Honda CRF80F CRF100F (2004-2013) Service Manual

A Few Words About Safety
Service Information
The service and repair informallon contained in this manual is intended tor use by qualified, professional techruc1ans
Attempting service or repairs without the proper training tools, and equipment could cause injury to you or others It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require lhe use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda must determine the nsl<s to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct pan number or an equivalent part. We strongly recommend
that you do not use repiacement parts of inferior quality.
For Your Customer's Safety

Proper service and maintenance are essential to the customer's safety and
AWARNING
the reliability of the vehicle Any error or oversight while servicing a vehicle Improper service or repairs can create an
can result in faulty operation damage to the vehicle or injury to others. unsafe condition that can cause your customer
or others to be seriously hurt or killed
For Your Safety
Follow 1he procedures and precautions in this
Because this manual is intended for tne professional service lechnioan, we manual and other service materials carefully.
do not provide warnings about many basic shop safety practices (e.g., Hot
parts-wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of sate servicing practice, we AWARNING
recommended that you do not attempt to perform the procedures described
Failure to properly follow instructions and
In this manual.
precautions can cause you to be seriously hurl
Some of the most important general service safety precautions are given or killed.
below. However, we cannot warn you of every conceivable hazard tnat can Follow the procedures and precautions 1n this
a rise In performing service and repair procedures. Only you can decide manual carefully.
whe1her or not you should perform a given task.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safely equipment. When performing any service task, be especially careful of the following:
• Read all of the tnstructions before you begin, and make sure you have the tools, the replacement or repair parts. and the skllls
required to perform the tasks safely and completely
• Protect your eyes by using proper safety glasses goggles or face shields any time you hammer, drill, grind, pry or work around
pressunzed air or liquids, and springs or other stored-energy components. II there 1s any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you 11ft the vehicle, either w1ll1 a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures. unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• lnJury from moving parts. If the instruction tells you to run the engine, be sure your hands. fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion be careful when
working around gasollne or batteries. •
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
HOW TO USE THIS MANUAL CONTENTS
This service manual describes the service procedures for the CRFSOF
and CRF100F.
Follow the Maintenance Schedule (Section 3) recommendations to

GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST
••
•
ensure that the vehicle 1s 1n peak operating condition and the em1ss1on
levels are wrthm the standard set by the U.S Environmental Protection SYSTEM
Agency (EPA) and Calilorma Air Resources Board (CARB) .
MAINTENANCE
Performing the first scheduled maintenance Is very important. It
compensates for the 1mtial wear that occurs during ltle break-in period.
LUBRICATION SYSTEM
Sections I and 3 apply 10 the whole motorcycle. Secnon 2 Illustrates
procedures for removal/installation of components that may be required
z FUEL SYSTEM
to perform service described In lhe following sections.
Section 4 through 14 describe parts of the motorcycle. grouped
according to location
<
a:
I- ENGINE REMOVAUINSTALLATION
Find the section you want on this page, then turn to the table of contents
w
>
on lhe first page of the section
a:0 CYLINDER HEAD/VALVES
Most sections start with an assembly or system illustration, service
information and troublesnooting for the section. The subsequent pages 0 CYLINDER/PISTON
give detailed procedures z
~
ii you don't know the source of the !rouble. go to Section 16 w CLUTCH/GEARSHIFT LINKAGE
Troubleshooting. ~
Cl
z ALTERNATOR
Your safety, and the safety of others, rs very lmportanl. To help you
w
make informed decisions we have provided safety messages and
other Information throughout this manual. Of course. it is not
CRANKSHAFT/TRANSMISSION/ KICKSTARTER
practical or possible lo warn you about all the hazards associated
with servicing this vehicle. U)
en FRONT WHEEUBRAKE/SUSPENSION/STEERING
You must use your own good Judgement.
U)
You will find important safety information in a variety of forms
<
:c
including
(,)
REAR WH EEUBRAKE/SUSPENSION
• Safety Labels - on the vehicle
• Safety Messages - preceded by a safety alert symbol j and _,
...: ELECTRICAL SYSTEM
one of three signal words, DANGER , WARNING . or CAUTION. <.>
These signal words mean. cc
I-
You WILL be KILLED or SERIOUSLY <.>
UJ
WIRING DIAGRAM
(t]•Wm:Jiil HURT if you don't follow instructions.
....J
UJ
You CAN be KILLED or SERIOUSLY HURT TROUBLESHOOTING

