The motorcycle presents you a challenge to master the machine, a challenge to adventure. You ride through the wind, linked to the road by a vehicle that responds to your commands as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a pre-ride inspection and regular maintenance are essential to your safety. Your reward is freedom. To meet the challenges safely, and to enjoy the adventure fully, you should become thoroughly familiar with this owner s manual BEFORE YOU RIDE THE MOTORCYCLE. ~ When service is required, remember that your Honda dealer knows your motorcycle best. As a result, the hands seen in the photographs are those of the author. Even the machines are not new: examples that have covered a consider- able mileage were selected so that the conditions encountered would be typical of those found by the average owner. Unless specially mentioned, and therefore considered essential, Honda service tools have not been used. There is invariably some alternative means of slackening or removing some vital component when service tools are not available and isk of damage has to be avoided at all costs. Each of the six Chapters is divided into numbered Sections. Within the Sections are numbered paragraphs. In consequence, cross reference throughout this manual is both straightforward and logical. Figure numbers usually line illustrations appear in numerical order, within a given Chapter. Left-hand and right-hand descriptions of the machines and their component parts refer to the right and left of a given machine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified,mare incorporated into our manuals at the earliest opportunity. We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular n motorcycle of which they do not inform us. Please Note -All prices quoted are correct at time of printing and are subject to change without prior notice. Before riding, take time to get acquainted with your motorcycle and how it works. To protect your investment, we urge you to take responsibility for keeping yourmotorcycle well maintained. Scheduled service is a must, of course. To make it easy to use, the manual contains a detailed list of topics at the beginning of each section, and both an in-depth table of contents 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 Honda, other property, or the environment. Attach the taillight using the top mounting screws, then pull the license plate holder down toward the bottom of the fender so that the taillight is pulled as horizontal as possible. When installing the bottom license plate mount bolt, make sure to install the 6 x 16 mm bolt from the bottom up to minimize the opportunity for the tire to grab it. Run the taillight wires along the left frame rail using the stock wire clamps to support it. You can achieve a clean, durable installation using this mounting location. T he respective headings can be entered in the list of contents. Shift the transmission into neutral. Turn the fuel valve OFF. Lightly open the throttle 1 2 — 3 times, and then close it. Depress and hold the engine stop button 2 until the engine stops completely. Failure to close the fuel valve may cause the carburetor to overflow, result in hard starting. Emergency Engine Stop To stop the engine in an emergency, press the engine stop button. During this period, avoid full-throttle starts and rapid acceleration. 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. An ICM Ignition Control Module 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 156. Always make a pre-ride inspection before you start the engine. You may prevent an accident or equipment damage. Most countries require a special riding test or license. Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider. Your size and manoeuvrability can surprise other motorists. Use extra caution at intersections, parking entrances and exits and driveways. A passenger should hold onto the motorcycle or the rider with both hands, and keep both feet on the passenger footrests. PROTECTIVE APPAREL 1 Most motorcycle accidents fatalities are due to head impact. ALWAYS wear a helmet. You should also wear a face shield or goggles; boots, gloves, and protective clothing. A passenger needs the same protection. The exhaust system becomes very hot during operation, and it remains hot after operation. Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs. Rear Wheel Removal i02495 1. Axle adjuster keep 3. Axle nut keep 4. Spacer 3 keep 6. Torx screw 5 replace 7. Brake disc keep 8. Wheel assembly replace 9. Valve cap keep 10. Compensator bowl keep 11. Compensator cushion keep 12. Lockwasher 5 keep 14. Sprocket assembly keep 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. Position motorcycle on a suitable lift. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative - battery cable before proceeding. Disconnect battery cables, negative - battery cable first. Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1. Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw 1093. This screw is included in the Crankcase Boring Tool Kit 94419-06 and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw 1093 between the cylinders and tighten to 50-90 in-lbs 5. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown.