Honda CRF250R (2013) manuel d'utilisation

CRF250R © Honda Motor Co., Ltd. 2013 OWNER’S MANUAL & COMPETITION HANDBOOK[...]

THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR COMPETITION USE ONLY AND IS SOLD “AS IS” WITH NO WARRANTY. IT DOES NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND OPERATION ON PUBLIC STREETS, ROADS, OR HIGHWAYS IS ILLEGAL. STATE LAWS PROHIBIT OPERATION OF THIS MOTORCYCLE EXCEPT IN AN ORGANIZED RACING OR COMPETITIVE EVENT UPON A CLOSE[...]

Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK[...]

Introduction Introduction Introduction Congratulations on choosing your Honda CRF motocross motorcycle. When you own a Honda, you’re part of a worldwide family of satisfied customers – people who appreciate Honda’s reputation for building quality into every product. Your CRF is a high performance racing motorcycle that utilizes the latest mot[...]

Safety Messages A Few Words About Safety A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety , as well as a number of Safety Messages throug[...]

Contents Contents MOTORCYCLE SAFETY ............................ 1 Important Safety Information ........................... 2 Important Safety Precautions ....................... 2 Accessories & Modifications ........................... 3 Accessories & Modifications ....................... 3 Safety Labels ...................................[...]

Contents Contents Chassis Suspension ...................................................... 86 Front Suspension Inspection ....................... 86 Rear Suspension Inspection ........................ 87 Recommended Fork Oil .............................. 88 Fork Oil Change .......................................... 88 Brakes .....................[...]

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Motorcycle Safety Motorcycle Safety 1 Motorcycle Safety This section presents some of the most important information and recommendations to help you ride your CRF safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your CRF. Important Safety Information ...............[...]

Important Safety Information 2 Motorcycle Safety Important Safety Information Your CRF can provide many years of pleasure, if you take responsibility for your own safety and understand the challenges you can meet in competitive racing. As an experienced rider, you know there is much you can do to protect yourself when you ride. The following are a [...]

Accessories & Modifications Motorcycle Safety 3 Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride. Accessories & Modifications[...]

Safety Labels 4 Motorcycle Safety This page shows the locations of safety labels on your CRF. These labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your dealer for replacement.[...]

Instruments & Controls Instruments & Controls 5 Instruments & Controls Read this section carefully before you ride. It presents the location of the basic controls on your CRF. Operation Component Locations ...................... 6 Indicator ............................................................ 7 MIL Blink Pattern ................[...]

Operation Component Locations 6 Instruments & Controls Operation Component Locations clutch lever engine stop button front brake lever throttle grip MIL fast idle knob (engine idle speed) shift lever kickstarter rear brake pedal[...]

Indicator Instruments & Controls 7 Indicator The MIL (1) on your CRF keeps you informed, alerts you to possible problems, and makes your riding safer and more enjoyable. Refer to the MIL frequently. The MIL flashes when there is any abnormality in the PGM-FI system. It should also light for a few seconds and then go off when the engine is start[...]

8 Instruments & Controls Indicator Always clean around the ECM and keep debris away from the connectors before disconnecting them. A faulty PGM-FI system is often related to poorly connected or corroded connections. Check the following connections. Remember, circuit inspection is not a “cure-all” for other problems in your engine’s PGM-FI[...]

Instruments & Controls 9 Indicator Refer to MIL Blink Pattern on page 7. Should be serviced by your dealer, unless the owner has proper tools and is technically qualified. The MIL blinks of the 12, 19, and 69 times can not be checked because the engine can not start at the situation. If the engine does not start, check all connector connections[...]

10 Instruments & Controls[...]

Before Riding Before Riding 11 Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and what items you should check on your CRF. For information about suspension, steering damper, and other adjustments, see page 111. A[...]

Are You Ready to Ride? 12 Before Riding Are You Ready to Ride? Before riding your CRF for the first time, we strongly recommend that you read this owner’s manual, make sure you understand the safety messages, and know how to operate the controls. Before each ride, it’s also important to make sure you and your CRF are both ready to ride. For inf[...]

Is Your Motorcycle Ready to Ride? Before Riding 13 Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the right): Check the following before each ride: • Engine oil level ......[...]

14 Before Riding[...]

Basic Operating Instructions Basic Operating Instructions 15 Basic Operating Instructions This section gives basic information on how to start and stop your engine as well as break-in guidelines. Safe Riding Precautions ............................... 16 Starting & Stopping the Engine ...................... 17 Fast Idle Knob ...................[...]

Basic Operating Instructions 16 Basic Operating Instructions Basic Operating Instructions Before riding your CRF for the first time, please review the Important Safety Precautions beginning on page 2 and the previous section, titled Before Riding . For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CR[...]

Starting & Stopping the Engine Basic Operating Instructions 17 Starting & Stopping the Engine Always follow the proper starting procedure described below. Your CRF can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter. The fast idle knob has two functions: • When pulled out, the f[...]

18 Basic Operating Instructions Starting & Stopping the Engine Normal Engine Stop 1. Shift the transmission into neutral. 2. Lightly open the throttle (1) two or three times, and then close it. 3. Push and hold the engine stop button (2) until the engine stops completely. Emergency Engine Stop To stop the engine in an emergency, push and hold t[...]

Break-in Guidelines Basic Operating Instructions 19 Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km (15 miles). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when[...]

20 Basic Operating Instructions[...]

Servicing Your Honda Servicing Your Honda 21 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required ser[...]

The Importance of Maintenance 22 Servicing Your Honda The Importance of Maintenance Keeping your CRF well-maintained is absolutely essential to your safety. It’s also a good way to get maximum performance during each heat. Careful pre-ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off-r[...]

Maintenance Safety Servicing Your Honda 23 Maintenance Safety This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should per[...]

Maintenance Schedule 24 Servicing Your Honda Maintenance Schedule To maintain the safety and reliability of your CRF, regular inspection and service is required as shown in the Maintenance Schedule that follows. The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are pro[...]

