, in order to retract the tensioner fully. Then insert the stopper tool fully to hold the stopper in the fully retracted position. (1) cam chain tensioner lifter cover bolt (2) sealing washer (3) stopper tool Servicing Your Honda...

  • Page 63

    Do not let the valve lifters and shims fall into the Be careful to not let the set rings of the camshaft crankcase. holders fall into the crankcase. (8) shims (7) valve lifters (4) camshaft holder bolts (6) camshaft (5) camshaft holders Servicing Your Honda...

  • Page 64

    (1) valve lifter 2. Measure the shim thickness and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...

  • Page 65

    (2) valve retainers 4. Rotate the primary drive gear lock bolt (4) (crankshaft) clockwise and align the “punch” mark (5) with the index mark (6). (4) primary drive gear lock bolt (5) “punch” mark (6) index mark (cont’d) Servicing Your Honda...

  • Page 66

    Tighten the camshaft holder bolts in a criss-cross pattern in 2 or 3 steps. (14) (12) (16) (16) sealing washer (17) cam chain tensioner lifter cover bolt (13) (14) (13) intake cam lobes (14) camshaft holder bolts Servicing Your Honda...

  • Page 67

    Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) direct ignition coil (8) breather tube 5. Install the fuel tank and the seat (page 31). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 68: Piston/piston Rings/piston Pin

    4. Remove the seat and fuel tank (page 30). 5. Remove the subframe (page 32). 6. Remove the carburetor (page 119). 7. Remove the exhaust pipe (page 90). (3) engine hanger nuts (4) engine hanger plates (1) water hose clamp (2) water hose Servicing Your Honda...

  • Page 69

    Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. (10) (5) cylinder head bolts (6) cylinder bolt (11) (9) dowel pins (11) cam chain guide (10) cylinder head gasket (7) cylinder head nuts/washers (8) cylinder head Servicing Your Honda...

  • Page 70

    2. Remove the dowel pins (3) and cylinder (1) piston ring gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin (4) piston rings Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...

  • Page 71

    1. Clean the piston ring thoroughly. oil ring We recommend you consult the Service Manual 2. Apply engine oil to piston rings and install or your authorized Honda dealer for correct them. Service Limit measurements. NOTICE Do not damage the piston ring by spreading the ends too far.

  • Page 72

    Do not align the piston pin clip end gap with the piston cut-out. (1) dowel pins (2) cylinder gasket 5. Clean the any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) cut-out Servicing Your Honda...

  • Page 73

    Do not damage the piston rings and cylinder walls. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (4) cylinder (5) piston rings (cont’d) Servicing Your Honda...

  • Page 74

    Do not let the washers and nuts fall into the crankcase. (7) engine hanger plates (8) engine hanger nuts/bolts of the frame side (9) engine hanger nut/bolt of the engine side (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...

  • Page 75

    – abnormal engine noise (page 29). – secondary air leaks – coolant leaks (10) (9) radiator hose (10) radiator hose clamp 7. Install the shims, valve lifters and camshaft (page 61). 8. Install the spark plug (page 55). Servicing Your Honda...

  • Page 76

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's (1) fork protector (2) dust seal front suspension.

  • Page 77

    (page 113). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Remove the subframe (page 32). The instructions found in this owner’s manual are 3.

  • Page 78: Fork Oil Change

    (weight) 5 W when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage, hold both the outer tube and slider equivalent when removing the fork damper.

  • Page 79

    12.4 US oz capacity (366 cm Maximum oil 13.9 US oz Slightly stiffer as capacity (410 cm it nears full compression. Minimum oil 10.6 US oz Slightly softer as capacity (314 cm it nears full compression. (cont’d) Servicing Your Honda...

  • Page 80

    (10) (2) fork damper (10) O-ring 7. Temporarily install the fork damper to the outer tube. After installing the fork leg (page 106) tighten the fork damper to the specified torque: 25 lb·ft (34 N·m, 3.5 kgf·m) Servicing Your Honda...

  • Page 81: Brakes

    (3) piston 80), there is probably air in the brake system. (2) adjuster (–) Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the 1. Loosen the lock nut (1). system. 2. To position the brake lever farther away from the handgrip, turn the adjuster (2) clockwise.

  • Page 82

    Worn brake pads should be replaced. If the pads (20 mm), there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda dealer for If the brake lever freeplay exceeds 0.8 in...

  • Page 83

    Brakes Adding Front Brake Fluid Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent. brake fluid or an equivalent. When adding brake fluid be sure the reservoir is...

  • Page 84

    0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) front brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 85: Wheels

    3. Check wheel rim runout. If runout is control. It’s also important that the rim locks are noticeable, see the Honda Service Manual for secure to prevent tire slippage. inspection instructions.

  • Page 86: Tires & Tubes

    Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...

  • Page 87

    • Use a replacement tire equivalent to the original. • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 88: Drive Chain

    Lubricate the drive chain (page 85) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed. (2) chain guide slider (3) wear limit Servicing Your Honda...

  • Page 89

    2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda Chain Lube or an equivalent, or SAE 80 rollers and replace them if below the service Align the index marks (4) of the axle plates or 90 gear oil is recommended.

  • Page 90

    17 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 91: Exhaust Pipe/muffler

    1. Remove the seat mounting bolts (1), side cover bolts (2) and side covers (3). (4) muffler clamp bolt (5) muffler (6) muffler mounting bolt (7) washer (1) seat mounting bolt (3) side cover (2) side cover bolt Servicing Your Honda...

  • Page 92

    (7) muffler mounting bolt (8) washer (9) muffler clamp bolt 3. Install the new gaskets (5) to the exhaust joint pipe (6). 4. Install each muffler to the exhaust joint pipe. (5) gasket (6) exhaust joint pipe Servicing Your Honda...

  • Page 93

    (3) joint pipe clamp bolt (4) exhaust joint pipe mounting bolt (5) exhaust joint pipe (4) exhaust joint pipe (5) gasket (6) exhaust pipe Servicing Your Honda...

  • Page 94

    6. Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt (page 89). 7. Tighten the muffler clamp bolts and muffler mounting bolts (page 88). 8. Installation can be done in the reverse order of removal. Servicing Your Honda Servicing Your Honda...

  • Page 95: Additional Maintenance Procedures

    If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to the Control Cables Honda Service Manual for replacement or adjustment procedures, or see your Honda Periodically, disconnect the throttle, clutch and dealer.

  • Page 96

    (9) cylinder head bolts (10) drive sproket bolt (1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cover bolts (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts Servicing Your Honda Servicing Your Honda...

  • Page 97: Appearance Care

    You may use Pro Honda Hondabrite, a performance. and steering head bearings-driving dirt inside multi-surface cleaner/degreaser, to remove both and needed lubrication out.

  • Page 98

    #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda Servicing Your Honda...

  • Page 99: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......96 for maximum competition performance. Rear Suspension Adjustments ......109 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ...........113 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....114 break-in time.

  • Page 100: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).

  • Page 101

    See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and lower the oil level in increments of 0.2 oz (5 cc)

  • Page 102

    Front Suspension Adjustments 4. Remove the washers/handlebar holder nuts (4), 7. Remove the disc cover (8) by removing the Do not support the brake caliper by the brake mounting rubbers and handlebar (5). disc cover bolts (9). hose. Do not operate the brake lever after the front wheel is removed.

  • Page 103

    Front Suspension Adjustments 12.Clean the fork assembly, especially the sliding 17.Temporarily install the fork damper to the NOTICE surface of the slider (19) and dust seal (20). outer tube. 13.Record the rebound damping adjuster position 18.Set the axle holder (28) in a vise with a piece of The outer tube can drop on the slider and and turn the adjuster counterclockwise until it damage the fork dust seal and guide bushing...

  • Page 104

    Front Suspension Adjustments 22.Apply pressure to the fork damper and insert a Damper Oil Change special tool or mechanic’s stopper tool (30) (see below) between the axle holder (28) and lock nut (31) 1. Set the fork damper (1) in a vise with a piece 23.Hold the lock nut and remove the center bolt (32) of wood or soft jaws to avoid damage.

  • Page 105

    (1) as shown. Recommended Oil: Be careful not to damage the fork cap bushing Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5W or equivalent (4). Recommended Amount: Do not disassemble the fork cap assembly.

  • Page 106

    Front Suspension Adjustments 9. Tighten the fork cap assembly (2) while 11.Screw in the lock nut (7) to the fork damper 13.Drain the extra oil from the fork damper oil piston rod (5) fully. holding the fork damper (1) using the lock nut hole (9).

  • Page 107

    Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 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 Wipe the oil completely off the fork damper.

  • Page 108

    Front Suspension Adjustments 4. Set the axle holder in a vise with a piece of 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the center bolt (8) O-ring. wood or soft jaws to avoid to damage. center bolt (8) clearance.

  • Page 109

    (1). No mark 1 scribe mark and (factory products) Recommended Oil: 3 scribe mark 75 degrees apart Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) Standard oil 12.6 US oz Standard oil 12.5 US oz...

  • Page 110

    Front Suspension Adjustments 15.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the assembly (4) is in good condition. Apply the specified torque using the lock nut wrench recommended fork oil to the O-ring. (14).

  • Page 111

    Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle Fit the brake caliper over the disc, taking care (18) and axle holder thoroughly. clamps contact each other. not to damage the brake pads. Apply locking agent to the bolt threads.

  • Page 112

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

  • Page 113: Rear Suspension Adjustments

    Min. : 9.88 in (251 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring) Min. (Softer, 5.1 kgf/mm): 9.92 in (252 mm) The instructions found in this owner’s manual are limited to adjustments of the shock assembly Min.

  • Page 114

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

  • Page 115

    Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT Standard Race Sag: 3.9 in (100 mm) important for competition use.

  • Page 116

    Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 117: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 118: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 96 - 110. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.

  • Page 119

    Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...

  • Page 120

    Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring preload). Example: –...

  • Page 121: Carburetor Adjustments & Tuning Tips

    (2) and is mixed with air from your CRF. See your Honda dealer. the air passage (3) (located above the throttle valve (4)) to provide a rich mixture for starting.

  • Page 122

    Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.

  • Page 123

    3. Tighten the drain screw. richen the mixture. Honda carburetor jet sizes are numbered in increments of 2 or 3. When changing the main jet The minimum to maximum range of pilot screw size, increase or decrease it gradually until the adjustment is 1 to 1 3/4 turns out from the lightly desired jetting is obtained.

  • Page 124

    Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 30). 9. Remove the hot start cable holder (4). 11.Remove the throttle drum cover bolt (7) and 5. Remove the sub-frame (page 32). throttle drum cover (8). 6. Loosen the insulator band screw (2). (4) hot start cable holder (7) throttle drum cover bolt 10.Disconnect the rear suspension (5) upper...

  • Page 125

    Carburetor Adjustments & Tuning Tips 3. Remove the link arm set screw (7). When installing the floating valve (10) onto Carburetor Disassembly/Assembly When installing the link arm set screw, apply the throttle valve (8) make sure the floating a locking agent to the link arm set screw valve’s flat side faces out and the hole (11) threads.

  • Page 126

    Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (19), throttle stop 9. Measure the float level (26) with the float (12) and accelerator pump cover (13). screw holder (20), float bowl screws (21), level gauge (27) during float tab just tube guides (22) and float bowl (18).

  • Page 127

    Carburetor Adjustments & Tuning Tips To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. • Route the throttle cables (1), hot start cable (2) and throttle sensor wire correctly. • After installing the carburetor, adjust the throttle grip free play and hot start lever free play.

  • Page 128

    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...

  • Page 129

    Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the situations that may require additional atmospheric conditions or race day situations that...

  • Page 130

    Carburetor Adjustments & Tuning Tips 6. Adjust the pilot screw as required. Carburetor Minor Adjustments WARNING The standard carburetor settings are ideal for the Gasoline is highly flammable and following conditions: sea level altitude, and 20°C explosive. You can be burned or (68 °F) air temperature.

  • Page 131

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

  • Page 132

    Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may Refer to Spark Plug on page 55.

  • Page 133: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle not adjustable. Align the groove in the outer tube changes in overall handling.

  • Page 134: Gearing

    Honda Service Manual, engine may bog in certain corners so you’ll wheelspin with a gearing change can make you sprocket changing should be done by your Honda need to slip the clutch to compensate; feel like you’re going slower when, in reality, dealer.

  • Page 135: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 136: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to Handlebar Position, Width & Shape help ensure the correct torque is retained.

  • Page 137: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......134 Storing Your Honda..........135 You & the Environment ........136 Troubleshooting..........137 Tips...

  • Page 138: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 139: Storing Your Honda

    Removal from Storage such as during the winter, thoroughly inspect bolt/sealing washer (1) at the water pump (2) to your Honda and correct any problem before drain coolant. storing it. That way, needed repairs won’t be After the coolant has been completely 1.

  • Page 140: You & The Environment

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

  • Page 141: Troubleshooting

    POSSIBLE CAUSES parenthesis. The items that require use of the • Lack of fuel in tank 1. Disconnect fuel FUEL FLOW Honda Service Manual are followed by an line at carburetor RESTRICTED (P-34) • Clogged fuel line and check for asterisk.

  • Page 142

    Tips...

  • Page 143: Technical Information

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

  • Page 144: Vehicle Identification, Serial Numbers

    Vehicle Identification The frame number (2) is stamped on the right Serial Numbers side of the steering head. RIGHT SIDE The frame, VIN, and engine serial numbers are required when you register your CRF. They may also be required when ordering replacement parts.

  • Page 145: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 85.5 in 2,172 mm Single 10˚ inclined from Overall width Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement vertical...

  • Page 146: Torque Specifications

    Torque Specifications Torque Nuts, Bolts, Fasteners Remarks Item lbf•ft N•m kgf•m ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts RIGHT SIDE Water pump cover bolts Crankshaft hole cap Transmission oil check bolt Clutch cover bolts...

  • Page 147

    Torque Specifications Frame Torque Item Remarks lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch (13) bolts (12) Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1...

  • Page 148

    Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (38) FRAME (34) (33) Front brake master (28) cylinder holder bolts Brake hose bolts Caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 1 (37) Rear brake disc nuts NOTE 1 Brake pedal pivot bolt (23) Spoke...

  • Page 149: High Altitude Carburetor Adjustment

    However, the carburetor must be returned to standard factory specifications when lower altitude riding is desired. See your Honda dealer for high altitude modification. NOTICE Sustained operation at altitudes below 5,000 feet...

  • Page 150: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions.

  • Page 151: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.

  • Page 152

    Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 153: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 296.8 lbf/in (5.30 kgf/mm) Standard 51 Teeth, Aluminum. Standard CARBURETOR Remarks <114>...

  • Page 154: Spare Parts & Equipment

    (front & rear) additives) or HP4M (with molybdenum additives) 4-stroke Oil (Engine Oil) Spare Parts Pro Honda HP Trans Oil or Pro Honda GN4 or General Tools HP4 (without molybdenum additives only) spark plugs 4-stroke Oil (Transmission Oil) air cleaner (clean &...

  • Page 155: Wiring Diagram

    Wiring Diagram SPARK THROTTLE POSITION PLUG SENSOR Technical Information...

  • Page 156

    Technical Information...

  • Page 157: Consumer Information

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

  • Page 158: Authorized Manuals

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

  • Page 159: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 160: Your Honda Dealer

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

  • Page 161: The Honda Rider's Club (usa Only), The Honda Rider's Club (usa Only)

    Safety Foundation training. Separate free training from the Specialty Vehicle Institute of America for ATV owners. • One full year of the Honda Red Rider magazine or Honda Red Rider ATV (for ATV purchasers). • Discounts from HRCA partners for experienced rider courses.

  • Page 162: Service Preparations Maintenance Component Locations, Fluids & Filters Fuel System, Engine Throttle, Chassis Suspension

    General Competition Maintenance ....22 Drive Chain ............84 Your Honda Dealer..........156 Before & After Competition Maintenance..26 Exhaust Pipe/Muffler ........87 The Honda Rider’s Club (USA only) .....157 Between Motos & Practice Maintenance ..26 Additional Maintenance Procedures ....91 After Competition Maintenance ....26 TABLE OF CONTENTS ......158 Appearance Care ..........93...

  • Page 163: Index

    ..............96 recommendation...........34 fluid level .............78 rear..............110 refueling ............34 lever, front adjustment .........77 dealer, your Honda ..........156 system............34 pad wear ............80 diagram, wiring ..........151 oxygenated ..........146 pedal height ..........77 drive chain............84 tank capacity ..........34 break-in guidelines ..........15 valve .............13...

  • Page 164

    Index gap, spark plug ..........55 maintenance, rear suspension maintenance......72 gasohol ............146 additional procedures ........91 Rider’s Club Honda.........157 gasoline..............34 after competition ..........26 riding, gearing.............130 before & after competition......26 basic operation ..........11 guidelines, suspension adjustment ....114 between motos & practice......26 before..............7 component locations ........28 important safety information......2...

  • Page 165

    Index suspension, front ............72,96 rear............73,109 suspension adjustment, front ..............96 rear..............109 for track conditions ........113 guidelines ...........114 transmission oil ..........39 tuning tips ............117 throttle, freeplay............46 inspection .............47 tires, air pressure ...........82 flat ..............82 selection............83 tools ...............150 torque specifications........142 transporting............134 troubleshooting..........137 tubes, replacing ..........82 valve, fuel............34 vehicle identification........140 washing your motorcycle ........93...

  • Page 166

    Memo...

  • Page 167

    Memo...

  • Page 168: Quick Reference

    Pro Honda GN4 or HP4 (without molybdenum additives) or HP4M (with molybdenum additives) 4-stroke oil, or an equivalent. Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdem additives) 4-stroke oil, or an equivalent. 80/100 – 21 51M 100/90 –...

  • www.manualslib.com

    HONDA CRF250R OWNER'S MANUAL Pdf Download.

  • Page 2

    CRF and how it works. To protect your Please report any change of address or ownership investment, we urge you to take to your Honda dealer so we will be able to responsibility for keeping your CRF well contact you concerning important production maintained.

  • Page 3

    2007 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...

  • Page 4

    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.

  • Page 5: Table Of Contents

    Pre-ride Inspection..........9 Chassis Contacting Honda..........153 Suspension............72 Your Honda Dealer..........154 BASIC OPERATING INSTRUCTIONS ..11 Brakes..............77 The Honda Rider’s Club .........155 Safe Riding Precautions........12 Wheels...............81 Starting & Stopping the Engine ......13 Tires & Tubes ............82 TABLE OF CONTENTS ......156 Break-in Guidelines ..........15 Drive Chain ............84...

  • Page 6: Motorcycle Safety, Motorcycle Safety

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

  • Page 7: Important Safety Information, Important Safety Precautions

    Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.

  • Page 8: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 9: Safety Labels

    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. Motorcycle Safety...

  • Page 10: Operating Controls

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

  • Page 11: Operation Component Locations

    Operation Component Locations hot start lever clutch lever front brake lever throttle grip engine stop button choke knob kickstarter fuel valve shift lever rear brake pedal Operating Controls...

  • Page 12: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....9 you prepared, this section discusses how to Pre-ride Inspection..........9...

  • Page 13: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 14: Is Your Motorcycle Ready To Ride, Pre-ride Inspection

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection 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 Check the following before each ride: right): •...

  • Page 15

    Before Riding...

  • Page 16: Basic Operating Instructions

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

  • Page 17: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 18: Starting & Stopping The Engine, Starting Procedure, Flooded Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting described below. levels before starting the engine (pages 37,40,41). 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. Your CRF can be kickstarted with the Cold Engine Starting 3.

  • Page 19

    Starting & Stopping the Engine How to Stop the Engine (1) throttle grip (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle grip (1) two or three times, and then close it.

  • Page 20: Break-in Guidelines

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

  • Page 21

    Basic Operating Instructions...

  • Page 22: Servicing Your Honda

    You’ll also find Exhaust Pipe/Muffler .........87 important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ....91 and tips for keeping your Honda looking good. Maintenance Component Locations....28 Seat Removal .............29 Appearance Care ..........93 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30...

  • Page 23: The Importance Of Maintenance

    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. Servicing Your Honda...

  • Page 24: Maintenance Safety, Important Safety Precautions

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 25: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine...

  • Page 26

    NOTE: 1.Clean after every moto for dusty riding conditions. 2.Replace every 2 years. Replacement requires mechanical skill. 3.Replace after the first break-in ride. 4.Inspect after the first break-in ride. 5.Replace the transmission oil, if the clutch discs and plates are replaced. Servicing Your Honda...

  • Page 27: General Competition Maintenance

    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.

  • Page 28

    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...

  • Page 29

    Make certain the throttle operation is to the proper torque specification. For added peace of mind, perfect after servicing and inspecting. remove the nuts, clean the threads, and apply Pro Honda Hondalock or an equivalent prior to torquing the nuts. Servicing Your Honda...

  • Page 30

    Application of a thread locking agent to essential fasteners should be replaced. offers added assurance and security. Remove the nuts, clean the threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent and tighten to the specified torque.

  • Page 31: Before & After Competition Maintenance, Between Motos & Practice Maintenance, After Competition Maintenance

    (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...

  • Page 32

    If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 93). Servicing Your Honda...

  • Page 33: Maintenance Component Locations

    Servicing Your Honda...

  • Page 34: Seat Removal

    2. Remove the seat (2) by sliding it backward. 2. Install and tighten the seat mounting bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (3) front prong (4) seat bracket (5) rear prong (6) tab Servicing Your Honda...

  • Page 35: Fuel Tank Removal

    3. Remove the shroud A bolts/collars (2). (7) air cleaner cover rubber 4. Remove the shroud B bolts (3) and shrouds (4). (8) fuel tank bolt (9) fuel line (10) fuel valve bolt (2) shroud A bolts/collars (3) shroud B bolts (4) shroud Servicing Your Honda...

  • Page 36

    7. Put the breather tube (7) in the steering stem (11) nut. (10) (12) (10) shroud (11) shroud B bolts (12) shrouds A bolts/collars (4) fuel tank bolt/collar (5) air cleaner cover rubber 12. Install the seat (page 29). (6) fuel tank band (7) breather tube Servicing Your Honda...

  • Page 37: Subframe Removal

    3. Remove the seat (page 29). (6) subframe lower mounting bolts (1) crankcase breather tube (7) subframe upper mounting bolt (2) fuel tank band (8) subframe (3) air cleaner cover rubber (4) screw (5) air cleaner connecting tube clamp Servicing Your Honda...

  • Page 38

    36 lbf·ft (49 N·m, 5.0 kgf·m) (4) screw (5) air cleaner connecting tube clamp (6) air cleaner cover rubber (7) fuel tank band (8) crankcase breather tube (1) subframe (2) subframe upper mounting bolt (3) subframe lower mounting bolts Servicing Your Honda...

  • Page 39: Fuel System

    If pinging or spark knock persists, WARNING consult your Honda dealer. Gasoline is highly flammable and Never use stale or contaminated gasoline. Avoid explosive. You can be burned or getting dirt, dust or water in the fuel tank.

  • Page 40

    Turn the fuel valve to ON; check for fuel approved gasoline container. leaks. 2. Remove the fuel tank (page 30). 3. Remove the fuel joint (1) from the fuel tank by removing the bolts (2). (1) fuel joint (3) fuel filter (2) bolts (4) O-ring Servicing Your Honda...

  • Page 41: Engine Oil

    JASO T 903 NOT RECOMMENDED suggested oil* Pro Honda GN4 4-stroke oil or an equivalent* Other viscosities shown in the following chart may be used when the average temperature in * Suggested 4-stroke engine oils are equal your riding area is within the indicated range.

  • Page 42

    6 races or about every 15.0 hours. Repeat steps 1–5. However, if you replace only the oil before 6. Reinsert the engine oil filler cap/dipstick. the recommended interval, see page 21. 7. Check for oil leaks. (cont’d) Servicing Your Honda...

  • Page 43

    (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the rubber seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage.

  • Page 44: Transmission Oil

    NOT RECOMMENDED suggested oil* Pro Honda GN4 4-stroke oil or an equivalent* Other viscosities shown in the following chart may be used when the average temperature in * Suggested 4-stroke engine oils are equal your riding area is within the indicated range.

  • Page 45

    5. After inspecting the oil level or adding oil, (3) sealing washer tighten the oil check bolt to the specified torque: Oil Check Bolt: 9 lbf·ft (12 N·m, 1.2 kgf·m) 6. Install the transmission oil filler cap securely. Servicing Your Honda...

  • Page 46: Coolant

    Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is low. Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing.

  • Page 47

    If oil leaks through the check hole, Always let the engine and radiator cool the oil seal is damaged. See the Honda down before removing the radiator cap. Service Manual or consult your Honda dealer for replacing the water seal or the oil seal.

  • Page 48: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.

  • Page 49

    Install and tighten the air cleaner retaining bolt (1) securely. (10) (1) air cleaner retaining bolt (2) two access top tabs (3) air cleaner assembly (4) “∆” mark (10) groove Servicing Your Honda...

  • Page 50: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...

  • Page 51

    5. Operate the throttle grip to ensure that it functions smoothly and returns completely. 6. Install the fuel tank (page 31). If you can’t get the freeplay within the specified (–) range, contact your Honda dealer. (2) dust cover (+) increase (3) lock nut (–) decrease...

  • Page 52

    If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commercially- available cable lubricant to prevent premature rust and corrosion. Servicing Your Honda...

  • Page 53: Idle Speed Adjustment, Engine Idle Speed

    Refer to Safety Precautions on page 19. Idle Speed Adjustment The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled 1. Turn the pilot screw (1) in until it is lightly servicing, including carburetor adjustment.

  • Page 54: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. Servicing Your Honda...