[1)WiJi1£11flfl if you don't follow instructions.
You CAN be HURT if you don't follow INDEX

(!J:f;}'lfl•l£1 instructions
• Instructions - how to service lhis vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a
~ symbol. The purpose of this message 1s to help prevent
damage to your vehicle, other property, or the environment.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
,,
these symbols, it will be explained specifically in the text without the use of the symbols.
,-
Replace the part(s) with new one(s) before assembly.
~ Use recommended engine oil, unless otherwise specified.
~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1) .
.....uimfl Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent).
--
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
~ Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent) .
Example: Molykote® G-n Paste manufactured by Dow Coming U.S.A.
~ Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
~ Use silicone grease.
c:a Apply a locking agent. Use a middle strength locking agent unless otherwise specified .
•tum Apply sealant.
I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
.. Use Fork or Suspension Fluid.

1. GENERAL INFORMATION
II
SERVICE RULES ......................................... 1.2 CRANKSHAFT/ TRANSMISSION/

KICKSTARTER SPECIFICATIONS
MODEL IDENTIFICATION ........................... 1.2 (CRF100F) .................................................. 1-10
GENERAL SPECIFICATIONs ...................... 1.5 CRANKSHAFT/ TRANSMISSION/

KICKSTARTER SPECIFICATIONS
(CRFSOF) ·· .................................................. 1-11
LUBRICATION SYSTEM
SPECIFICATIONS ········································ 1-7
FRONT WHEEL/BRAKE/ SUSPENSION/
STEERING SPECIFICATIONS .................. 1.11
FUEL SYSTEM SPECIFICATIONS
(CRF100F) .................................................... 1.7
REAR WHEEL/ BRAKE/ SUSPENSION
SPECIFICATIONS ..................................... 1-12
FUEL SYSTEM SPECIFICATIONS
{CRFSOF) ...................................................... 1.1
ELECTRICAL SYSTEM
SPECIFICATIONS ,.................................... 1-12
CYLINDER HEAD/ VALVES
SPECIFICATIONS · ............. ····· ...·········· ........ 1-8
STANDARD TORQUE VALUEs ............... 1-13
CYLINDER/ PISTON SPECIFICATIONS

(CRF100F) ...... ..... ......................................... 1.9 ENGINE & FRAME TORQUE VALUES·"· 1-13
LUBRICATION & SEAL POINTS .............. 1-15

CYLINDER/PISTON SPECIFICATIONS
{CRFSOF) ...................................................... 1. 9
CABLE & HARNESS ROUTING ............... 1-17
CLUTCH/ GEARSHIFT LINKAGE
SPECIFICATIONS ··· ................................... 1.10 EMISSION CONTROL SYSTEMS ............ 1-21
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don 't meet Honda's
design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fasteners.
4. Install new gaskets, 0 -rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified .
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-17).
MODEL IDENTIFICATION
1-2
GENERAL INFORMATION
The Vehicle Identification Number is stamped on the left side of the
steering head.
The engine serial number is stamped on the lower left side of the lower
crankcase.
The Model Identification Label (U.S.A.) or Safety Certification Label