Maintenance Schedule Servicing Your Honda 25 Perform the Pre-ride Inspection (page 13) at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. A: Adjust. L: Lubricate. R: Replace. *WE RECOMMEND THESE ITEMS BE SERVICED BY REFERRING TO THE HONDA SHOP MANUAL. This maintenance schedule is based u[...]

General Competition Maintenance 26 Servicing Your Honda General Competition Maintenance Perform maintenance on firm, level ground using an optional workstand, or equivalent support. When tightening bolts, nuts or screws, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a crisscross pattern. Use Honda[...]

General Competition Maintenance Servicing Your Honda 27 Spark Plug Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range. Replace periodically as specified in the Maintenance Schedule (page 25). Spark Plug Cap Install a[...]

General Competition Maintenance 28 Servicing Your Honda Gaskets Always use new gaskets when reassembling components. Cylinder head/Cylinder Put a little grease on the dowel pins of the cylinder head and cylinder to prevent corrosion from dissimilar metals. The tolerances are quite tight, so it’s important to keep these dowels absolutely clean (pa[...]

General Competition Maintenance Servicing Your Honda 29 Suspension Linkage Lubrication Disassemble, clean, inspect and lubricate all suspension linkage pivot bearings with molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive) after each 7.5 hours of running time in order to maintain proper suspension performance and mi[...]

Before & After Competition Maintenance 30 Servicing Your Honda Before & After Competition Maintenance After practice or between heats you have a chance to make additional checks and adjustments. • Clean accumulated dirt from under the fenders and off the wheels, suspension components, handgrips, controls, and footpegs. A stiff, nylon part[...]

Servicing Your Honda 31 Before & After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program. Right after the event is a good time to begin your next maintenance cycle. After Race Lubrication Apply a light coating of rust-inhibiting oil to the drive sprocket and any steel p[...]

Maintenance Component Locations 32 Servicing Your Honda Maintenance Component Locations clutch lever front brake fluid reservoir front brake lever throttle grip radiator cap fuel fill cap air bleed bolt spark plug fast idle knob (engine idle speed) air cleaner crankcase breather tube B drive chain transmission oil drain bolt engine oil filter engin[...]

Seat Servicing Your Honda 33 Seat Refer to Important Safety Precautions on page 23. Removal 1. Remove the seat mounting bolts (1). 2. Remove the seat (2) by sliding it backward. Installation 1. Install the seat while aligning the seat front prong (1) with the front seat bracket (2) and seat rear prong (3) with the seat stopper plate (4). 2. Install[...]

Fuel Tank 34 Servicing Your Honda Fuel Tank Refer to Important Safety Precautions on page 23. Removal 1. Remove the seat (page 33). 2. Remove the shroud A bolts and collars (1). 3. Remove the shroud B bolts (2). 4. Slide the shrouds (3) toward the front to separate them from the air cleaner housing covers (4). 5. Slide the shrouds toward the rear u[...]

Fuel Tank (cont’d) Servicing Your Honda 35 13. Check for interference between the frame and tank and adjust the cushion rubbers (15) if necessary. Installation 1. Install the fuel feed hose (1) to the clamp (2) if it is removed. 2. Install the fuel tank (3) on the frame. 3. Install the collar and fuel tank bolt (4). 4. Hook the fuel tank band (5)[...]

36 Servicing Your Honda Fuel Tank 5. Put the breather tube (6) in the steering stem nut (7). 6. Remove the hose clamp (8) from the breather tube. 7. Align the shroud hooks (9) with the recesses (10) of the fuel tank. 8. Turn the shrouds (11) and hook them onto the frame (12). 9. Slide the shrouds (11) toward the rear so that the shroud tabs (13) an[...]

Subframe (cont’d) Servicing Your Honda 37 Subframe Refer to Important Safety Precautions on page 23. Removal 1. Remove the seat (page 33). 2. Remove the right and left mufflers (page 100). 3. Remove the rear fender mounting bolts, nut (1) and rear fender (2) backward. 4. Remove the air cleaner case (3) from the subframe (4). 5. Remove the air cle[...]

38 Servicing Your Honda Subframe 3. Install the air cleaner case (3) to the subframe (4). 4. Install the rear fender (5) and align the hole in the rear fender with the hole in the subframe, and then install the rear fender mounting bolts and nuts (6). 5. Hook the fuel tank band (7). 6. Install the air cleaner mounting bolts (8). 7. Install the left[...]

Fuel System Servicing Your Honda 39 Fuel System Refer to Important Safety Precautions on page 23. Use only unleaded fuel in your CRF. If you ride your CRF in a country where leaded fuel might be available, take precautions to use only unleaded fuel. Your engine is designed to use any unleaded petrol that has a pump octane number (R + M)/2 of 91 or [...]

40 Servicing Your Honda Fuel System 1. Hang the fuel tank to the left side of the frame (page 34). 2. Disconnect the fuel pump connector (1). 3. Reposition the fuel tank and start the engine and let it idle until the engine stalls. Disconnection 1. Relieve the fuel pressure (this page). 2. Hang the fuel tank to the left side of the frame. 3. Remove[...]

Fuel System (cont’d) Servicing Your Honda 41 8. Hold the connector with one hand and squeeze the retainer tabs (9) with the other hand to remove the locking pawls (10) from the connector grooves. Pull the connector off, then remove the retainer. • Use a shop towel to absorb the remaining fuel in the fuel feed hose. • Be careful not to damage [...]

42 Servicing Your Honda Fuel System 2. Install the joint rubber (5) and seat it onto the fuel joint as shown. Align the fuel quick connect fitting with the fuel joint. Then press the quick fitting onto the pipe of the fuel joint until both retainer pawls lock with a “click”. If it is hard to connect, put a small amount of engine oil on the pipe[...]

Fuel System (cont’d) Servicing Your Honda 43 Empty the fuel tank into an approved petrol container using a commercially available hand siphon or an equivalent method. Be careful not to damage the fuel pump while draining the fuel in the fuel tank. Removal 1. Relieve the fuel pressure (page 40). 2. Disconnect the fuel line (page 40). 3. Remove the[...]

