Honda crf450r 2012 мануал

Ниже представлены прямые ссылки на скачку сервисной документации.

Для Honda CRF450

• Руководство пользователя (Owners Manual) на Honda CRF450R (на русском)
• Руководство пользователя (Owners Manual) на Honda CRF450X (на русском)
• Сервисный мануал (Service Manual) на Honda CRF450X (2005-2012)
• Сервисный мануал (Service Manual) на Honda CRF450R (2009-2010)

Обзор модели

• Honda CRF450

Источник — «https://bikeswiki.ru/index.php?title=Honda_CRF450:_мануалы&oldid=9478»

Категория:

• Сервисная документация

Page: 1

Contents
MOTORCYCLE SAFETY………………………….1
Important Safety Information…………………………2
Important Safety Precautions……………………..2
Accessories & Modifications …………………………3
Safety Labels……………………………………………….4
INSTRUMENTS & CONTROLS………………..5
Operation Component Locations ……………………6
Indicator ……………………………………………………..7
MIL Blink Pattern…………………………………….7
Current DTC/Freeze DTC …………………………7
Circuit Inspection……………………………………..8
DTC Index ………………………………………………9
BEFORE RIDING…………………………………….11
Are You Ready to Ride? ……………………………..12
Is Your Motorcycle Ready to Ride?….. ………….13
Pre-ride Inspection………………………………….13
BASIC OPERATING INSTRUCTIONS ……15
Safe Riding Precautions…………………………..16
Starting & Stopping the Engine ……………………17
Fast Idle Knob ……………………………………….17
Preparation…………………………………………….17
Starting Procedure ………………………………….17
How to Stop the Engine…………………………..18
Break-in Guidelines ………………………………..19
Contents
SERVICING YOUR HONDA……………………21
Before You Service Your Honda
The Importance of Maintenance …………………..22
Maintenance Safety…………………………………….23
Important Safety Precautions……………………23
Maintenance Schedule ………………………………..24
General Competition Maintenance ……………….26
Before & After Competition Maintenance……..30
Between Motos & Practice Maintenance …..30
After Competition Maintenance ……………….30
Service Preparations
Maintenance Component Locations………………32
Seat…………………………………………………………..33
Fuel Tank…………………………………………………..34
Subframe …………………………………………………..36
Service Procedures
Fluids & Filters
Fuel System……………………………………………….40
Engine Oil …………………………………………………49
Transmission Oil ………………………………………..52
Coolant ……………………………………………………..54
Air Cleaner ………………………………………………..56
Crankcase Breather …………………………………….58
Engine
Throttle……………………………………………………..59
Engine Idle Speed ………………………………………61
Clutch System ……………………………………………62
Spark Plug …………………………………………………67
Valve Clearance………………………………………….68
Piston/Piston Rings/Piston Pin……………………..77
Chassis
Suspension…………………………………………………87
Brakes……………………………………………………….91
Wheels………………………………………………………95
Tires & Tubes…………………………………………….96
Drive Chain ……………………………………………….98
Exhaust Pipe/Muffler ………………………………..101
Steering Damper……………………………………….104
Additional Maintenance Procedures ……………107
Appearance Care ………………………………………109

Page: 2

Contents
ADJUSTMENTS FOR COMPETITION….111
Front Suspension Adjustments……………………112
Front Suspension Air Pressure………………..112
Front Suspension Damping…………………….113
Fork springs …………………………………………113
Front Suspension Disassembly ……………….114
Damper Oil Change ………………………………117
Fork Assembly……………………………………..120
Rear Suspension Adjustments…………………….126
Rear Suspension Spring Pre-Load …………..126
Rear Suspension Damping……………………..127
Rear Suspension Race Sag …………………….128
Suspension Adjustments for Track
Conditions ……………………………………………….130
Suspension Adjustment Guidelines……………..131
Tuning Tips ……………………………………………..134
Spark Plug Reading ………………………………134
Steering Damper Adjustment……………………..135
Steering Damper Damping …………………….135
Steering Damper Adjustment Guidelines……..136
Chassis Adjustments………………………………….137
Rear End ……………………………………………..137
Fork Height/Angle ………………………………..137
Wheelbase……………………………………………137
Gearing……………………………………………………138
Tire Selection for Track Conditions…………….139
Personal Fit Adjustments …………………………..140
Control Positioning……………………………….140
Handlebar Position, Width & Shape………..140
TIPS……………………………………………………….141
Transporting Your Motorcycle……………………142
Storing Your Honda…………………………………..143
Preparation for Storage ………………………….143
Removal from Storage…………………………..143
You & the Environment …………………………….144
Troubleshooting………………………………………..145
TECHNICAL INFORMATION ………………147
Vehicle Identification ………………………………..148
Serial Numbers …………………………………….148
Specifications …………………………………………..149
Torque Specifications………………………………..150
Nuts, Bolts, Fasteners ……………………………150
Oxygenated Fuels……………………………………..153
Competition Logbook ……………………………….154
Optional Parts List ……………………………………156
Spare Parts & Equipment …………………………..157
Spare Parts …………………………………………..157
General Tools……………………………………….157
Honda Special Tools……………………………..157
Chemical Products ………………………………..157
Other Products ……………………………………..157
Wiring Diagram………………………………………..158
CONSUMER INFORMATION……………….159
Authorized Manuals ………………………………….160
Contacting Honda……………………………………..161
Your Honda Dealer……………………………………162
The Honda Rider’s Club (USA only) ………….163
Contents
INDEX……………………………………………………164
QUICK REFERENCE