  • Page 55

    1. Check for smooth clutch lever operation. If or worn, or the clutch discs may be worn. See necessary, lubricate the clutch lever pivot or your Honda dealer or refer to the Honda Service clutch cable. Manual (page 152). 2. Check the clutch cable for deterioration, kinks, or damage.

  • Page 56

    4. Remove the five clutch spring bolts and clutch (9) clutch lifter (11) clutch discs and plates (10) clutch lifter rod springs (7). (2) clutch plate Loosen the bolts in a crisscross pattern in two or three progressive steps. Servicing Your Honda...

  • Page 57

    5. Apply engine oil to the needle bearing of the bolts to the specified torque: clutch lifter. 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Install the clutch lifter (4) onto the clutch lifter rod. (7) O-ring (8) clutch cover (3) clutch lifter rod (4) clutch lifter Servicing Your Honda...

  • Page 58

    Connect the brake pedal return spring (13) if it was removed. (12) (11) (13) (10) (9) dust seals (12) washer (10) rear brake pedal (13) brake pedal return spring (11) brake pedal pivot bolt 17. Fill the crankcase with transmission oil (page 40). Servicing Your Honda...

  • Page 59: Hot Start Lever

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

  • Page 60: Spark Plug

    10. Connect the direct ignition coil. Take care to with a new one. avoid pinching any cables or wires. (3) sealing gasket 11. Install the fuel tank and seat (pages 29,31). (4) spark plug gap Servicing Your Honda...

  • Page 61: Valve Clearance, Cylinder Head Cover Removal, Positioning On Compression Stroke

    2. Remove the spark plug (page 55). (1) breather tube (2) direct ignition coil 3. Remove the cylinder head cover bolts (3) and cylinder head cover (4). (3) cylinder head cover bolts (4) cylinder head cover 4. Remove the spark plug hole packing. Servicing Your Honda...

  • Page 62: Valve Clearance Inspection

    If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 58) and select the correct shim for each valve. (2) primary drive gear bolt (4) index mark (3) punch mark (5) exhaust rocker arm Servicing Your Honda...

  • Page 63

    (3) until it stops, in order to valve clearance. retract the tensioner fully. Then insert the tensioner stopper fully to hold the stopper in the fully retracted position. (1) cam chain tensioner lifter cover bolt (2) sealing washer (3) tensioner stopper Servicing Your Honda...

  • Page 64

    Be careful to not let the set rings of the camshaft Do not let the valve lifters or shims fall into the holders fall into the crankcase. crankcase. (8) shims (4) camshaft holder bolts (6) camshaft (7) valve lifters (5) camshaft holders Servicing Your Honda...

  • Page 65

    2. Measure the shim thickness with a micrometer and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...

  • Page 66

    (1) shims (2) valve retainers 4. Rotate the primary drive gear bolt (4) (crankshaft) clockwise and align the punch mark (5) with the index mark (6). (4) primary drive gear bolt (5) punch mark (6) index mark (cont’d) Servicing Your Honda...

  • Page 67

    Tighten the camshaft holder bolts in a criss-cross (18) feeler gauge pattern in two or three steps. (14) (12) (16) (16) sealing washer (17) cam chain tensioner lifter cover bolt (13) (14) (12) camshaft holders (13) intake cam lobes (14) camshaft holder bolts Servicing Your Honda...

  • Page 68

    Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) direct ignition coil (8) breather tube 5. Install the fuel tank and the seat (pages 29,31). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 69: Piston/piston Rings/piston Pin

    4. Remove the seat and fuel tank (pages 29,30). 5. Remove the subframe (page 32). 6. Remove the carburetor (page 119). 7. Remove the exhaust pipe (page 90). (3) engine hanger nuts/bolts (4) engine hanger plates (1) water hose clamp (2) water hose Servicing Your Honda...

  • Page 70

    Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. (10) (5) cylinder head bolts (6) cylinder bolt (11) (9) dowel pins (11) cam chain guide (10) cylinder head gasket (7) cylinder head nuts/washers (8) cylinder head Servicing Your Honda...

  • Page 71

    2. Remove the dowel pins (3) and cylinder (1) piston ring gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...

  • Page 72

    1. Clean the piston ring thoroughly. oil ring We recommend you consult the Service Manual 2. Apply engine oil to piston rings and install or your Honda dealer for correct Service Limit them. measurements. NOTICE Do not damage the piston ring by spreading the ends too far.

  • Page 73

    Do not align the piston pin clip end gap with the piston cut-out (6). (1) dowel pins (2) cylinder gasket 5. Clean any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) piston cut-out Servicing Your Honda...

  • Page 74

    Do not damage the piston rings and cylinder walls. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (4) cylinder (5) piston rings (cont’d) Servicing Your Honda...

  • Page 75

    Do not let the washers and nuts fall into the (7) engine hanger plates crankcase. (8) engine hanger nuts/bolts of the frame side (9) engine hanger nut/bolt of the engine side (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...

  • Page 76

    – abnormal engine noise (page 29). – secondary air leaks – coolant leaks (10) (11) (10) radiator hose (11) radiator hose clamp 7. Install the shims, valve lifters and camshaft (page 61). 8. Install the spark plug (page 55). Servicing Your Honda...

  • Page 77

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's (1) fork protector (2) dust seal front suspension.

  • Page 78

    (page 113). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Remove the subframe (page 32). The instructions found in this owner’s manual are 3.

  • Page 79: Fork Oil Change

    (5) and guide bushing viscosity (weight) 5 W (6) when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage, hold both the outer tube and slider (7) equivalent when removing the fork damper.

  • Page 80

    12.5 US oz capacity (369 cm Maximum oil 13.9 US oz Slightly stiffer as capacity (410 cm it nears full compression. Minimum oil 10.6 US oz Slightly softer as capacity (314 cm it nears full compression. (cont’d) Servicing Your Honda...

  • Page 81

    7. Temporarily install the fork damper to the outer tube. After installing the fork leg (page 106) tighten the fork damper to the specified torque: Actual: 25 lbf·ft (34 N·m, 3.5 kgf·m) Torque wrench scale reading: 23 lbf·ft (31 N·m, 3.2 kgf·m) Servicing Your Honda...

  • Page 82: Brakes

    (page (1) lock nut 80), there is probably air in the brake system. (2) adjuster Refer to the Honda Service Manual or see your (–) Honda dealer to have the air bled from the 1. Loosen the lock nut (1).

  • Page 83

    Worn brake pads should be replaced. If the pads (20 mm), there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda dealer for If the brake lever freeplay exceeds 13/16 in brake bleeding.

  • Page 84

    Do not mix different types of fluid, they may not be compatible. not be compatible. • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent. DOT 4 brake fluid or an equivalent.