44 Servicing Your Honda Fuel System 7. Check the hooks (12) of the fuel pump unit holder and tabs (13) on the fuel pump base for damage or discoloration. If the hooks and tabs are damaged or discolored, replace the fuel pump unit as an assembly. 8. Release the hooks of the fuel pump unit holder from the grooves (14) in the fuel pump base tabs while[...]

Fuel System (cont’d) Servicing Your Honda 45 Installation 1. Install a new fuel pump filter (1) onto the fuel pump assembly (2) aligning its hook (3) with the joint boss (4) completely. Be careful not to damage the hook. 2. Apply small amount of engine oil to a new O-ring (5). Install a new O-ring to the fuel pump assembly (6). 3. Install the fue[...]

46 Servicing Your Honda Fuel System 7. Connect the fuel pump red (19) and black (20) wire terminals to the fuel pump base terminals (21). Push the wire terminals until they stop as shown. Be careful not to damage the wires. 8. Apply 0.5 g (0.02 oz) maximum of engine oil to a new O-ring (22). Install a new O-ring onto the fuel pump unit (23). 9. Ins[...]

Servicing Your Honda 47 Fuel System Make sure the fuel remains enough (1.0 ℓ (0.3 US gal, 0.2 Imp gal) minimum) in the fuel tank and add fuel if necessary before increasing fuel pressure. 1. Connect the fuel pump connector (1). 2. Disconnect the DLC/fuel pump sub harness connector (2). 3. Before connecting the battery harness cables to a 12V batt[...]

Engine Oil 48 Servicing Your Honda Engine Oil Refer to Important Safety Precautions on page 23 . Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the engine. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage y[...]

Engine Oil (cont’d) Servicing Your Honda 49 1. Run the engine at idle for 3 minutes, then shut it off. 2. Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine. 3. Support the CRF in an upright position on a level surface. 4. Remove the engine oil fill cap/dipstick (1), wipe it clean, and insert[...]

50 Servicing Your Honda Engine Oil 7. It is recommended to replace the oil and filter every 6 races or about every 15.0 hours. However, if you replace only the oil before the recommended interval, see page 25. 8. Remove the oil filter cover bolts (4) and oil filter cover (5). 9. Remove the oil filter (6) and O-ring (7) from the oil filter cover. NO[...]

Transmission Oil Servicing Your Honda 51 Transmission Oil Refer to Important Safety Precautions on page 23. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the transmission and clutch. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with o[...]

52 Servicing Your Honda Transmission Oil 1. Run the engine at idle for 3 minutes, then shut it off. 2. Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission. 3. Support the CRF in an upright position on a level surface. 4. Remove the transmission oil fill cap (1), oil check bolt ([...]

Coolant Servicing Your Honda 53 Coolant Your CRF’s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head. Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion. Use only genuine HONDA PRE-MIX COOLANT containing corrosi[...]

54 Servicing Your Honda Coolant 1. Check the cooling system for leaks (see an official Honda Shop Manual for troubleshooting of leaks). 2. Check the radiator hoses (1) for cracks, deterioration, and radiator hose clamps for looseness. 3. Check the radiator mount for looseness. 4. Make sure the overflow hose (2) is connected and not clogged. 5. Chec[...]

Air Cleaner (cont’d) Servicing Your Honda 55 Air Cleaner Refer to Important Safety Precautions on page 23. The air cleaner uses polyurethane inner and outer pieces which can’t be separated. A dirty air cleaner will reduce engine power. Proper air cleaner maintenance is very important for off-road vehicles. A dirty, water-soaked, worn- out, or d[...]

56 Servicing Your Honda Air Cleaner 4. Remove the air cleaner element (6) from the air cleaner holder (7) by releasing the holder tabs (8) from the holes (9) of the air cleaner element. 5. Wash the air cleaner in clean non-flammable cleaning solvent. Then wash in hot, soapy water, rinse well, and allow to dry thoroughly. The air cleaner element is [...]

Crankcase Breather Servicing Your Honda 57 Crankcase Breather Refer to Important Safety Precautions on page 23. Service more frequently if your CRF is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the crankcase breather tubes. If the drain tube overflows, the air filter may [...]

Throttle 58 Servicing Your Honda Throttle Refer to Important Safety Precautions on page 23 . Inspection Check freeplay (1). Freeplay: 2 – 6 mm (0.08 – 0.24 in) If necessary, adjust to the specified range. Upper Adjustment Minor adjustments are generally made with the upper adjuster. 1. Pull the dust cover (1) back. 2. Loosen the lock nut (2). 3[...]

Servicing Your Honda 59 Throttle 1. Check that the throttle assembly is positioned properly (the end of the throttle housing (1) is aligned with the paint mark (2) on the handlebar) and the securing bolts are tight. 2. Check for smooth rotation of the throttle (3) from fully open to fully closed in all steering positions. If there is a problem, see[...]

Engine Idle Speed 60 Servicing Your Honda Engine Idle Speed Refer to Important Safety Precautions on page 23. Remember, idle speed adjustment is not a “cure - all” for other problems in your engine’s PGM-FI system. Adjusting the idle speed will not compensate for a fault elsewhere. The engine must be at normal operating temperature for accura[...]

Clutch System Servicing Your Honda 61 Clutch System Refer to Important Safety Precautions on page 23. The distance between the tip of the clutch lever and the grip may be adjusted. Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable disconnected. 1. Loosen the lock nut (1). 2. To position the clu[...]

62 Servicing Your Honda Clutch System Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster. Turning the cable end adjuster (1) in direction (+) will increase freeplay and turning it in direction (–) will decrease freeplay. If the adjuster is threaded out near its limit or the correct freeplay cannot be reac[...]

Servicing Your Honda 63 Clutch System 1. Drain the transmission oil (page 52). 2. Remove the clutch cover bolt A (1), clutch cover bolts B (2), and clutch cover (3). 3. Remove the five clutch spring bolts and springs (4). Loosen the bolts in a crisscross pattern in two or three progressive steps. 4. Remove the clutch pressure plate (5). 5. Remove t[...]