Page: 3

2012
Honda CRF450R
OWNER’S MANUAL & COMPETITION HANDBOOK

Page: 4

Introduction
Congratulations on choosing your Honda CRF
motocross motorcycle.
When you own a Honda, you’re part of a
worldwide family of satisfied customers – people
who appreciate Honda’s reputation for building
quality into every product.
Your CRF is a high performance racing
motorcycle that utilizes the latest motocross
technology and is intended for competition use in
sanctioned, closed-course events by experienced
riders only.
Be aware that motocross is a physically
demanding sport that requires more than just a
fine motorcycle. To do well, you must be in
excellent physical condition and be a skillful
rider. For the best results, work diligently on
your physical conditioning and practice
frequently.
Before riding, take time to get acquainted with
your CRF and how it works. To protect your
investment, we urge you to take responsibility for
keeping your CRF well maintained. Scheduled
service is a must, of course. But it’s just as
important to observe the break-in guidelines, and
perform all the pre-ride and other periodic checks
detailed in this manual.
You should also read the owner ’s manual before
you ride. It’s full of facts, instructions, safety
information, and helpful tips. To make it easy to
use, the manual contains a table of contents, a
detailed list of topics at the beginning of each
section, and an index at the back of the book.
As you read this manual, you will find
information that is preceded by a
symbol. This information is intended to help you
avoid damage to your CRF, other property, or the
environment.
Unless you are mechanically qualified and have
the proper tools, you should see your dealer for
the service and adjustment procedures discussed
in this manual.
An official Honda Service Manual for your CRF
is available (page 160). It is the same manual
your dealer uses. If you plan to do any service
on your CRF beyond the standard maintenance
procedures in this manual, you will find an
official Honda Service Manual a valuable
reference.
If you have any questions, or if you ever need a
special service or repairs, remember that your
Honda dealer knows your CRF best and is
dedicated to your complete satisfaction.
Please report any change of address or ownership
to your dealer so we will be able to contact you
concerning important product information.
You may also want to visit our website at
USA: www.powersports.honda.com.
Canada: www.honda.ca.
Happy riding!
California Proposition 65 Warning
WARNING: This product contains or emits
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
NOTICE
ABBREVIATION
Throughout this manual, the following
abbreviations are used to identify the respective
parts or system.
Introduction
Abbrev. term
CKP sensor
DLC
DTC
ECM
ECT sensor
HPSD
IAT sensor
MAP sensor
MIL
PGM-FI
TDC
TP sensor
Crankshaft Position sensor
Data Link Connector
Diagnostic Trouble Code
Engine Control Module
Engine Coolant Temperature sensor
Honda Progressive Steering Damper
Intake Air Temperature sensor
Manifold Absolute Pressure sensor
Malfunction Indicator Lamp
Programmed Fuel Injection
Top Dead Center
Throttle Position sensor
Full term

Page: 5

A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.
To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages
throughout the manual.
Safety Messages are preceded by a safety alert symbol and one of three signal words: DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good
judgement.
Safety Messages
DANGER
WARNING
CAUTION

Page: 6

Motorcycle Safety
This section presents some of the most important
information and recommendations to help you
ride your CRF safely. Please take a few
moments to read these pages. This section also
includes information about the location of safety
labels on your CRF.
Important Safety Information………………………….2
Important Safety Precautions……………………..2
Accessories & Modifications ………………………….3
Safety Labels………………………………………………..4
Motorcycle Safety 1

Page: 7

Important Safety Information
Important Safety Precautions
Your CRF can provide many years of pleasure, if
you take responsibility for your own safety and
understand the challenges you can meet in
competitive racing.
As an experienced rider, you know there is much
you can do to protect yourself when you ride.
The following are a few precautions we consider
to be most important.
Never Carry a Passenger.
Your CRF is designed for one operator only.
Carrying a passenger can cause an accident in
which you and others can be hurt.
Wear Protective Gear.
Whether you’re practicing to improve your skills,
or riding in competition, always wear an
approved helmet, eye protection, and proper
protective gear.
Take Time to Get to Know Your CRF.
Because every motorcycle is unique, take time to
become thoroughly familiar with how this one
operates and responds to your commands before
placing your machine, and yourself, in
competition.
Learn and Respect Your Limits.
Never ride beyond your personal abilities or
faster than conditions warrant. Remember that
alcohol, drugs, illness and fatigue can reduce
your ability to perform well and ride safety.
Don’t Drink and Ride.
Alcohol and riding don’t mix. Even one drink
can reduce your ability to respond to changing
conditions, and your reaction time gets worse
with every additional drink. So don’t drink and
ride, and don’t let your friends drink and ride
either.
Keep your Honda in Safe Condition.
Maintaining your CRF properly is critical to your
safety. A loose bolt, for example, can cause a
breakdown in which you can be seriously
injured.
2 Motorcycle Safety

Page: 8

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.
WARNING
Improper accessories or modifications
can cause a crash in which you can be
seriously hurt or killed.
Follow all instructions in this owner’s
manual regarding modifications and
accessories.

Page: 9

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

Page: 10

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……………………………………..7
Current DTC/Freeze DTC ………………………….7
Circuit Inspection………………………………………8
DTC Index ……………………………………………….9

Page: 11

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

Page: 12

Instruments & Controls 7
Indicator
The MIL on your CRF keeps you informed,
alerts you to possible problems, and makes your
riding safer and more enjoyable. Refer to the
MIL frequently.
(1)
(1) MIL
The MIL flashes when there is any abnormality
in the PGM-FI system. It should also light for a
few seconds and then go off when the engine is
started.
If the MIL comes on at any other time, reduce
speed and refer to an official Honda Service
Manual available for purchase from your dealer
(page 160).
If the MIL does not come on when it should,
have your dealer check it for problems.
MIL Blink Pattern
The MIL will blink the appropriate DTC number
if the ECM detects an active problem while the
engine is running at less than 4,000 rpm.
The MIL will stay on when engine speed is over
4,000 rpm.
The MIL has two types of blinks: a long blink
and short blink. The long blinking lasts for 1.2
seconds, the short blinking lasts for 0.4 seconds.
One long blink is the equivalent of ten short
blinks. For example, when one long blink is
followed by two short blinks, the MIL is 12 (one
long blink = 10 blinks, plus two short blinks).
When the ECM stores more than one DTC, the
MIL will indicate them by blinking in the order
from the lowest number to highest number.
Current DTC/Freeze DTC
The DTC is indicated in two ways according to
the failure status.
– In the case that the ECM detects an active
problem, the MIL will come on and will start to
blink the DTC when the engine is started.
– In the case that the ECM does not detect an
active problem but has recorded a previous
problem in its memory, the MIL will not come
on. If it is necessary to retrieve any past
problems stored in the memory, refer to an
official Honda Service Manual.

Page: 13

8 Instruments & Controls
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
(6) No.1/No.2 CKP sensor connector
(7) ECM connector
Remember, circuit inspection is not a “cure-all”
for other problems in your engine’s PGM-FI
system.
(1) (7)
(5)
(6)
(2)
(3)
(4)

Page: 14

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

Page: 15

10 Instruments & Controls

Page: 16

Before Riding 11
Before each ride, you need to make sure you and
your CRF 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.
Before Riding
Are You Ready to Ride?……………………………….12
Is Your Motorcycle Ready to Ride? ……………….13
Pre-ride Inspection………………………………….13

Page: 17

12 Before Riding
Are You Ready to Ride?
Before riding your CRF for the first time, we
strongly recommend that you read this owner ’s
manual, make sure you understand the safety
messages, and know how to operate the controls.
Before each ride, it’s also important to make sure
you and your CRF are both ready to ride.
For information about suspension, steering
damper, and other adjustments, see page 111.
Whether you’re preparing for competition or for
practice, always make sure you are:
• In good physical and mental condition
• Free of alcohol and drugs
• Wearing an approved helmet, eye protection,
and other appropriate riding gear
Although complete protection is not possible,
wearing the proper gear can reduce the chance or
severity of injury when you ride.
WARNING
Not wearing a helmet increases the
chance of serious injury or death in a
crash.
Be sure you always wear a helmet, eye
protection and other protective apparel
when you ride.

