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Page 29 If replacement is necessary, both seals offers added assurance and security. Remove the nuts, clean should be replaced. 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 31 If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. Page Seat Removal 2. Remove the seat 2 by sliding it backward. Page 35 5. Hook the air cleaner case cover 5. Install and hook the fuel tank band 6. Page Subframe Removal 14 by pulling it straight backward. Page 37 7. Install the muffler clamp 9 and new gasket specified torque: 10 to the exhaust pipe.
Page Fuel System 2 fuel filter of gasoline. Check the fuel valve 1 and fuel filter 2 for Gasoline is highly flammable and contamination. Page 39 Install the fuel filter in the fuel tank. Refill the fuel tank. Attach the fuel valve and fuel line, and turn the fuel valve to ON; check for leaks.
Page Engine Oil weight the engine. Page 41 Repeat steps 1—4. Reinsert the engine oil filler cap. However, if you replace only the oil before 7.
Check for oil leaks. Page 42 11 facing out, away from the engine. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. Page 44 1 transmission oil filler cap steps 1—4.
After inspecting the oil level or adding oil, 3 sealing washer tighten the oil check bolt to the specified torque:. Add coolant up to the filler neck if the level is low. Inspect the coolant level before each outing. Page 46 Refer to Safety Precautions on page Honda Service Manual for troubleshooting of leaks. Coolant should be replaced by your Honda 2. Check the water hoses 1 for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.
Page Air Cleaner Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions. Page 48 Air Cleaner 5. Remove the air cleaner 3 from the air 9.
Grease to the sealing surface. Assemble the air cleaner and holder. Improper installation of the air cleaner assembly Page Crankcase Breather Service the breather if you can see deposits in the transparent section of the drain tube. Draining 1. Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits. Reinstall the crankcase breather tube plug. Page Throttle 5. Operate the throttle grip to ensure that it functions smoothly and returns completely.
Install the fuel tank page Page 51 If the cable is kinked or chafed, have it replaced. Check the cables for tension or stress in all steering positions. Lubricate the cables with a commercially-available cable lubricant to prevent premature rust and corrosion. Page Engine Idle Speed 3. Connect a tachometer to the engine.
Start the engine. Keep the motorcycle in an upright position. Adjust idle speed with the throttle stop screw 2. Page Clutch System To position the brake lever closer to the handgrip, turn the adjuster clockwise.
Tighten the lock nut. Adjust the cable end adjuster for minor adjustement. See your Honda dealer or refer to the Honda Service Manual page Page 55 4. Remove the six clutch spring bolts and springs 5. Install the clutch pressure plate 7. If the gap is out of specification, replace the spark plug with a new one. Page Valve Clearance 4. Remove the cylinder head cover A bolt 3 , cylinder head cover B bolts 4 and cylinder head cover 5. Page 60 If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Holder Assembly Removal page 57 and select the correct shim for each valve.
Page 62 4 cam sprocket bolts 5 cam sprocket 6 cam chain 10 8 camshaft holder assembly 7 camshaft holder assembly bolts 9 intake valve lifters 8 camshaft holder assembly 10 shims 6. Remove the valve shims. Then realign the valve timing.
Page 67 19 decompressor arm adjusting screw 20 right side rocker arm 1 feeler gauge 4 lock nut 5 decompressor arm adjusting screw 6 right side rocker arm Recheck the clearance between the adjusting screw and right side rocker arm.
Page 68 2 spark plug hole 1 O-ring 2 crankshaft hole cap 2. Install the cylinder head cover packing 3 into the groove of the cylinder head cover 4. Remove the cylinder head cover page Remove the spark plug 8. Page 72 2. Remove the A dowel pins 3 , B dowel pin 4 and cylinder gasket 5. Page 73 1. Remove the carbon deposits from the piston oil ring We recommend you consult the Service Manual head and piston ring grooves with the or your authorized Honda dealer for correct removed ring.
Service Limit measurements. Apply engine oil to the piston rings and install the piston rings. Page 74 1 cylinder gasket 3 B dowel pin 2 A dowel pins 4.
Clean the any gasket material off the cylinder. Page 75 Do not damage the piston rings and cylinder walls. Page 77 17 ignition coil bolts 18 ignition coil nut page Install the fuel tank and the seat page Add the coolant up to the filler neck page Page Suspension See page for damper locking the front brake and pushing down on fork oil replacement.
Page Rear Suspension Inspection page Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Remove the subframe page Page Recommended Fork Oil weight 5 W when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when equivalent removing the fork damper.