64 Servicing Your Honda Clutch System • Replace the clutch discs (1) if they show signs of scoring or discoloration. Measure the thickness of each clutch disc. Service Limit: 2.85 mm (0.112 in) Replace the clutch discs and clutch plates as a set. • Check the clutch plates (2) for excessive warpage or discoloration. Check the plate warpage on a [...]

Servicing Your Honda 65 Clutch System 4. Apply grease to the clutch lifter rod (10) and insert it into the mainshaft. 5. Install the clutch lifter assembly (11) onto the rod. 6. Install the clutch pressure plate (12). 7. Install the five clutch springs and bolts (13). 8. Tighten the bolts in a crisscross pattern in two or three steps to the specifi[...]

Spark Plug 66 Servicing Your Honda Spark Plug Refer to Important Safety Precautions on page 23. The recommended standard spark plug is satisfactory for most racing conditions. Use only the recommended type of spark plugs in the recommended heat range. NOTICE Using a spark plug with an improper heat range or incorrect reach can cause engine damage. [...]

Valve Clearance (cont’d) Servicing Your Honda 67 Valve Clearance Refer to Important Safety Precautions on page 23. Excessive valve clearance will cause noise and eventual engine damage. Little or no clearance will prevent the valve from closing and cause valve damage and power loss. Check valve clearance when the engine is cold at the intervals s[...]

68 Servicing Your Honda Valve Clearance 4. Rotate the crankshaft by turning the primary drive gear bolt (2) clockwise until the punch mark (3) on the primary drive gear aligns with the index mark (4) on the right crankcase cover. In this position, the piston may either be on the compression or exhaust stroke at TDC. If the crankshaft passed the pun[...]

Valve Clearance (cont’d) Servicing Your Honda 69 3. Measure the exhaust valve clearance by inserting a feeler gauge (1) between the exhaust rocker arm (4) and shims (5). Valve Clearance: If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (this page) and select the correct shim for each valve. 1. Record the[...]

70 Servicing Your Honda Valve Clearance 5. Make sure the piston is at TDC on the compression stroke (page 67). Loosen the camshaft holder bolts A (7), B (8) in a crisscross pattern in two or three steps. Remove the camshaft holder bolts, set rings and camshaft holders (9). As you remove the camshaft holder, set rings may be sticking in the camshaft[...]

Servicing Your Honda 71 Valve Clearance 1. Clean the valve shim contact area in the valve lifter (1) with compressed air. 2. Measure the shim thickness with a micrometer and record it. Sixty-nine different shims (2) are available in 0.025 mm thickness intervals, from 1.200 mm (the thinnest) to 2.900 mm (the thickest). 3. Calculate the new shim thic[...]

72 Servicing Your Honda Valve Clearance 1. Install the newly selected shims (1) on the valve spring retainers (2). NOTICE Do not let the shims fall into the crankcase. 2. Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the following parts. – [...]

Valve Clearance (cont’d) Servicing Your Honda 73 6. Make sure that the dowel pins (11) are installed into the camshaft holders (12). 7. Install the set rings (13) on the camshaft bearing grooves (14). NOTICE Do not let the set rings fall into the crankcase. Each camshaft holder has an identification mark (15). 8. Install the camshaft holders (12)[...]

74 Servicing Your Honda Valve Clearance 12. Install the condenser stay (21) and tighten the condenser stay mounting bolt (22). 13. Rotate the camshaft by rotating the crankshaft clockwise several times and make sure that the piston is at TDC on the compression stroke (page 71). 14. Measure the intake valve and exhaust valve clearances by inserting [...]

Servicing Your Honda 75 Valve Clearance 1. Check that the spark plug hole packing (1) is in good condition and replace it if necessary. Apply engine oil to the spark plug hole packing and install it to the cylinder head cover (2). 2. Check that the cylinder head cover packing (3) is in good condition and replace it if necessary. Install the cylinde[...]

Piston/Piston Rings/Piston Pin 76 Servicing Your Honda Piston/Piston Rings/Piston Pin 1. Clean the area above the engine before disassembly to prevent dirt falling into the engine. 2. Drain the radiator coolant after cooling the motorcycle (page 145). 3. Remove the seat and hang the fuel tank (pages 33, 34). 4. Remove the left and right mufflers (p[...]

Piston/Piston Rings/Piston Pin (cont’d) Servicing Your Honda 77 16. Remove the air cleaner case (10) along with the air cleaner connecting tube. 17. Remove the rear shock absorber upper nut and bolt (11). 18. Loosen the insulator band screw (12) and pull the throttle body (13) out from the insulator (14). Do not hang the throttle body and support[...]

78 Servicing Your Honda Piston/Piston Rings/Piston Pin 20. Remove the cylinder head A bolts (19). 21. Loosen the cylinder bolt (20). 22. Remove the cylinder head B bolts, washers (21) and the cylinder head (22). Loosen the bolts in a crisscross pattern in two or three steps. NOTICE Do not let the washers and cam chain fall into the crankcase. 23. R[...]

Servicing Your Honda 79 Piston/Piston Rings/Piston Pin 2. Remove the dowel pins (3) and cylinder gasket (4). NOTICE Do not let the dowel pins fall into the crankcase. 1. Place clean shop towels in the crankcase to keep the piston pin clips, or other parts, from falling into the crankcase. 2. Remove the piston pin clips (1) using a pair of needle-no[...]

80 Servicing Your Honda Piston/Piston Rings/Piston Pin We recommend you consult an official Honda Shop Manual or your dealer for correct Service Limit measurements. 1. Remove the carbon deposits from the piston head and piston ring grooves. NOTICE Do not damage the piston when removing the carbon deposit. 2. Apply engine oil to each piston ring who[...]

Servicing Your Honda 81 Piston/Piston Rings/Piston Pin 1. Place clean shop towels (1) over the crankcase opening to keep the piston pin clips from falling into the crankcase. 2. Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the connecting rod[...]

82 Servicing Your Honda Piston/Piston Rings/Piston Pin 1. Clean off any gasket material from the gasket surface of the crankcase, being careful not to let any material fall into the crankcase. 2. Remove the shop towels. Do not let any gasket debris fall into the crankcase. 3. Install a new cylinder gasket (1) and dowel pins (2). NOTICE Do not let t[...]

Piston/Piston Rings/Piston Pin (cont’d) Servicing Your Honda 83 1. Clean any gasket material off cylinder head. 2. Install the cam chain guide (1) and fit the cam chain guide tabs (2) in the cylinder cut-outs (3). Push the guide until it bottoms in the crankcase guide groove. 3. Install the dowel pins (4) and a new cylinder head gasket (5). NOTIC[...]

84 Servicing Your Honda Piston/Piston Rings/Piston Pin 8. Install the left cylinder head hanger plate (10) and right cylinder head hanger plate (11), then loosely install the cylinder head hanger plate bolts (12) and cylinder head hanger bolts (13). Tighten the cylinder head hanger bolts and cylinder head hanger plate bolts to the specified torque:[...]

Servicing Your Honda 85 Piston/Piston Rings/Piston Pin 12. Connect the breather tube A (22). Connect the IAT sensor connector (23). 13. Secure the breather tube B (24) with the clip (25). 14. Connect the radiator hose (26) to the water hose joint (27) of the cylinder head. 15. Tighten the radiator hose clamp screw (28) as illustrated below. 16. Con[...]

Suspension 86 Servicing Your Honda Suspension Refer to Important Safety Precautions on page 23. Loose, worn, or damaged suspension components may adversely affect the handling and stability of your CRF. If any suspension components appear worn or damaged, see your dealer for further inspection. Your dealer is qualified to determine whether or not r[...]

Suspension Servicing Your Honda 87 The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure. The gas pressure in the reservoir is contained within a rubber bladder. The rear suspension’s spring pre-load and damping adjustments (compression and rebound) should be adjusted for the rider[...]

Suspension 88 Servicing Your Honda Refer to Front Suspension Disassembly on page 114 for front suspension removal. 1. Clean the fork assembly, especially the sliding surface of the slider and dust seal. 2. Hold the outer tube (1), then remove the fork damper (2) from the outer tube using a lock nut wrench (3). Gently slide the outer tube down onto [...]

Servicing Your Honda 89 Suspension 5. Pour the recommended fork oil (page 88) into the outer tube. Fork Oil Capacity Standard 4.59 N/mm (26.21 lbf/in) Fork Spring Optional Softer 4.40 N/mm (25.12 lbf/in) Fork Spring Optional Stiffer 4.80 N/mm (27.41 lbf/in) Fork Spring Be sure the oil capacity is the same in both fork legs. 6. Check that the O-ring[...]

Brakes 90 Servicing Your Honda Brakes Refer to Important Safety Precautions on page 23. Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop. Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect th[...]

Brakes Servicing Your Honda 91 Front Brake Fluid Level Check With the motorcycle in an upright position, check the fluid level. It should be above the LWR mark (1). If the level is at or below the LWR mark, check the brake pads for wear (page 93). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for lea[...]

92 Servicing Your Honda Brakes Adding Front Brake Fluid NOTICE Spilled brake fluid will severely damage painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first. • Always use fresh DOT4 brake fluid from a sealed container when servicing the system. Do [...]

Servicing Your Honda 93 Brakes Brake pad wear depends on the severity of usage and track conditions. (Generally, the pads will wear faster with wet and dirty track conditions.) Inspect the brake pads at each regular maintenance interval (page 25). Front Brake Pads Inspect the brake pads (1) through the front wheel to determine the brake pad wear. I[...]

Wheels 94 Servicing Your Honda Wheels Refer to Important Safety Precautions on page 23. Keeping the wheels true (round) and maintaining correct spoke tension are critical to safe motorcycle operation. During the first few rides, spokes will loosen more rapidly due to the initial seating of the parts. Excessively loose spokes may result in instabili[...]

Tyres & Tubes Servicing Your Honda 95 Tyres & Tubes Refer to Important Safety Precautions on page 23. To safely operate your CRF, the tyres must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated. The following pages give detailed information on how and when to check your air pressure, how [...]

Tyres & Tubes 96 Servicing Your Honda The tyres that came on your CRF were designed to provide a good combination of handling, braking, durability, and comfort across a broad range of riding conditions. • Use a replacement tyre equivalent to the original. • Replace the tube any time you replace a tyre. The old tube will probably be stretche[...]

Drive Chain Servicing Your Honda 97 Drive Chain Refer to Important Safety Precautions on page 23. The service life of the chain depends on proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain or sprockets. When the motorcycle is ridden on unusually dusty or muddy tracks, more frequent maintenance[...]

Drive Chain 98 Servicing Your Honda Check the upper drive chain roller (1) and lower drive chain roller (2) for wear or damage. Measure the diameter of the drive chain rollers and replace them if below the service limit. Service Limit: Upper roller: 33 mm (1.3 in) Lower roller: 35 mm (1.4 in) Replace the roller if necessary as follows. Install the [...]

Servicing Your Honda 99 Drive Chain For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each outing. 1. Remove the master link retaining clip (1) with pliers. Do not bend or twist the clip. 2. Remove the master link (2). Remove the drive chain. 3. Clean the drive chain in high flash-point solvent and allow i[...]

Exhaust Pipe/Muffler 100 Servicing Your Honda Exhaust Pipe/Muffler Check the mounting bolts and exhaust pipe joint nuts for tightness. Check the exhaust pipe and mufflers for cracks or deformation. A damaged exhaust pipe and mufflers may reduce engine performance. 1. Remove the seat (page 33). 2. Remove the side covers (1) and air cleaner housing c[...]

Exhaust Pipe/Muffler (cont’d) Servicing Your Honda 101 5. Loosen the right muffler clamp bolt (8). 6. Remove the right muffler mounting A bolt (9), washer A (10), right muffler mounting B bolt (11), washer B (12) and right muffler (13). 1. Remove the gasket (1). 2. Install the right muffler clamp (2) and a new gasket onto the exhaust pipe (3). 3.[...]