  • Page 85

    0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) front brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 86: Wheels

    3. Check wheel rim runout. If runout is control. It’s also important that the rim locks are noticeable, see the Honda Service Manual for secure to prevent tire slippage. inspection instructions.

  • Page 87: Tires & Tubes

    Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...

  • Page 88

    • Use a replacement tire equivalent to the original. • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 89: Drive Chain

    Lubricate the drive chain (page 85) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed. (2) chain guide slider (3) wear limit Servicing Your Honda...

  • Page 90

    2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda HP Chain Lube or an equivalent, or SAE rollers and replace them if below the service Align the index marks (4) of the axle plates 80 or 90 gear oil is recommended.

  • Page 91

    17 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 92: Exhaust Pipe/muffler

    1. Remove the seat mounting bolts (1), side cover bolts (2) and side covers (3). (4) muffler clamp bolt (5) muffler (6) muffler mounting bolt (7) washer (1) seat mounting bolt (3) side cover (2) side cover bolt Servicing Your Honda...

  • Page 93

    (7) muffler mounting bolt (8) washer 3. Install a new gaskets (5) to the exhaust joint (9) muffler clamp bolt pipe (6). 4. Install each muffler to the exhaust joint pipe. (5) gasket (6) exhaust joint pipe Servicing Your Honda...

  • Page 94

    (3) joint pipe clamp bolt (4) exhaust joint pipe mounting bolt (5) exhaust joint pipe (4) exhaust joint pipe (5) gasket (6) exhaust pipe Servicing Your Honda...

  • Page 95

    6. Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt (page 89). 7. Tighten the muffler clamp bolts and muffler mounting bolts (page 88). 8. Installation can be done in the reverse order of removal. Servicing Your Honda Servicing Your Honda...

  • Page 96: Additional Maintenance Procedures

    (3) paint mark not see any movement in the steering head, the fork bushings may be worn. Refer to the Control Cables Honda Service Manual for replacement or adjustment procedures, or see your Honda dealer. Periodically, disconnect the throttle, clutch and hot start cables at their upper ends.

  • Page 97

    (10) drive sprocket bolt (11) transmission oil drain bolt (1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cover bolts (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts Servicing Your Honda Servicing Your Honda...

  • Page 98: Appearance Care

    Wet any heavy deposits with water first. Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge.

  • Page 99

    #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda Servicing Your Honda...

  • Page 100: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......96 for maximum competition performance. Rear Suspension Adjustments ......109 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ...........113 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....114 break-in time.

  • Page 101: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).

  • Page 102

    See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and •...

  • Page 103

    Front Suspension Adjustments 3. Remove the washers/handlebar holder nuts (3), 6. Remove the disc cover (8) by removing the Do not support the brake caliper by the brake mounting rubbers (4) and handlebar (5). disc cover bolts (9). hose. Do not operate the brake lever after the front wheel is removed.

  • Page 104

    Front Suspension Adjustments 12.Clean the fork assembly, especially the sliding 17.Temporarily install the fork damper to the NOTICE surface of the slider (19) and dust seal (20). outer tube. 13.Record the rebound damping adjuster position 18.Set the axle holder (28) in a vise with a piece of The outer tube can drop on the slider and and turn the adjuster counterclockwise until it wood or soft jaws to avoid damage.

  • Page 105

    Front Suspension Adjustments 22.Apply pressure to the fork damper and insert a Damper Oil Change special tool or mechanic’s stopper tool (30) (see below) between the axle holder (28) and lock nut (31) 1. Set the fork damper (1) in a vise with a piece 23.Hold the lock nut and remove the center bolt of wood or soft jaws to avoid damage.

  • Page 106

    (1) as shown. Recommended Oil: Be careful not to damage the fork cap bushing Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5W or equivalent (4). Recommended Amount: Do not disassemble the fork cap assembly.

  • Page 107

    Front Suspension Adjustments 10.Tighten the fork cap assembly (2) while 12.Screw in the lock nut (7) to the fork damper 14.Drain the extra oil from the oil hole (9). piston rod (5) fully. holding the fork damper (1) using the lock nut wrench (3) to the specified torque: By doing this procedure, about 0.6 US oz (17 22 Ibf·ft (30 N·m, 3.1 kgf·m)

  • Page 108

    Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 1. Drain the fork oil from the outer tube/slider (1) by placing it upside down. Wipe the oil completely off the fork damper.

  • Page 109

    Front Suspension Adjustments 4. Set the axle holder in a vise with a piece of 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the center bolt O-ring (7). wood or soft jaws to avoid to damage. center bolt (8) clearance.

  • Page 110

    (1). No mark 1 scribe mark and (factory products) Recommended Oil: 3 scribe marks 75 degrees apart Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) Standard oil 12.7 US oz Standard oil 12.6 US oz...

  • Page 111

    Front Suspension Adjustments 15.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the assembly (4) is in good condition. Apply the specified torque using the lock nut wrench recommended fork oil to the O-ring. (14).

  • Page 112

    Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle Fit the brake caliper (21) over the disc, taking (18) and axle holder thoroughly. clamps contact each other. care not to damage the brake pads. Apply locking agent to the bolt threads.

  • Page 113

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

  • Page 114: Rear Suspension Adjustments

    Min. gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 5.1 kgf/mm): 9.9 in (252 mm) limited to adjustments of the shock assembly Min.

  • Page 115

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

  • Page 116

    Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT Standard Race Sag: 3.9 in (100 mm) important for competition use.

  • Page 117

    Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 118: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 119: Suspension Adjustment Guidelines

    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.

  • Page 120

    Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...

  • Page 121

    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: –...

  • Page 122: Cold/hot Start Circuit, Carburetor Adjustments & Tuning Tips

    (2) and is mixed with air from circuit resulting in a lean condition. your CRF. See your Honda dealer. the air passage (3) (located above the throttle valve (4)) to provide a rich mixture for starting.

  • Page 123: Accelerator Pump/slow Circuit, Main Circuit/baffle Plates/float Bowl

    Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.

  • Page 124

    Honda carburetor jet sizes are numbered in The minimum to maximum range of pilot screw increments of 2 or 3. When changing the main jet adjustment is 1 3/4 to 2 1/2 turns out from the size, increase or decrease it gradually until the lightly seated position.

  • Page 125

    Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 30). 9. Remove the hot start cable holder (4). 11.Remove the throttle drum cover bolt (7) and 5. Remove the subframe (page 32). throttle drum cover (8). 6. Loosen the insulator band screw (2). (4) hot start cable holder (7) throttle drum cover bolt 10.Disconnect the rear suspension (5), upper...

  • Page 126

    Carburetor Adjustments & Tuning Tips 3. Remove the link arm torx screw (6). When installing the floating valve (9) onto the Carburetor Disassembly/Assembly When installing the link arm torx screw, apply throttle valve (7) make sure the floating a locking agent to the link arm torx screw valve’s flat side faces out and the hole (10) threads.

  • Page 127

    Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (18), throttle stop 9. Measure the float level (25) with the float (11) and accelerator pump cover (12). screw holder (19), float bowl screws (20), level gauge (26) while the float tab is just tube guides (21) and float bowl (17).

  • Page 128

    Carburetor Adjustments & Tuning Tips To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. • Route the throttle cables (1), hot start cable (2) and throttle sensor wire correctly. • After installing the carburetor, adjust the throttle grip free play and hot start lever free play.

  • Page 129

    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 2 1/4 turns out Slow jet...

  • Page 130

    Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the atmospheric conditions or race day situations that situations that may require additional...

  • Page 131

    Carburetor Adjustments & Tuning Tips 6. Adjust the pilot screw as required. Carburetor Minor Adjustments WARNING The standard carburetor settings are ideal for the Gasoline is highly flammable and following conditions: sea level altitude, and 20°C explosive. You can be burned or (68 °F) air temperature.

  • Page 132

    Carburetor Adjustments & Tuning Tips 12.Change the main jet (4) and slow jet (5) as 17.Remove the jet needle/holder assembly (8). 19.Reinstall the jet needle/holder assembly, required. carburetor top and carburetor top bolts. 20.Rotate the carburetor and align the lug (12) on the carburetor with the slot (13) on the insulator.

  • Page 133

    Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may Refer to Spark Plug on page 55.

  • Page 134: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle not adjustable. Align the groove in the outer tube changes in overall handling.

  • Page 135: Gearing

    Honda Service Manual, higher gear (less teeth) to keep engine rpm appraisal of the gearing change. “Seat-of-the- sprocket changing should be done by your Honda down, and avoid unwanted wheelspin. The pants” feelings can’t be trusted. Eliminating dealer.

  • Page 136: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 137: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to the threads of these bolts prior to adjustment to Handlebar Position, Width & Shape help ensure the correct torque is retained.

  • Page 138: Tips

    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 You & the Environment ........136 Troubleshooting..........137 Tips...

  • Page 139: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 140: Storing Your Honda

    Removal from Storage such as during the winter, thoroughly inspect bolt/sealing washer (1) at the water pump (2) to your Honda and correct any problem before drain coolant. storing it. That way, needed repairs won’t be After the coolant has been completely 1.

  • Page 141: You & The Environment

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

  • Page 142: Troubleshooting

    The items that require use of the • Lack of fuel in tank CHECK POSSIBLE CAUSES 1. Disconnect fuel FUEL FLOW Honda Service Manual are followed by an (P.34) line at carburetor RESTRICTED • Over-oiled air cleaner. 1. Check if air INCORRECT •...

  • Page 143

    Tips...

  • Page 144: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........140 other technical data. Specifications ...........141 Torque Specifications........142 Oxygenated Fuels..........145 Competition Logbook ........146 Optional Parts List ...........148 Spare Parts & Equipment.........149 Wiring Diagram..........150 Technical Information...

  • Page 145: Vehicle Identification

    Vehicle Identification The VIN (vehicle identification number) (1) is Serial Numbers stamped on the right side of the steering head. RIGHT SIDE 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.

  • Page 146: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 85.5 in 2,172 mm Overall width Single 10˚ inclined from Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement vertical...

  • Page 147: Torque Specifications

    Torque Specifications Torque Nuts, Bolts, Fasteners Remarks Item lbf•ft N•m kgf•m ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts RIGHT SIDE Water pump cover bolts Crankshaft hole cap NOTE 1 Transmission oil check bolt...

  • Page 148

    Torque Specifications Frame Torque Item Remarks lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1 Chain adjuster lock nuts...

  • Page 149

    Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (38) (42) FRAME (34) Caliper mounting bolts NOTE 4 (28) Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 Brake pedal pivot bolt NOTE 5 Spoke (front) 3.68 (37) (rear) Rim locks...

  • Page 150: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States use oxygenated Fuel system damage or performance problems fuels to help reduce emissions.

  • Page 151: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.

  • Page 152

    Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 153: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 296.8 lbf/in (5.30 kgf/mm) Standard 51 Teeth, Aluminum. Standard CARBURETOR Remarks <114>...

  • Page 154: Spare Parts & Equipment

    Pro Honda GN4 4-stroke Oil brake hoses (front & rear) (Engine and Transmission Oil) SAE80 or 90 gear oil Spare Parts Pro Honda HP Fork Oil 5W General Tools Pro Honda DOT4 Brake Fluid spark plugs Pro Honda HP Chain Lube air cleaner (clean &...

  • Page 155: Wiring Diagram

    Wiring Diagram SPARK THROTTLE POSITION PLUG SENSOR Technical Information...

  • Page 156: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........152 contacting Honda and how to get an official Contacting Honda..........153 Honda service manual. Your Honda Dealer...........154 The Honda Rider’s Club ........155 Consumer Information...

  • Page 157: Authorized Manuals

    For purchases outside U.S.A., please write to the address shown below for a quotation. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service...

  • Page 158: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 159: Your Honda Dealer

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

  • Page 160: The Honda Rider's Club

    • 24-hour, toll-free roadside assistance for your new Honda (includes roadside assistance for your transport vehicle [up to one ton] as long as your Honda is aboard or in tow) For street- legal motorcycles and scooters only. • An exclusive HRCA website complete with...

  • Page 161: Table Of Contents

    Optional Parts List ..........148 Suspension............72 Spare Parts & Equipment........149 SERVICING YOUR HONDA......17 Front Suspension Inspection......72 Wiring Diagram..........150 Before You Service Your Honda Rear Suspension Inspection......73 The Importance of Maintenance .......18 Fork Oil Change ...........74 CONSUMER INFORMATION ....151 Maintenance Safety...........19 Brakes..............77 Authorized Manuals ........152...

  • Page 162: Index

    & practice maintenance ...26 front ..............96 filter ..............35 brakes, rear..............110 recommendation...........34 fluid level .............78 dealer, your Honda ..........154 refueling ............34 lever, front adjustment .........77 diagram, wiring ..........150 system............34 pad wear ............80 drive chain............84 oxygenated ..........145 pedal height ..........77 tank capacity ..........34...