Page: 18

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):
Pre-ride Inspection
Check the following before each ride:
• Engine oil level ………………………………………50
• Transmission oil level……………………………..53
• Fuel line for condition …………………………….40
• Coolant for proper level…………………………. 54
• Cooling system and hoses for condition…….55
• Spark plug for proper heat range, carbon
fouling and spark plug wire terminal for
looseness ……………………………………………….67
• Air cleaner for condition and
contamination…………………………………………56
• Clutch lever adjustment and freeplay ………..62
• Breather drain for cleaning ………………………58
• Steering head bearing and related parts
for condition…………………………………………107
• Steering damper operation……………………..104
• Throttle operation …………………………………..59
• Tires for damage or improper inflation
pressure ………………………………………………..96
• Spokes for looseness……………………………….95
• Rim locks for looseness …………………………..95
• Front and rear suspension for proper
operation ………………………………………….87, 88
• Front and rear brakes, check operation ……..91
• Drive chain for correct slack and adequate
lubrication………………………………………..98, 99
• Drive chain sliders and drive chain rollers
for damage or wear ……………………………98, 99
• Exhaust pipe/Muffler for looseness …………101
• Every possible part for looseness (such as
cylinder head nuts, engine mounting
bolts/nuts, axle nuts, handlebar holder bolts,
fork bridge pinch bolts, drive chain adjuster,
drive chain guide, wire harness connectors,
kickstarter mounting bolt) ……………….150-152
• Indicator………………………………………………….7
WARNING
Improperly maintaining this motorcycle or
failing to correct a problem before riding
can cause a crash in which you can be
seriously hurt or killed.
Always perform a pre-ride inspection
before every ride and correct any
problems.

Page: 19

Basic Operating Instructions 15
Basic Operating Instructions 15
Basic Operating Instructions
This section gives basic information on how to
start and stop your engine as well as break-in
guidelines.
Safe Riding Precautions…………………………..16
Starting & Stopping the Engine …………………….17
Fast Idle Knob ……………………………………….17
Preparation…………………………………………….17
Starting Procedure ………………………………….17
How to Stop the Engine…………………………..18
Break-in Guidelines …………………………………….19

Page: 20

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

Page: 21

Basic Operating Instructions 17
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.
Fast Idle Knob
The fast idle knob has two functions:
• When pulled out, the fast idle knob assists in
first-time start-up for cold weather starting.
• When pushed in, it acts like an idle
adjustment screw. Refer to Idle Speed
Adjustment on page 61.
Preparation
Make sure that the transmission is in neutral.
Starting Procedure
Always follow the proper starting procedure
described as follow.
Check the engine oil, transmission oil and coolant
levels before starting the engine (pages 50, 53, 54).
Cold Engine Starting
1. Shift the transmission into neutral.
2. If the temperature is 95°F (35°C) or below,
pull the fast idle knob (1) fully out.
(1) fast idle knob
3. With the throttle closed, operate the
kickstarter starting from the top of the
kickstarter stroke, kick through to the bottom
with a rapid, continuous motion.
4. About a minute after the engine starts, push
the fast idle knob back all the way to fully
OFF.
If idling is unstable, open the throttle slightly.
(1)
Warm Engine Starting
1. Shift the transmission into neutral.
2. Kick-start the engine. (Do not open the
throttle.)
If Difficult to Start After Stalling
1. Shift the transmission into neutral.
2. With the throttle fully opened, repeat
kickstarter operation approximately 10 times
to discharge excessive fuel from the engine.
3. Kick-start the engine. (Do not open the
throttle.)
Snapping the throttle or fast idling for more than
about 5 minutes may cause exhaust pipe and
muffler discolorations.

Page: 22

18 Basic Operating Instructions
Starting & Stopping the Engine
18 Basic Operating Instructions
How to Stop the Engine
(1)
(2)
(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.
Emergency Engine Stop
To stop the engine in an emergency, push and
hold the engine stop button.

Page: 23

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

Page: 24

20 Basic Operating Instructions

Page: 25

Servicing Your Honda 21
Servicing Your Honda
Keeping your CRF well maintained is absolutely
essential to your safety. It’s also a good way to
protect your investment, get maximum
performance, avoid breakdowns, and have more
fun.
To help keep your CRF in good shape, this
section includes a Maintenance Schedule for
required servicing and step-by-step instructions
for specific maintenance tasks. You’ll also find
important safety precautions, information on oils,
and tips for keeping your CRF looking good.
An ECM system is used on this motorcycle;
consequently, routine ignition timing adjustment
is unnecessary. If you want to check the ignition
timing, refer to the Honda Service Manual (page
160).
An optional tool kit may be available. Check
with your dealer’s parts department.
Before You Service Your Honda
The Importance of Maintenance ……………………22
Maintenance Safety……………………………………..23
Important Safety Precautions……………………23
Maintenance Schedule …………………………………24
General Competition Maintenance ………………..26
Before & After Competition Maintenance………30
Between Motos & Practice Maintenance …..30
After Competition Maintenance ……………….30
Service Preparations
Maintenance Component Locations……………….32
Seat …………………………………………………………..33
Fuel Tank …………………………………………………..34
Subframe …………………………………………………..36
Service Procedures
Fluids & Filters
Fuel System………………………………………………..40
Engine Oil ………………………………………………….49
Transmission Oil …………………………………………52
Coolant ………………………………………………………54
Air Cleaner …………………………………………………56
Crankcase Breather ……………………………………..58
Engine
Throttle………………………………………………………59
Engine Idle Speed ……………………………………….61
Clutch System …………………………………………….62
Spark Plug ………………………………………………….67
Valve Clearance…………………………………………..68
Piston/Piston Rings/Piston Pin………………………77
Chassis
Suspension………………………………………………….87
Front Suspension Inspection ………………………87
Rear Suspension Inspection ……………………….88
Recommended Fork Oil …………………………….89
Fork Oil Change……………………………………….89
Brakes………………………………………………………..91
Wheels……………………………………………………….95
Tires & Tubes……………………………………………..96
Drive Chain ………………………………………………..98
Exhaust Pipe/Muffler …………………………………101
Steering Damper………………………………………..104
Additional Maintenance Procedures …………….107
Appearance Care ……………………………………….109

Page: 26

22 Servicing Your Honda
WARNING
Improperly maintaining this motorcycle or
failing to correct a problem before you
ride can cause a crash in which you can
be seriously hurt or killed.
Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.
The Importance of Maintenance
Keeping your CRF well-maintained is absolutely
essential to your safety. It’s also a good way to
get maximum performance during each moto.
Careful pre-ride inspections and good
maintenance are especially important because
your CRF is designed to be ridden in of f-road
competition.
Remember, proper maintenance is your
responsibility. Be sure to inspect your CRF
before each ride and follow the Maintenance
Schedule in this section.

Page: 27

Servicing Your Honda 23
Maintenance Safety
This section includes instructions on how to
perform some important maintenance tasks.
Some of the most important safety precautions
follow. However, we cannot warn you of every
conceivable hazard that can arise in performing
maintenance. Only you can decide whether or
not you should perform a given task.
Important Safety Precautions
• Make sure the engine is off before you begin
any maintenance or repairs.
This will help eliminate several potential
hazards:
Carbon monoxide poisoning from engine
exhaust. Be sure there is adequate ventilation
whenever you operate the engine.
Burns from hot motorcycle parts. Let the
engine and exhaust system cool before
touching.
Injury from moving parts. Do not run the
engine unless instructed to do so.
• Read the instructions before you begin, and
make sure you have the tools and skills
required.
• To help prevent the motorcycle from falling
over, park it on a firm, level surface, using an
optional workstand or a maintenance stand to
provide support.
• To reduce the possibility of a fire or
explosion, be careful when working around
gasoline. Use only a non-flammable (high
flash point) solvent such as kerosene —not
gasoline— to clean parts. Keep cigarettes,
sparks, and flames away from all fuel-related
parts.
WARNING
Failure to properly follow maintenance
instructions and precautions can cause
you to be seriously hurt or killed.
Always follow the procedures and
precautions in this owner’s manual.

Page: 28

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

Page: 29

Servicing Your Honda 25
Maintenance Schedule
ITEMS
FUEL LINE
FUEL PUMP FILTER
THROTTLE OPERATION
AIR FILTER
CRANKCASE BREATHER
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
ENGINE IDLE SPEED
PISTON AND PISTON RINGS
PISTON PIN
TRANSMISSION OIL
RADIATOR COOLANT
COOLING SYSTEM
DRIVE CHAIN
DRIVE CHAIN SLIDER
DRIVE CHAIN ROLLER
DRIVE SPROCKET
DRIVEN SPROCKET
BRAKE FLUID
BRAKE PADS WEAR
BRAKE SYSTEM
CLUTCH SYSTEM
CONTROL CABLES
EXHAUST PIPE/MUFFLER
SUSPENSION
SWINGARM/SHOCK LINKAGE
FORK OIL EXCEPT DAMPER
FORK OIL DAMPER
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING HEAD BEARINGS
(NOTE 6)
(NOTE 6)
(NOTE 1)
(NOTE 4)
(NOTE 3)
(NOTE 3)
(NOTE 5)
(NOTE 2)
(NOTE 2)
(NOTE 5)
(NOTE 3)
I
I
C
I
I
I
I
I
I
I
I, L
I
I
I
I
I
I
I
I
I, L
I
I
I
I
40
44
60
56
58
67
68-76
49
50
61
77
80
52
54
54
98
98
99
100
100
92
94
91
62
107
101
87, 88
29, 88
89
117
108, 150-152
95-97
107
R
L
R
I
R
R
R
R
R
R
R
R
I
FREQUENCY
NOTE Ref. Page
Each race
or about
2.5 hours
Every 3 races
or about
7.5 hours
Every 6 races
or about
15.0 hours
Every 9 races
or about
22.5 hours
Every 12 races
or about
30.0 hours
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.
2.Replace every 2 years. Replacement requires mechanical skill.
3.Replace after the first break-in ride.
4.Inspect after the first break-in ride.
5.Replace the transmission oil, if the clutch discs and plates are replaced.
6.Replace every year.
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.

Page: 30

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 Genuine Parts or their equivalent
when servicing your CRF.
Clean parts in non-flammable (high flash point)
cleaning solvent (such as kerosene) when
disassembling. Lubricate any sliding surface,
O-rings, and seals before reassembling. Grease
parts by coating or filling where specified.
After any engine disassembly, always install new
gaskets, O-rings, cotter pins, piston pin clips,
snap rings, etc. when reassembling. After
reassembly, check all parts for proper installation
and operation.
All Pre-ride Inspection Items
Refer to Pre-ride Inspection page 13.

Page: 31

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).
Engine Oil and Filter
Drain and replace engine oil often to ensure the greatest
service life of the piston, cylinder and crankshaft.
Also replace engine oil filter often to ensure the greatest
service life. Frequent changes will also assure consistent
performance of power and response (page 50).
Air Cleaner
Clean and oil your air cleaner regularly because the volume
of air able to pass through it has a great effect on
performance. Both engine performance and long term
durability may be affected by an air cleaner that has
deteriorated and allows dirt to pass. Inspect the air cleaner
closely each time it’s serviced for evidence of small tears or
seam separation. Keep a spare air cleaner oiled and ready to
install, sealed in a plastic bag. Riding in dusty conditions
may require servicing the air cleaner or replacing it with a
pre-serviced air cleaner between motos. Be careful not to
over oil the air cleaner. While it is important to oil the air
cleaner thoroughly, over oiling will cause an overall rich
running condition, probably more noticeable off idle and in
low rpm performance. Follow the servicing instructions in
the Maintenance section. Use Pro Honda Foam Filter Oil or
an equivalent. Be sure to grease the air cleaner flange where
it contacts the air cleaner housing. Pro Honda White
Lithium Grease, or an equivalent, is handy for this because
any dirt that penetrates this sealing area will show up clearly
(page 56).
Use the Honda Genuine air cleaner or an equivalent air
cleaner specified for your model.
Using the wrong Honda air cleaner or a non-Honda air
cleaner which is not of equivalent quality may cause
premature engine wear or performance problems.
Transmission Oil
Drain and replace transmission oil often to ensure the
greatest service life of the transmission and clutch. Frequent
changes will also assure consistent performance of both
shifting and clutch action (page 53).
Air Cleaner Housing Sealing
Remove and reseal the air cleaner housing boot where it
connects to the air cleaner housing with Pro Honda Handgrip
Cement or equivalent if there is any doubt to its sealing
integrity. Inspect the air cleaner and air intake tract regularly
for signs of deterioration or dirt penetration.
Spark Plug Cap
Install a small plastic tie-wrap around the spark plug cap to
reduce any possibility of it loosening or of water
penetration.
Servicing Your Honda 27
General Competition Maintenance