102 Servicing Your Honda Exhaust Pipe/Muffler 7. Tighten the right muffler mounting B bolt (8) and right muffler mounting A bolt (10) to the specified torque: 26 N·m (2.7 kgf·m, 19 lbf·ft) 8. Remove the gasket (12). 9. Install a new gasket onto the right muffler (4). 10. Install the left muffler (13). 11. Install the left muffler mounting bolt ([...]

Servicing Your Honda 103 Exhaust Pipe/Muffler 1. Remove the left and right mufflers (page 104). 2. Remove the exhaust pipe joint nuts (1), exhaust pipe (2) and gasket (3). 1. Install a new exhaust pipe gasket (1) as shown. 2. Install the exhaust pipe (2) and exhaust pipe joint nuts (3) but do not tighten the nuts yet. 3. Install the right muffler ([...]

Steering Damper 104 Servicing Your Honda Steering Damper Refer to Important Safety Precautions on page 23. Loose, worn or damaged steering damper components may adversely affect the handling and stability of your CRF. If any steering damper components appear worn or damaged, see your dealer for further inspection. Your dealer is qualified to determ[...]

Steering Damper (cont’d) Servicing Your Honda 105 3. With your CRF on a box or an optional workstand (front wheel elevated), check that the steering moves smoothly from side-to-side. 4. Install the number plate (3) by aligning its holes (7) with the tabs (8) on the steering stem. Install and tighten the bolts (2). Route the number plate tab (1) a[...]

106 Servicing Your Honda Steering Damper 2. Check the condition of the spherical bearings (2). Move the spherical bearing with your finger. The spherical bearing should move smoothly and quietly. Replace the spherical bearing if it does not move smoothly and quietly. Refer to an official Honda Shop Manual or see your dealer. 1. Clean and apply a lo[...]

Additional Maintenance Procedures Servicing Your Honda 107 Additional Maintenance Procedures Refer to Important Safety Precautions on page 23. 1. With your CRF on a box or optional workstand (front wheel elevated), turn the handlebar to the right and left to check for roughness in the steering head bearings. 2. Stand in front of your CRF, grab the [...]

108 Servicing Your Honda Additional Maintenance Procedures Check and tighten nuts, bolts, and fasteners before every outing. RIGHT SIDE LEFT SIDE Nuts, Bolts, Fasteners Item Torque N•m kgf•m lbf•ft 1 Cylinder head cover bolts 10 1.0 7 2 Exhaust pipe joint nuts 21 2.1 15 3 Water pump cover bolts 10 1.0 7 4 Crankshaft hole cap 15 1.5 11 5 Trans[...]

Appearance Care Servicing Your Honda 109 Appearance Care Refer to Important Safety Precautions on page 23. Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values his motorcycle. A clean CRF is also easier to inspect and service. While you’re cleaning, be sure to look[...]

110 Servicing Your Honda Appearance Care Some condensation can form within the transmission cavity as well. This is natural and just one more reason you should change the engine and transmission oil often. There are some things you should do just after washing your CRF to help prevent rust and corrosion. Once your CRF is clean and dry, you should p[...]

Adjustments for Competition Adjustments for Competition 111 Adjustments for Competition This section tells you how to fine tune your CRF for maximum competition performance. Initial suspension adjustments should be performed after a minimum of 2 hours of easy break-in time. Optional front and rear suspension springs are available in order to tailor[...]

Front Suspension Adjustments 112 Adjustments for Competition Front Suspension Adjustments The front suspension can be adjusted for the rider’s weight and riding conditions by using one or more of the following methods: • Oil volume — The effects of higher or lower fork oil capacity are only felt during the final 100 mm (3.9 in) of fork travel[...]

Adjustments for Competition 113 Front Suspension Adjustments Both compression and rebound damping can be increased by turning the adjuster clockwise. NOTICE Always start with full hard when adjusting damping. Do not turn the adjuster screw more than the given positions or the adjuster may be damaged. Be sure that the compression and rebound adjuste[...]

114 Adjustments for Competition Front Suspension Adjustments • If your CRF is brand-new, put enough part- throttle break-in time (about 1 hour) on it to ensure that the suspension has worked in. • For optimum performance, and extended fork life, the fork should be completely disassembled and cleaned after the first 3 hours of riding. See an off[...]

Front Suspension Adjustments (cont’d) Adjustments for Competition 115 7. Remove the front axle nut (10) and loosen the axle pinch bolts (11) on both forks. Pull the front axle shaft (12) out of the wheel hub and remove the front wheel with collars. 8. Remove the brake hose clamp bolts (13), stay A (14) and stay B (15). 9. Remove the front brake c[...]

116 Adjustments for Competition Front Suspension Adjustments 14. Hold the outer tube, then remove the fork damper (6) from the outer tube using a lock nut wrench (7). Gently slide the outer tube down onto the lower end (axle holder) (24). NOTICE The outer tube (25) can drop on the slider (26) and damage the fork dust seal (22). To avoid damage, hol[...]

Front Suspension Adjustments (cont’d) Adjustments for Competition 117 21. Remove the push rod (32) from the fork damper. 22. Remove the piston base (30) or mechanic’s stopper tool between the axle holder (24) and fork center bolt lock nut (31) while pushing the fork damper. NOTICE Be careful not to damage the lock nut and fork center bolt hole.[...]

118 Adjustments for Competition Front Suspension Adjustments 3. Remove the fork cap assembly (2) from the fork damper threads and then pop it out by pumping the fork damper piston rod (4) slowly. 4. Remove the fork cap assembly (2). Be careful not to damage the fork cap bushings. Do not disassemble the fork cap assembly. Replace the fork cap as an [...]

Front Suspension Adjustments (cont’d) Adjustments for Competition 119 10. Extend the fork damper piston rod (4) to maximum length, holding it, install the fork cap assembly (2) to the fork damper (1) with vertical position. Be careful not to damage the fork cap piston ring. If it is difficult to install the fork cap assembly, the fork damper oil [...]

120 Adjustments for Competition Front Suspension Adjustments 15. Drain the extra oil from the oil holes (12) of the fork damper oil chamber (5). By doing this procedure, about 5 cm 3 (0.2 US oz, 0.2 Imp oz) of fork oil will be drained from the fork damper oil chamber through the oil hole and cause 243 cm 3 (8.2 US oz, 8.6 Imp oz) of fork oil to be [...]

Front Suspension Adjustments (cont’d) Adjustments for Competition 121 3. Install the collar (3) to the C-ring (4) of the fork damper assembly (5) as shown. Install the washer (6) and spring retainer (7) to the fork damper assembly. Make sure the black side of the washer is seated on the collar side. 4. Blow out the oil completely off the fork spr[...]

122 Adjustments for Competition Front Suspension Adjustments 9. Measure the clearance between the fork center bolt lock nut (2) and fork center bolt (12). Standard: 1.5 – 2.0 mm (0.06 – 0.08 in) If the clearance is out of specification, check the fork center bolt lock nut and fork center bolt installation. 10. Tighten the fork center bolt lock [...]

Front Suspension Adjustments (cont’d) Adjustments for Competition 123 14. Remove the fork damper from the fork. 15. Pour the recommended fork oil (14) into the fork assembly (1). Recommended Oil: Cushion Oil SS19 or Ultra CO special-IV Fork Oil Capacity Standard 4.59 N/mm (26.21 lbf/in) Fork Spring Optional Softer 4.40 N/mm (25.12 lbf/in) Fork Sp[...]

124 Adjustments for Competition Front Suspension Adjustments 16. Install a new O-ring (15) on the fork damper assembly (5). Apply the recommended fork oil to the O-ring. 17. Pull up the fork assembly (1) slowly and install the fork damper assembly into the outer tube. 18. Insert both fork legs into the fork clamps. Tighten the fork bridge lower pin[...]

Front Suspension Adjustments (cont’d) Adjustments for Competition 125 23. Clean the threads of the fork protector socket bolts (22) and axle holder thoroughly. Apply locking agent to the bolt threads. Install the fork protectors (23), fork protector socket bolts. Tighten the fork protector socket bolts to the specified torque: 7 N·m (0.7 kgf·m,[...]

126 Adjustments for Competition Front Suspension Adjustments 30. Install the handlebar (34), mounting rubbers, washers and handlebar lower holder nuts (35) and tighten the handlebar holder nuts to the specified torque: 44 N·m (4.5 kgf·m, 32 lbf·ft) 31. Install the number plate (page 108). 32. With the front brake applied, pump the fork up and do[...]

Rear Suspension Adjustments Adjustments for Competition 127 Rear Suspension Adjustments The rear suspension can be adjusted for the rider’s weight and riding conditions by changing the spring pre-load and the rebound and compression damping. The rear suspension assembly includes a damper unit that contains high pressure nitrogen gas. Do not attem[...]

128 Adjustments for Competition Rear Suspension Adjustments Compression Damping Compression damping may be adjusted in two stages with separate adjusters. The high speed damping adjuster (1) is effective when damping adjustment is desired for high speed operation. The low speed damping adjuster (2) should be used when damping adjustment is desired [...]

Adjustments for Competition 129 Rear Suspension Adjustments Setting the proper race sag (ride height) is very important for competition use. Race sag refers to the amount of rear wheel travel used by your CRF at rest, ready to ride, with you on the seat. As a general rule of thumb, the race sag dimension should be about one-third of the maximum tra[...]

130 Adjustments for Competition Rear Suspension Adjustments Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre-load, consider an aftermarket rear shock spring. A spring that is too soft for your weight forces you to add excessive spring pre-load to get the [...]

Suspension Adjustments for Track Conditions Adjustments for Competition 131 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[...]

Suspension Adjustment Guidelines 132 Adjustments for Competition Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 112 – 130. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment A[...]

Suspension Adjustment Guidelines Adjustments for Competition 133 Symptom Action Stiff suspension Initial travel too stiff: • Stiff on small bumps while riding at full throttle in a straight line. • Stiff on small cornering bumps. • Front end wanders while riding at full throttle in a straight line. – Test softer compression damping adjustme[...]

Suspension Adjustment Guidelines 134 Adjustments for Competition 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 spri[...]

Tuning Tips Adjustments for Competition 135 Tuning Tips An optional PGM-FI setting tool can change the ignition timing and amount of the fuel injection (page 159). Be sure to observe the PGM-FI setting by checking the spark plug. Refer to Spark Plug on page 66. The following procedure is recommended. You may not get an accurate reading if you simpl[...]

Steering Damper Adjustment 136 Adjustments for Competition Steering Damper Adjustment The steering damper can be adjusted for riding conditions by using following method: • Damping – Turning the steering damper adjuster adjusts how quickly the steering damper compresses or extends. The steering damper adjuster (1) has 13 positions or more. Turn[...]

Steering Damper Adjustment Guidelines Adjustments for Competition 137 Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF. Symptoms and Adjustment • Always begin with the standard settings. • Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at[...]

Chassis Adjustments 138 Adjustments for Competition Chassis Adjustments The following suggestions may improve a specific concern. Subtle changes in overall handling may also be noted. If you have a problem with rear wheel traction, raise the rear end of your CRF by increasing the rear suspension spring pre-load. Instead of running 105 mm (4.1 in) o[...]

Gearing Adjustments for Competition 139 Gearing You can “adjust” the power delivery of the standard engine to suit track conditions by changing gearing. This allows you to utilize a different portion of the engine’s power range at a given throttle setting. New gearing may provide the change you are looking for without the need to consider fur[...]

Tyre Selection for Track Conditions 140 Adjustments for Competition Tyre Selection for Track Conditions Choosing the correct tyre tread pattern and rubber compound can affect your placing in competition. The tyres on your CRF offer a “happy medium” for the variety of soil conditions the majority of riders are likely to encounter. Experienced co[...]

Personal Fit Adjustments Adjustments for Competition 141 Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input. • Position the control levers so that you can use them comfortably when seated and standing. • Adjust the mounting bolt torque of the clutch and front bra[...]