  • Page 163

    Index gap, spark plug ..........55 maintenance, rear suspension maintenance......73 gasohol ............145 additional procedures ........91 Rider’s Club Honda.........155 gasoline..............34 after competition ..........26 riding, gearing.............130 before & after competition......26 basic operation ..........11 guidelines, suspension adjustment ....114 between motos & practice......26 before..............7 component locations ........28 important safety information......2...

  • Page 164

    Index suspension, front ............72,96 rear............73,109 suspension adjustment, front ..............96 rear..............109 for track conditions ........113 guidelines ...........114 transmission oil ..........39 tuning tips ............117 throttle, freeplay............46 inspection .............47 tires, air pressure ...........82 flat ..............82 selection............83 tools ...............149 torque specifications ........142-144 transporting............134 troubleshooting..........137 tubes, replacing ..........82 valve, fuel............13 vehicle identification no.

  • Page 165: Quick Reference

    Engine No. important notes. Owner’s: Name How To Avoid Costly Repairs Address City/State The engine of your Honda can be the most Phone expensive component to repair. Proper Dealer’s: maintenance, especially the use of the Name recommended fluids and filters, prevents Address premature wear and damage.

  • www.manualslib.com

    HONDA 2004 CRF250R SERVICE MANUAL Pdf Download.

    Page of 406 Go

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    www.manualslib.com

    HONDA 2009 CRF 250 R ASSEMBLY INSTRUCTIONS MANUAL Pdf Download.

  • Page 1

    Assembly Instructions HONDA CRF 250 R 2009 FAST part-no.: 9060...

  • Page 2: Table Of Contents

    LIST OF CONTENTS INTRODUCTION ..........3 1.

  • Page 3: Introduction

    INTRODUCTION Dear Customer, We would like to thank you for choosing our product and we wish to provide you with some information about this entirely unique and exclusive product, the FAST Box. In over 50 years of operation, the Sito Group has achieved a series of goals and advances that have con- tributed towards building a position of leadership in the aftermarket motorcycle exhaust system sector.

  • Page 4: Technical Data

    1. TECHNICAL DATA LeoVince FAST Kit 9060 Exhaust item X3 LeoVince 3508 (Full 1/1 <<X3>> system - off-road RACING – Full Titanium line “SUPERMOTO” “MOTOCROSS”) FAST Electronic Control Unit (ECU) dimensions Size and weight Length 90.00 mm Width 64.00 mm Height 26.50 mm Weight (without wiring)

  • Page 5: General Guarantee Conditions

    3. GENERAL GUARANTEE CONDITIONS 3.1 GUARANTEE SITO GRUPPO INDUSTRIALE S.p.A. guarantees its own products in accordance with current legislation. In particular it guarantees conformity defects by repair or replacement within a suitable period of time. Except where the customer’s request is for the goods to be repaired or replaced, SITO GRUPPO INDUSTRIALE S.p.A. reserves the right to evaluate whether the remedy requested is objectively possible and not excessively onerous compared to the alternative.

  • Page 6: Preparing To Install

    4. IMPORTANT INFORMAITON Information in this manual that is of critical importance is marked with the following symbols: A danger symbol means BE CAREFUL! YOUR SAFETY IS AT RISK! Failure to observe the instructions that follow this symbol could cause serious injury, if not WARNING the death of the rider, people nearby, or people engaged in repairing the motorcycle.

  • Page 7: Wiring Layout

    If there are rust/stains, connect and disconnect the parts several times. 13) Clean the connectors thoroughly before attaching the FAST wiring. 7. POSITIONING OF THE MAIN COMPONENTS Key: 1. Original HONDA ECU. 2. Original connectors (under the side panel) 3. Original connectors (under the fuel tank) Fig. 1...

  • Page 8: Removing The Fairing

    8. REMOVING THE FAIRING Take off the seat removing the nuts shown in Figure 2. Fig. 2 Dismantle the right and left side panels, removing the nuts, shown in Figure 2a. CAUTION take special care when undoing the side panel nuts in position 4 fastened to the radiator. NOTE: clean all the parts and put them on a tray, Fig.

  • Page 9: Removing The Fuel Tank

    9. REMOVING THE FUEL TANK Before removing the fuel tank make sure the tap is in the OFF position, then disconnect the fuel hose from the engine (Position 1, Figure 3) and remove the nut that keeps the tap fastened to the frame (Position 2, Figure 3). Fig.

  • Page 10: Removing The Original Wiring

    10. REMOVING THE ORIGINAL WIRING Disconnect the original HONDA connectors positioned under the side panels and under the fuel tank that have just been removed, as shown in Figure 4 and Figure 4a. CONNECTORS Fig. 4 CONNECTORS NOTE: Check the electric wires and the connection elements, checking for the presence of stains, rust, dampness etc.

  • Page 11

    Remove the original wiring. HARNESS LAYOUT Fig. 5 HARNESS NOTE: Thoroughly clean the connectors removing LAYOUT Fig. 5a traces of dust, mud or debris.

  • Page 12: Installation Of The Fast Ecu

    11. INSTALLATION OF THE FAST ECU Fix the FAST ECU, placed inside the rubber support, to the frame, using brackets found in the kit, as shown in Figure 6. Check that the connection between the FAST wiring and the ECU is correct, and if the connection is loose, check the con- nectors.

  • Page 13

    Fig. 7b Fig. 7c NOTE: Where the colors of the FAST wiring connectors do not match the colors of the connectors of the original wiring, refer to the colored guides used to identify the connection correspondence (for example: colored paint dot). Position the connectors in Figure 7 in the proper clamps on the frame, as shown in Figure 8.

  • Page 14: Installation Of The Fast Mapping Switch

    12. INSTALLATION OF THE FAST MAPPING SWITCH The FAST kit also includes the FAST mapping switch, which utilizes a three-position switch complete with wiring, which makes it is possible to select one of the three different maps stored in the control unit’s memory. There are three positions, the top position of the switch for full power (map 1), the middle/central position of the switch is the original map (map 2) and the final lower position of the switch is the wet map (map 3).

  • Page 15: Connecting The Fast Mapping Switch

    14. CONNECTING THE FAST MAPPING SWITCH The FAST mapping switch is connected to the ECU via a special piece of wiring (grey connector). See Figure 10. Keep the wiring away from exces- CAUTION sively hot parts and away from moving parts, as to avoid damage or wear from rubbing.

  • Page 16

    Assembly Instructions INSTRUCTION MANUAL 2009 SITO GRUPPO INDUSTRIALE All rights reserved Reproduction or unauthorized use Without the written permission of SITO GRUPPO INDUSTRIAL, S.p.A. is strictly forbidden 05/03/’09...

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