Page: 32

28 Servicing Your Honda
General Competition Maintenance
Handgrips
Always use Pro Honda Handgrip Cement when replacing
handgrips.
Refer to an official Honda Service Manual (page 160) for
installation instructions.
Throttle Grip
Right throttle grip: Align the index mark on the throttle grip
with the index mark of the throttle pipe.
Left handlebar grip: Align the index mark on the left
handlebar grip with the paint mark on the handlebar.
For added security, you may choose to bind the handgrips to
the handlebar and throttle pipe with safety wires to prevent
the possibility of them loosening. Position the twisted wire
ends away from your palms and be sure to bend the wire
ends well into the handgrip rubber so they will not snag your
glove.
Throttle Control
Remove the throttle control every few rides, clean the inside
of the throttle pipe and handlebar thoroughly. Inspect the
cable carefully for kinks or other damage that may restrict
throttle control in anyway. Move the handlebar from lock to
lock to be sure there is no cable interference. Make certain
the throttle operation is perfect after servicing and
inspecting.
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 (pages 77, 79).
Fuel Line
Refer to Fuel System on page 40.
Check the fuel line for deterioration, damage, or leakage.
Replace the fuel line every year.
Engine Mounting Bolts and Nuts
Make sure the engine mounting bolts and nuts are tightened
to the proper torque specification. For added peace of mind,
remove the nuts, clean the threads, and apply Pro Honda
Hondalock or an equivalent prior to torquing the nuts.
Electrical Connectors
Clean electrical connectors and wrap them with electrical
tape to reduce the possibility of unwanted disconnections,
water shorts or corrosion. Additional corrosion protection is
offered by using Pro Honda Dielectric Grease on all
electrical connections.

Page: 33

Suspension Linkage Lubrication
Disassemble, clean, inspect and lubricate all suspension
linkage pivot bearings with grease after each 7.5 hours of
running time in order to maintain proper suspension
performance and minimize component wear.
Swingarm Pivot Lubrication
Clean, inspect and lubricate the swingarm and suspension
linkage pivots with grease. Be sure all of the dust seals are
in good condition.
Swingarm
Do not attempt to weld or otherwise repair a damaged
swingarm. Welding will weaken the swingarm.
Footpegs
Worn footpeg teeth can be repaired by filing the grooves
between the teeth with a triangular shaped file.
Be aware that filing them too sharp will reduce boot sole
lifespan. Sharpen only the points of the teeth. Filing the
grooves deeper will weaken the footpegs. Be sure the pegs
are free to pivot freely and that the pivot pin retaining cotter
pins are in good condition.
Brake Fluid Replacement
Refer to Brake Pad Wear in your Owner’s Manual, page 94.
Brake Caliper Inspection: Be sure both the front and rear
calipers are able to move freely on the caliper pin and caliper
bracket pins. Check pad thickness periodically and replace
the pads when minimum thickness is reached. If the brakes
fade when they are hot, inspect the pads for glazing or
damage, and replace if necessary.
Brake Fluid Replacement: Refer to an official Honda
Service Manual (page 160) for brake fluid replacement
instructions. Replace the brake fluid in the brake system
every 2 years. Replace the fluid more frequently if you
subject your brakes to severe use. Heavy braking heats the
brake fluid and it may deteriorate sooner than expected. Any
type of riding, that requires frequent use of the brakes, such
as in tight woods, can shorten the service life of brake fluid.
Steering Head Bearings
Periodically clean, inspect and regrease the steering head
bearings — especially if wet, muddy or extremely dusty
courses are encountered often.
Use urea based multi-purpose grease designed for high
temperature, high pressure performance (example:
EXCELITE EP2 manufactured by KYODO YUSHI, Japan
or Shell Stamina EP2 or equivalent)
Bleed Hole
After every race, check the bleed hole below the water pump
cover for leakage. Clean away any clogged dirt or sand, if
necessary. Check for signs of seal leakage. If water leaks
through the bleed hole, replace the mechanical seal. If oil
leaks through the bleed hole, replace the oil seal. Make sure
that there is no continuous coolant leakage from the bleed
hole while operating the engine. A small amount of coolant
weeping from the bleed hole is normal. See an official
Honda Service Manual or consult your dealer for replacing
the mechanical seal or oil seal. Both seals should be
replaced at the same time.
Fork Oil/Performance
Disassemble, clean and inspect the fork and replace the oil
regularly. Contamination due to the tiny metal particles
produced from the normal action of the fork, as well as
normal oil breakdown, will deteriorate the performance of
the suspension. Refer to an official Honda Service Manual
(page 160). Use only KHL15-11 (KYB) which contains
special additives to assure maximum performance of your
CRF’s front suspension.
Frame
Because your CRF is a high-performance machine, the frame
should not be overlooked as part of your overall competition
maintenance program. Periodically inspect the frame
closely for possible cracking or other damage. It makes
good racing sense.
Spokes
Check spoke tension frequently between the first few rides.
As the spokes, spoke nuts and rim contact points seat-in, the
spokes may need to be retightened. Once past this initial
seating-in period, the spokes should hold their tension. Still,
be sure your race maintenance program includes checking
spoke tension and overall wheel condition on a regular basis
(page 95).
Nuts, Bolts, Etc
Application of a thread locking agent to essential fasteners
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.
GREASE
GREASE
GREASE
Servicing Your Honda 29
General Competition Maintenance

Page: 34

(1) chain adjuster index marks
• Suspend the front wheel above the ground and
use the fork air pressure release screws (2) to
release the built-up pressure (in excess of
normal atmospheric pressure: 0 psi (0 kPa, 0
kgf/cm2)) in the fork tubes. This pressure is
caused by normal fork action while riding. (If
you are riding at altitude, remember that fork
pressure of 0 at sea level will increase as
elevation increases.)
30 Servicing Your Honda
Before & After Competition Maintenance
(1)
(2)
After Competition Maintenance
It is important to the long term performance of
your CRF to practice a consistent maintenance
program. Right after the event is a good time to
begin your next maintenance cycle.
After Race Lubrication
Apply a light coating of rust-inhibiting oil to the
drive sprocket and any steel portions of the
chassis or engine where the paint has worn away.
This will prevent rusting of the exposed metal.
Apply rust-inhibiting oil more heavily if the
event was particularly wet or muddy. Take care
to avoid spraying any oil near the brake pads or
the brake discs.
Take care to prevent catching your fingers
between the chain and sprocket.
Remove the drive chain, clean and lubricate it
(pages 99, 100). Be sure the chain is wiped clean
and is dry before lubricating the chain.
(2) fork air pressure release screws
Between Motos & Practice Maintenance
After practice or between motos you have a
chance to make additional checks and
adjustments.
• Clean accumulated dirt from under the
fenders and off the wheels, suspension
components, handgrips, controls, and
footpegs. A stiff, nylon parts cleaning brush
works well.
• Check tire air pressure.
• Check spoke tension, and make sure the rim
locks are secure.
• Check to make sure the sprocket bolts and
nuts are secure.
• Clean the sides of the drive chain with a stif f,
nylon parts-cleaning brush. Lubricate and
adjust the chain as necessary.
Do not perform maintenance while engine is
running. Injury to your fingers or hands may
result.
• After adjustment, check that the chain adjuster
index marks (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.