Page 81 Minimum oil Page 82 Temporarily install the fork damper 2 to the outer tube 1. Page Brakes 1 lock nut 3 piston 82 , there is probably air in the brake system. Loosen the lock nut 1. Page 84 Worn brake pads should be replaced. If the pads 20 mm , there is probably air in the brake are not worn, have your brake system inspected system and it must be bled.
Refer to the Honda for leaks. Service Manual or see your Honda motorcycle If the front brake lever freeplay exceeds 0. Page 86 Make sure there are no fluid leaks. Check for grooves deterioration or cracks in the hoses and fittings. Page Wheels Excessively loose spokes may result in 3. Check wheel rim runout. If runout is instability at high speeds and the possible loss of noticeable, see the Honda Service Manual for control. If necessary, install a new cap. The old tube will probably be stretched and, if installed in a new tire, could fail.
Page Drive Chain Adjust chain slack if needed. Check the chain slider 4 for wear. If the wear is 0. Page 91 Pro Align the index marks 4 of the axle plates otherwise appears unserviceable.
Honda Chain Lube or an equivalent, or SAE 80 5 with the same reference marks 6 on both or 90 gear oil is recommended. Page 92 Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation.
Recheck chain slack and adjust as necessary. Remove the seat bolt 1 , side cover bolt 2 and right side cover 3. Page 94 9 muffler A bolt 3. Install the muffler 4. Install the muffler clamp 5 by aligning the tab 6 of the muffler clamp with the cut-out 7 of the muffler.
Install the muffler page Page Additional Maintenance Procedures Refer to the Periodically, disconnect the throttle, clutch and Honda Service Manual for replacement or hot start cables at their upper ends.
Thoroughly adjustment procedures, or see your Honda lubricate the cable pivot points with a dealer. Page 97 6 oil filter cover bolts 7 cylinder bolt 8 cylinder head bolts 1 cylinder head cover bolts 2 clutch cover bolts 3 water pump cover bolts 4 transmission oil check bolt 5 crankshaft hole cap 9 exhaust pipe joint nuts Servicing Your Honda Page 99 maroon is for removing stains on the non-coated aluminum frame only.
Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Page Servicing Your Honda Front Suspension Air Pressure Page Fork Springs See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service.
Remove the handlebar holder nuts 3 , 7. Remove the disc cover 7 by removing the Do not support the brake caliper by the brake washers, mounting rubbers and handlebar 4. Do not operate the brake lever after the front wheel is removed. Page Front Suspension Adjustments Clean the fork assembly, especially the sliding Record the rebound damping adjuster position The outer tube can drop on the slider and Set the lower end axle holder 27 of the and turn the adjuster counterclockwise until it slider in a vise with a piece of wood or soft Apply pressure to the fork damper and insert a Damper Oil Change 27 special tool or mechanic's stopper tool 29 see below between the axle holder 27 and 29 lock nut Set the fork damper 1 in a vise with a piece Hold the lock nut and remove the fork center of wood or soft jaws to avoid damage.
Page Recommended Oil: Be careful not to damage the fork cap bushing. Oil Level: 1. Recommended Amount: Replace the fork cap as an assembly if it is 6. Tighten the fork cap 1 while holding the cut Screw in the lock nut 9 to the fork damper Page Subframe 5. Disconnect the crankcase breather tube. Loosen the screw on the air cleaner connecting tube 1. Loosely attach the upper and lower ends of the Subframe Removal clamp.
Remove the seat page Page 22 4. Install the muffler. Install the side covers, side cover bolts and collars. Tighten the screw on the air cleaner connecting tube 7. Install the muffler clamp by aligning the tab of the clamp. Remove the left engine guard bolt and left engine guard. Inspecting and Adding Engine Oil 2. Support the CRF in an upright position on a level 1. Page 24 0. Install the engine oil filler cap.
Run the engine for three minutes, then shut if off. Support the CRF in an upright position on a level without molybdenum additives 4-stroke oil, or an 1. A ity ethylene glycol based anti-freeze containing corro- coolant loss of 0.
Remove the fuel tank page Disconnect the spark plug cap. Standard: 3. Remove the spark plug. Page Ignition If you want to check the igni- Coast to a stop, then remove and inspect the spark the same number of turns. The porcelain insulator around the center elec- trode should appear tan or medium gray. Page Crankcase Breather 8. Allow the air cleaner to dry thoroughly. After dry- ing, soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil.
Apply air cleaner oil to the entire surface, inner and outer, and rub it with both hands to saturate the air cleaner with oil. Page Clutch 4. NOTE: Operation The clutch springs have sky blue paint. Coat the clutch plates with transmission oil. Install the six clutch springs and bolts.