142 Adjustments for Competition[...]

Tips Tips 143 Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ..................... 144 Storing Your Honda ..................................... 145 Preparation for Storage .............................. 145 Removal from Storage .......................[...]

Transporting Your Motorcycle 144 Tips Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda, we recommend that you follow these guidelines: • Use a loading ramp. • Relieve the fuel pressure (page 40) and drain the fuel from the fuel tank into an approved petrol container. • Secure the motorcycle in an u[...]

Storing Your Honda Tips 145 Storing Your Honda If you won’t be riding for an extended period, such as during the winter, thoroughly inspect your Honda and correct any problem before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your CRF running again. To reduce or prevent deterioration that can occur durin[...]

You & the Environment 146 Tips You & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally responsible motorcycle[...]

Troubleshooting Tips 147 Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis. The items that require use of an official Honda Shop Manual are followed by an asterisk (*). ENGINE DOES NOT START OR IS HARD TO START CHECK POSSIBLE CAUSES 1. Check the spark plug condition (P.66) • [...]

148 Tips Troubleshooting POOR HANDLING Steering is heavy • Steering stem adjusting nut too tight* • Damaged steering head bearings • Faulty HPSD* Either wheel is wobbling • Excessive wheel bearing play • Bent rim • Improperly installed wheel hub • Excessively worn swingarm pivot bearings • Bent frame The motorcycle pulls to one side[...]

Technical Information Technical Information 149 Technical Information This section contains dimensions, capacities, and other technical data. Vehicle Identification .................................... 150 Serial Numbers........................................... 150 Specifications ................................................ 151 Torque Specifi[...]

Vehicle Identification 150 Technical Information Vehicle Identification The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts. The VIN (vehicle identification number) (1) is stamped on the right side of the steering head. The engine number (2) is stamped on the left crank[...]

Specifications Technical Information 151 Specifications Item Metric English Dimension Overall length 2,181 mm 85.9 in Overall width 827 mm 32.6 in Overall height 1,271 mm 50.0 in Wheelbase 1,489 mm 58.6 in Seat height 951 mm 37.4 in Footpeg height 418 mm 16.5 in Ground clearance 322 mm 12.7 in Frame Type Twin tube F. suspension Telescopic fork trav[...]

Torque Specifications 152 Technical Information Torque Specifications Check and tighten nuts, bolts, and fasteners before every outing. Nuts, Bolts, Fasteners (14) (1) (2) (3) (7) (5) (4) (8) (6) RIGHT SIDE (1) (11) (14) (9) (10) (13) (12) LEFT SIDE ENGINE Item Torque Remarks N•m kgf•m lbf•ft 1 Cylinder head cover bolts 10 1.0 7 2 Exhaust pip[...]

Torque Specifications Technical Information 153 (2) (5) (6) (7) (4) (1) (9) (14) (21) (14) (17) (16) (3) (15) (13) (12) (17) LEFT SIDE (8) (9) (2) (3) (19) (20) (18) (11) (12) (16) (10) (13) RIGHT SIDE FRAME Item Torque Remarks N•m kgf•m lbf•ft 1 Steering stem nut 108 11.0 80 2 Fork bridge upper pinch bolts 22 2.2 16 3 Fork bridge lower pinch[...]

Torque Specifications 154 Technical Information (41) (43) (46) (42) (38) (37) (28) (48) (34) (28) (25) (31) (24) (35) (49) (30) (50) (23) (24) (47) LEFT SIDE (22) (46) (31) (42) (38) (42) (36) (26) (29) (40) (45) (27) (36) (29) (35) (41) (23) (39) (44) (32)(33) (50) (23) (23) RIGHT SIDE FRAME Item Torque Remarks N•m kgf•m lbf•ft 22 Front brak[...]

Petrol Containing Alcohol Technical Information 155 Petrol Containing Alcohol If you decide to use a petrol containing alcohol (gasohol), be sure it’s octane rating is at least as high as that recommended by Honda. Do not use petrol that contains more than 20% ethanol. • When certain types of petrol containing alcohol are used, problems such as[...]

Competition Logbook 156 Technical Information Competition Logbook Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events. The best way to organize the many bits of information is to record them in a logbook. Your logbook can include such information as suspension adjustments, steering damper a[...]

Competition Logbook Technical Information 157 Date Running Time Location/Event Comments (Suspension Settings, Steering Damper Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.) (Make several photocopies of this page for future use)[...]

Optional Parts List 158 Technical Information Optional Parts List These parts and tools may be ordered from your authorized dealer. The standard fork spring and shock spring mounted on the motorcycle when it leaves the factory are not marked. Before replacing the springs, be sure to mark them so they can be distinguished from other optional springs[...]

Spare Parts & Equipment Technical Information 159 Spare Parts & Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding. In addition to the usual nuts and bolts, consider the following: spark plugs air cleaner (clean & oiled, sealed in a plastic bag) chain & masterlinks chain [...]

Wiring Diagram 160 Technical Information Wiring Diagram ENGINE STOP SWITCH Bl BLACK Br BROWN E IG Y YELLOW O ORANGE PUSH Bu BLUE Lb LIGHT BLUE FREE G GREEN Lg LIGHT GREEN COLOR Bl/W R/Y R RED P PINK W WHITE Gr GRAY ENGINE STOP SWITCH ENG STOP REGULATOR/ RECTIFIER CONDENSER FUEL PUMP FRAME GROUND IGNITION COIL SPARK PLUG NO.1 CKP SENSOR NO.2 CKP SEN[...]

Technical Information 161[...]

Index 162 Index Index accessories ......................................................... 3 adjustments, chassis....................................................... 138 control freeplay .............................. 58, 61, 90 for competition ......................................... 111 gearing ...............................................[...]

Index 163 Index gap, spark plug ................................................ 66 gasohol ........................................................... 155 gearing ........................................................... 139 guidelines, steering damper ........................................ 137 suspension adjustment ...........................[...]

164 Index Index suspension, front ............................................................ 86 rear .............................................................. 87 suspension adjustment, for track conditions................................... 131 front .......................................................... 112 guidelines ..................[...]