Page: 35

Servicing Your Honda 31
Before & After Competition Maintenance
Routine Cleaning
If your CRF is only slightly dirty, it is best to
clean it by hand with the aid of a stif f bristled
nylon brush and some clean rags.
Take care to prevent catching your fingers
between the chain and sprocket.
A variety of reasonably priced cleaning brushes
are available from variety, drug, food, and
hardware stores. Some of these brushes are
extremely useful in removing dirt from the many
tight contours of the metal pieces of your CRF.
Avoid using stiff, abrasive brushes on the plastic
or rubber parts.
If your CRF was exposed to sea air or salt water ,
rinse it as soon as possible after the event, dry it,
and apply a spray lubricant to all metal parts.
If you decide to wash your CRF or use cleaners,
refer to Appearance Care (page 109).

Page: 36

32 Servicing Your Honda
Maintenance Component Locations
front brake
caliper
engine oil
filter
engine oil
fill cap
transmission
oil drain bolt drive chain
crankcase
breather
tube
rear suspension
spring pre-load
adjuster
air cleaner
fast idle knob
(engine idle speed)
spark plug
rear brake
caliper
rear brake
fluid reservoir
rear brake
pedal
transmission oil
fill cap
engine oil
drain bolt
transmission oil
check bolt
front suspension
rebound damping
adjuster
front suspension compression
damping adjuster
steering damper
adjuster
rear suspension
rebound damping
adjuster
rear suspension high speed
compression damping adjuster
rear suspension low speed
compression damping adjuster
·
·
clutch lever
front brake lever
front brake fluid reservoir
throttle grip
radiator cap
fuel fill cap

Page: 37

Servicing Your Honda 33
Seat
Refer to 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 seat bracket (2) and seat
rear prong (3) with the ECM bracket (4).
2. Install and tighten the seat mounting bolts to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
(2)
(1)
(2)
(1)
(3)
(4)
(1) seat mounting bolts (2) seat
(1) seat front prong (3) seat rear prong
(2) seat bracket (4) ECM bracket

Page: 38

34 Servicing Your Honda
Fuel Tank
Refer to 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) and shrouds (3).
7. Remove the fuel tank bolt and collar (7).
(2)
(1) (3)
(5)
(7)
(6)
(8)
(11)
(10)
WARNING
Gasoline is highly flammable and
explosive. You can be burned or seriously
injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
(8) fuel feed hose (11) fuel tank stopper cable
(10) fuel tank
10. Check for interference between the frame and
tank and adjust the cushion rubbers (12) if
necessary.
(1) shroud A bolts and collars (3) shrouds
(2) shroud B bolts
4. Install a hose clamp (4) to the breather tube
(5) and shut the hose clamp securely.
(5)
(4)
(4) hose clamp (5) breather tube
5. Pull the breather tube (5) out of steering stem
nut.
6. Unhook the fuel tank band (6).
(5) breather tube
(6) fuel tank band
(7) fuel tank bolt and collar
8. Unhook the fuel feed hose (8) from the
clamp (9).
(12)
2.4 in (60 mm)
(12) cushion rubbers
(8) fuel feed hose (9) clamp
9. Pull the fuel tank (10) out of the frame and
hang it to the left of the frame.
Check the fuel tank stopper cable (11) for
deterioration, kinks or other damaged.
Do not support the fuel tank by the fuel feed
hose (8).
(8)
(9)

Page: 39

Servicing Your Honda 35
Fuel Tank
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Installation
1. Install the fuel feed hose (1) to the clamp (2)
if it is removed.
(1) fuel feed hose (2) clamp
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).
5. Put the breather tube (6) in the steering stem
nut (7).
6. Remove the hose clamp (8) from the breather
tube.
(6) breather tube (8) hose clamp
(7) steering stem nut
7. Install the shrouds (9) by aligning shroud
tabs (10) with the air cleaner housing cover
tabs (11).
(3) fuel tank (5) fuel tank band
(4) collar and fuel tank bolt
(12)
(13) (10)
(11)
(9)
(9) shrouds
(10) shroud tabs
(11) air cleaner housing cover tabs
(12) shroud B bolts
(13) collars and shroud A bolts
8. Install the shroud B bolts (12), collars and
shroud A bolts (13).
Tighten the shroud B bolts to the specified
torque:
3.7 lbf·ft (5 N·m, 0.5 kgf·m)
9. Install the seat (page 33).

Page: 40

36 Servicing Your Honda
Subframe
Refer to Safety Precautions on page 23.
Removal
1. Remove the side covers (1) by removing the
seat mounting bolts (2) and bolts (3).
2. Remove the seat (4).
(1) side cover (3) bolts
(2) seat mounting bolts (4) seat
3. Loosen the muffler clamp bolt (5).
(3)
(4)
(2)
(1)
(5) muffler clamp bolt
(5)
(15)
(16)
4. Remove the muffler mounting A bolt (6),
muffler mounting B bolt (7), washer A (8),
washer B (9) and muffler (10).
(6) muffler mounting A bolt (9) washer B
(7) muffler mounting B bolt (10) muffler
(8) washer A
5. Disconnect the IAT sensor connector (11).
6. Remove the ECM mounting rubber (12) from
the ECM bracket (13).
Unhook the fuel tank band (14).
(12) ECM mounting rubber
(13) ECM bracket
(14) fuel tank band
7. Loosen the screw (15) on the air cleaner
connecting tube clamp (16).
(15) screw
(16) air cleaner connecting tube clamp
(6)
(10)
(7)
(8) (9)
(12)
(14) (13)
(11) IAT sensor connector
(11)