Install the six clutch discs which has yellow paint on Tighten the bolts in a crisscross pattern in 2 or 3 steps. Page Valve 4. Cylinder Head Cover Removal Remove the crankshaft hole cap. Lubricate the rear brake pedal pivot and pivot bolt and NOTE: tighten the pivot bolt.
Page 34 4. Page 35 Remove the cam sprocket bolt. Remove the camshaft holder assembly bolts, camshaft Rotate the primary drive gear lock bolt crankshaft holder assembly, intake valve lifters and shims.
Then attach a piece of wire to the As you remove the camshaft holder assembly, the in- cam chain to prevent it from falling into the crankcase. Page 36 4. Install the newly selected shims on the valve retainers.
Page 37 Install the cam shaft holder assembly onto the cylinder Insert the feeler gauge between the intake valve lifter Place the cam sprocket and align the timing mark on head with the intake cam lobes facing up as illustrated and cam lobe. Page 38 4. Page 39 Measure the intake valve clearance and exhaust valve Measure the decompressor arm clearance by inserting Decompressor Arm Clearance Adjustment clearance. Page 40 4. Spark Plug Installation Cylinder Head Cover Installation Insert the feeler gauge right exhaust valve clearance Install the spark plug by hand until finger tight, then Remove the spark plug hole packing from the cylinder 0.
Page 42 4. Remove the engine hanger nut, engine hanger A bolt, sion stroke page Loosen the cylinder bolt. Remove the cam shaft holder assembly page Page 43 Remove the dowel pins, cylinder head gasket and cam Piston Removal Cylinder Removal chain guide.
Place clean shop towels in the crankcase to keep the Remove the cylinder bolt and cylinder. Page 44 Apply engine oil to the piston rings and install the pis- We recommended you consult the Service Manual or ton rings.
Page 45 Piston Installation Cylinder Installation Clean off any gasket material from the gasket surface Place clean shop towels in the crankcase to keep the of the crankcase, being careful not to let any material piston pin clips from falling into the crankcase.
Page Cylinder Head Installation 4. Install the dowel pins and new cylinder head gasket. Route the cam chain though the cylinder. Page 47 Route the cam chain through the cylinder head. Install the cylinder bolt and cylinder head bolts to the Install the cylinder head.
Page 48 4. Install a new exhaust pipe gasket, exhaust pipe and tighten the radiator hose clamp securely. Install the cylinder head cover page Page Fuel Line 4. Reassemble the fuel filter in the reverse order of re- moval.
Make sure the O-ring is in place. Check the fuel valve and fuel filter for contamina- The fuel filter is mounted on the bottom of the fuel tank. Install the fuel filter in the fuel tank.
Check the axle for runout. Page Rear Suspension Do not attempt to disassemble, disconnect or replacement. Page Brakes Rein- is probably air in the brake system and it must be bled. Refer to the Honda Service Manual or see your autho- Tighten the screws. Page Drive Chain 4. If either pad is worn anywhere per to determine the pad wear.
Page 55 Adjustment Removal, Cleaning and Inspection 1. Loosen the rear axle nut. For maximum service life, the drive chain should be 2. Loosen the lock nuts and turn the adjusting bolt cleaned, lubricated, and adjusted before each outing. Page Drive Chain Sliders Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil. Loosen the muffler clamp bolt. Check the flange bolts for tightness.
Page 58 4. Tighten the muffler B bolt and muffler A bolt. Remove the muffler page Remove the gasket. Install a new exhaust pipe gasket, exhaust pipe and Lubrication exhaust pipe joint nuts and tighten to the specified Periodically, disconnect the throttle, clutch and hot start torque. Page Nuts, Bolts, Fasterers 4. Apply Honda Thread Lock or an equivalent to the threads.
Apply oil to the threads and flange surface. UBS nut. Page 62 Rear brake reservoir cap bolts 0. SH bolt. Page Carburetor Adjustment 5. When the hot start lever is is opened. Page 64 5. Fuel is metered by the main jet, jet needle and needle Fuel is metered by the slow jet and mixed with air from 2.
Drain the remaining fuel in the float bowl by remov- jet. Page 65 4. Disconnect the fuel line. Remove the hot start cable holder. Remove the throttle drum cover bolt and throttle 5. Remove the sub frame page Loosen the intake band screw. Page 66 5. Remove the carburetor top bolts and carburetor top.
Remove the link arm set screw. Page 67 Remove the accelerator pump cover screws and ac- Remove the holder screw, throttle stop screw holder, Measure the float level with the float tab just con- celerator pump cover. Page 68 5. Pre-adjustment Checks To install the carburetor, reverse the removal proce- Before adjusting carburetor settings, check the follow- dures. Page 69 Adjustment Procedure 7. Change the main jet and slow jet as required.
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