Page: 41

Servicing Your Honda 37
Subframe
8. Remove the right subframe lower bolt (17)
and left subframe lower bolt (18).
Remove the subframe upper bolts (19).
(17) right subframe lower bolt
(18) left subframe lower bolt
(19) subframe upper bolts
9. Slightly pull the subframe (20) backward and
disconnect the crankcase breather tube (21)
from the air cleaner connecting tube.
Remove the subframe.
Be careful not to damage the ECM and wires.
(20) subframe
(21) crankcase breather tube
(19)
(18)
(19)
(17)
Left side: Right side:
(20)
(21)
(1)
(1) crankcase breather tube
2. Position the ECM (2) in the bracket (3).
3. Align the shroud tabs (4) with the air cleaner
housing cover tabs (5).
4. Loosely attach the upper and lower end of the
subframe to the main frame while connecting
the air cleaner connecting tube (6) to the
throttle body (7).
5. Loosely install all subframe bolts.
Installation
1. Connect the crankcase breather tube (1).
(2) ECM (5) air cleaner housing cover tabs
(3) bracket (6) air cleaner connecting tube
(4) shroud tabs (7) throttle body
(4) (2)
(3)
(7) (6) (5)
6. Align the subframe with the rear wheel and
tighten the subframe upper bolts (8), left
subframe lower bolt (9) and right subframe
lower bolt (10) to the specified torque:
subframe upper bolts:
24 lbf·ft (33 N·m, 3.4 kgf·m)
left subframe lower bolt:
24 lbf·ft (33 N·m, 3.4 kgf·m)
right subframe lower bolt:
36 lbf·ft (49 N·m, 5.0 kgf·m)
(8) subframe upper bolts
(9) left subframe lower bolt
(10) right subframe lower bolt
(8)
(9)
(8)
(10)
Left side: Right side:
(cont’d)

Page: 42

Subframe
38 Servicing Your Honda
7. Make sure the air cleaner connecting tube
tab (11) aligns with the air cleaner connecting
tube clamp hole (12).
(11) air cleaner connecting tube tab
(12) air cleaner connecting tube clamp hole
8. Tighten the screw (13) on the air cleaner
connecting tube clamp to the specified torque:
0.5 lbf·ft (0.7 N·m, 0.1 kgf·m)
Check the distance between the band ends is
0.18 ± 0.06 in (4.5 ± 1.5 mm).
(11)
(12)
9. Hook the fuel tank band (14).
Install the ECM mounting rubber (15) to the
ECM bracket (16).
(14) fuel tank band
(15) ECM mounting rubber
(16) ECM bracket
(15)
(14)
(16)
(18) muffler clamp (20) exhaust pipe
(19) gasket (new)
13. Install the muffler (21).
14. Install the muffler clamp (18) by aligning the
tab (22) of the muffler clamp with the
cutout (23) of the muffler.
(20)
(19) (18)
(13) screw
(13)
0.18 ± 0.06 in
(4.5 ± 1.5 mm)
(17) IAT sensor connector
(17)
(18) muffler clamp (22) tab
(21) muffler (23) cutout
(23)
(21)
(22)
(18)
11. Remove the old gasket from exhaust pipe.
12. Install the muffler clamp (18) and a new
gasket (19) to the exhaust pipe (20).
10. Connect the IAT sensor connector (17).

Page: 43

Subframe
Servicing Your Honda 39
15. Install the washer A (24), washer B (25),
muffler mounting B bolt (26) and muffler
mounting A bolt (27).
(24) washer (A)
(25) washer (B)
(26) muffler mounting B bolt
(27) muffler mounting A bolt
16. Tighten the muffler clamp bolt (28) to the
specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
(27)
(26)
(24) (25)
17. Tighten the muffler mounting B bolt (26) and
muffler mounting A bolt (27) to the specified
torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
18. Install the seat (29).
19. Install the side covers (30), seat mounting
bolts (31) and bolts (32). Then tighten the seat
mounting bolts and side cover bolts to the
specified torque:
seat mounting bolts:
19 lbf·ft (26 N·m, 2.7 kgf·m)
side cover bolts:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(26) muffler mounting B bolt
(27) muffler mounting A bolt
(29) seat
(30) side covers
(31) seat mounting bolts
(32) bolts
(32)
(29)
(27)
(26)
(31)
(30)
(28) muffler clamp bolt
(28)

Page: 44

Refer to Safety Precautions on page 23.
Fuel
Use only unleaded fuel in your CRF. If you ride
your CRF in a country where leaded fuel might
be available, take precautions to use only
unleaded fuel.
Your engine is designed to use any unleaded
gasoline that has a pump octane number of 91 or
higher. Gasoline pumps at service stations
normally display the pump octane number.
For information on the use of oxygenated fuels,
see page 153.
Use of lower octane gasoline can cause persistent
“pinging” or “spark knock” (a louder rapping
noise) which, if severe, can lead to engine
damage. (Light pinging experienced while
operating under a heavy load, such as climbing a
hill, is no cause for concern.)
If pinging or spark knock occurs at a steady
engine speed under normal load, change brands
of gasoline. If pinging or spark knock persists,
consult your dealer.
Never use stale or contaminated gasoline. Avoid
getting dirt, dust or water in the fuel tank.
Type Unleaded
Pump Octane Number 91 (or higher)
40 Servicing Your Honda
Fuel System
Refueling Procedure
1. To open the fuel fill cap (1), pull the breather
tube (2) out of the steering stem nut (3). Turn
the fuel fill cap counterclockwise and remove
it.
(1) fuel fill cap (3) steering stem nut
(2) breather tube
2. Add fuel until the level reaches the bottom of
the filler neck.
Fuel Tank Capacity: 1.51 US gal (5.7R)
Be careful not to damage the fuel pump while
filling the fuel tank.
Avoid overfilling the tank. There should be no
fuel in the filler neck.
WARNING
Gasoline is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
(1) fuel quick connect fitting cover
(2) fuel line
(3)
(2)
(1)
(1)
(2)
3. Close the fuel fill cap and insert the breather
tube in the steering stem nut.
Fuel Line
1. Hang the fuel tank to the left side of the frame
(page 34).
2. Remove the fuel quick connect fitting cover
(1).
3. Check the fuel line (2) for cracks,
deterioration, damage or leakage. Replace the
fuel line, if necessary.
4. Install the fuel quick connect fitting cover.
5. Install the fuel tank (page 34).

Page: 45

Servicing Your Honda 41
Fuel System
Fuel Pressure Relieving
1. Hang the fuel tank to the left side of the frame
(page 34).
2. Disconnect the fuel pump connector (1).
(1) fuel quick connect fitting cover
(2) fuel pump
(3) fuel quick connect fitting
5. Remove the bolt (4), clamp and setting
rubber (5).
(1)
(2)
Injector side: Fuel Pump side:
(3)
(1)
Fuel Line Replacement
Disconnection
1. Relieve the fuel pressure (page 41).
2. Hang the fuel tank to the left side of the frame.
3. Remove the fuel quick connect fitting cover
(1) from the fuel pump (2).
4. Check the fuel quick connect fitting (3) for
dirt, and clean if necessary.
(1) fuel pump connector
3. Reposition the fuel tank and start the engine
and let it idle until the engine stalls.
(4) bolt (5) clamp and setting rubber
(5)
(4)
6. Pull and release the joint rubber (6) of the
injector side from the retainer (7).
(6) joint rubber (injector side only)
(7) retainer
7. Place a shop towel (8) over the fuel quick
connect fitting.
(6)
(7)
(8) shop towel
Injector side: Fuel Pump side:
(8)
(cont’d)

Page: 46

Fuel System
42 Servicing Your Honda
8. Hold the connector with one hand and squeeze
the retainer tabs (9) with the other hand to
remove them from the locking pawls (10).
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 the hose or other
parts.
• Do not use tools.
• If the connector does not move, keep the
retainer tabs pressed down, and alternately
pull and push the connector until it comes
off easily.
(9) retainer tabs
(10) locking pawls
WARNING
Gasoline is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
Injector side: Fuel Pump side:
(9) (9)
(10)
(10)
9. To prevent damage and keep foreign matter
out, cover the disconnected connectors (11)
and fuel joints (12) with plastic bags (13).
(11) disconnected connector
(12) fuel joint
(13) plastic bags
(13)
(12)
(11)
Connection
1. Insert a new retainer (1) into the connector (2)
by aligning its locking pawls (3) with the
connector grooves (4).
• Always replace the retainer of the quick
connect fitting when the fuel feed hose is
disconnected.
• If the joint rubber is damaged or cut, replace
it with a new one.
• Do not bend or twist the fuel feed hose.
• If any retainer needs replacing, use the same
manufacture’s retainer as the ones being
removed (The various manufacture’s feature
different retainer specification).
(1) retainer (new) (3) locking pawls
(2) connector (4) connector grooves
(2)
(4)
Align
(1)
(3)

Page: 47

Fuel System
Servicing Your Honda 43
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 end.
(5) joint rubber (injector side only)
(5)
3. Make sure the connection is secure and that
the pawls are firmly locked into place; check
visually and by pulling the connector.
4. Make sure the joint rubber (5) is in place
between the flange (6) and retainer tab (7).
(5) joint rubber (injector side only)
(6) flange
(7) retainer tab
5. Install the rubber (8), clamp (9) and bolt (10)
by aligning the clamp tab (11) with the groove
(12) of the stay.
(5)
(7)
(6)
6. Install the fuel quick connect fitting cover
(13) and set the rubber cover tab (14) to the
hole (15) of the fuel quick connect fitting
cover.
Be sure the rubber cover (16) is properly
installed between the fuel quick connect fitting
cover and fuel pump.
(13) fuel quick connect fitting cover
(14) rubber cover tab
(15) fuel quick connect fitting cover hole
(16) rubber cover
7. Increase the fuel pressure (page 44).
(13)
(15)
(14)
(16)
(8) rubber (11) clamp tab
(9) clamp (12) groove
(10) bolt
(10)
(11)
(12)
(9)
(8)

Page: 48

44 Servicing Your Honda
Fuel System
Fuel Pump Filter Replacement
Empty the fuel tank into an approved gasoline
container using a commercially available hand
siphon or an equivalent method.
Be careful not to damage the fuel pump while
draining the fuel in the fuel tank.
WARNING
Gasoline is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
Removal
1. Relieve the fuel pressure (page 41).
2. Disconnect the fuel line (page 41).
3. Remove the fuel pump mounting bolts (1),
stopper cable guide (2), stopper cable (3),
washers (4), collars (5), conical spring
washers (6) and fuel pump plate (7) while
holding the fuel tank.
4. Remove the fuel tank.
Be careful not to drop the fuel tank when remove
the stopper cable.
(1) fuel pump mounting bolts
(2) stopper cable guide
(3) stopper cable
(4) washers
(5) collars
(6) conical spring washers
(7) fuel pump plate
5. Remove the fuel pump unit (8) and O-rings
(9).
Be careful not to damage the fuel pump unit.
(8) fuel pump unit (9) O-rings
6. Disconnect the fuel pump wire terminals (10)
from the fuel pump base (11).
Be careful not to damage the wires when
disconnect the fuel pump wire terminals.
(10) fuel pump wire terminals
(11) fuel pump base
(7)
(6)
(5)
(4)
(1)
(3)
(2)
(8)
(9)
(11)
(10)

Page: 49

Servicing Your Honda 45
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) on the fuel pump
base tabs while pushing the holder against the
base and slightly spreading the base tabs.
Be careful not to damage the hooks and tabs.
9. Remove the fuel pump unit holder assembly
(15) from the fuel pump base (16) and remove
the O-ring (17).
Wipe the spilled out fuel immediately.
(15) fuel pump unit holder assembly
(16) fuel pump base
(17) O-ring
10. Remove the fuel pump stopper (18) and
damper rubber (19).
(12) hooks (14) grooves
(13) tabs
(18) fuel pump stopper
(19) damper rubber
11. Remove the fuel pump assembly (20) with
fuel pump filter (21), O-ring (22) from the
fuel pump unit holder (23).
(20) fuel pump assembly
(21) fuel pump filter
(22) O-ring
(23) fuel pump unit holder
12. Check the fuel pump filter (21) for clog,
damage or deterioration and replace if
necessary.
13. Remove the fuel pump filter from the fuel
pump assembly (20).
(20) fuel pump assembly (21) fuel pump filter
(12)
(13)
(14)
(13) (14)
(15)
(17)
(16)
(18)
(19)
(23)
(22)
(20) (21)
(20)
(21)

Page: 50

46 Servicing Your Honda
Fuel System
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.
(1) new fuel pump filter (3) hook
(2) fuel pump assembly (4) joint boss
2. Apply small amount of silicone grease to a
new O-ring (5).
Install a new O-ring to the fuel pump
assembly (6).
3. Install the fuel pump assembly with fuel pump
filter into the fuel pump unit holder (7) while
routing the fuel pump red (8) and black (9)
wires through the holder grooves (10) as
shown.
(5) new O-ring (8) red wire
(6) fuel pump assembly (9) black wire
(7) fuel pump unit holder (10) grooves
4. Install a new damper rubber (11) to the fuel
pump filter as shown.
Install fuel pump stopper (12).
(11) new damper rubber (12) fuel pump stopper
5. Apply small amount of silicone grease to a
new O-ring (13).
Install a new O-ring to the fuel pump base
(14).
6. Install the fuel pump unit holder assembly
(15) into the fuel pump base while aligning its
hooks (16) with the grooves (17) in the fuel
pump base tabs (18).
If the gap between the hooks and tabs is more
than 0.04 in (1.0 mm), replace the fuel pump
unit.
Be sure that the hooks are completely seated.
(13) new O-ring
(14) fuel pump base
(15) fuel pump unit holder assembly
(16) hooks
(17) grooves
(18) tabs
(2)
(3)
(4)
(1)
(10)
(10)
(7) (9)
(9)
(8)
(8)
(10)
(10)
(5) (6)
(11)
(12)
(13)
(14)
(17) (18) (17) (18)
(15)
(16)