(Canada) is located on right side of the steering head.
The carburetor identification number is stamped on the right side of

the carburetor body as shown.
1-3
GENERAL INFORMATION
The Emission Control Information Label is attached as shown.
'04- '07
~ EMISSION CONTROL
<. lt:;IFORMATION LABEL
After '07
U.S.A. TYPE CM TYPE
~-
MISSION CONTROL
INFORMATION LABEL
The color label is attached as shown. When ordering color-coded parts,

always specify the designated color code.
1-4
GENERAL INFORMATION
GENERAL SPECIFICATIONS
CRFSOF
ITEM SPECIFICATION
DIMENSIONS Overall length 1,749 mm (68.9 in )
Overall width I 727 mm (28.6 in)
Overall height 995 mm (39.2 in)
Wheelbase 1,209 mm (47.6 in)
Seat height 734 mm (28.9 in)
Footpeg height 271 mm (10.7 in)
Ground clearance 218 mm (8.6 in)
Curb weight 75 kg (165 lbs)
FRAME Frame type Back bone
Front suspension Telescopic fork
Front wheel travel 123 mm (5.02 in)
Rear suspension Swingarm
Rear wheel travel 110.0 mm (4.33 in)
Rear damper Conventional type oi l damper
Front tire size 2.50-16 4PR
Rear tire size 3.60-14 4PR
Tire brand IRC
Front brake Internal expanding shoe
Rear brake Internal expanding shoe I
Caster angle 28°02'
Trai l length 74 mm (2.9 in)
Fuel tank capacity ('04- '07) 5.5 liter (1.45 US gal, 1.21 Imp gal )
(After '07) 5.0 liter (1.32 US gal, 1. 10 Imp gal)
Fuel tank reserve capacity ('04- '07) 1. 1 liter (0.29 US gal, 0.24 Imp gal )
(After '07) 0.7 liter (0.18 US gal, 0.15 Imp gal}
ENGINE Bore and stroke 47.5 x 45.0 mm (1.87 x 1.77 in)
Displacement 79.7 cm 3 (4.86 cu-in)
Compression ratio 9.7: 1
Va lve train Chain drive and OHC with rocker arm
Intake valve opens at 1 mm (0.04 in ) lift 8° BTDC
closes at 1 mm (0.04 in) lift 40° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 40° BBDC
closes at 1 mm (0.04 in) lift 8° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Oiled polyurethane foam
Crankshaft type Assembled type
Engine dry weight 18.9 kg (41.7 lbs)
Cylinder arrangement Single cylinder inclined 15° from vertical
CARBURETOR Carburetor type Piston valve type
Throttle bore 18 mm (0.71 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Mechanical type
Transmission 5 speeds
Primary reduction 4.437 (71 /16)
Final reduction 3.285 (46/14)
Gear ratio 1st 2.692 (35/13)
2nd 1.823 (31/ 17)
3rd 1.400 (28/20)
4th 1.130 (26/23)
5th 0.960 (24/25)
Gearshift pattern Left foot operated return system,
1 - N-2-3 - 4 - 5
ELECTRICAL Ignition system Capacitive Discharged Ignition
r Starting system Kickstarter
1-5
GENERAL INFORMATION
CRF100F
ITEM SPECIFICATION
DIMENSIONS Overall length 1,853 mm (73Ji in)
Overall width 786 mm (30.9 in)
Overall height 1,046 mm (4. 12 in)
Wheelbase 1,249 mm (49.2 in)
Seat height 786 mm (30.9 in)
Footpeg height 319 mm (12.6 in)
Ground clearance 252 mm (9.9 in)
Curb weight ('04- '07) 79 kg (174 lbs)
(After '07) 77 kg (170 lbs)
FRAME Frame type Back bone
Front suspension Telescopic fork
Front wheel travel 132 mm (5.2 in)
Rear suspension Swingarm
Rear wheel travel 148.0 mm (5.83 in)
Rear damper Conventional type oil damper
Front t ire size 70/100-19 M/C 42M
Rear tire size 90/ 100-16 M/C 51M
Tire brand Cheng shin
Front brake Internal expanding shoe
Rear brake Internal expanding shoe
Caster angle 28°50'
Trail length 99 mm (3.9 in)
Fuel tank capacity ('04- '07) 5.5 liter (1.45 US gal, 1.21 Imp ga l)
(After '07) 5.0 liter (1.32 US gal, 1.10 Imp gal)
Fuel tank reserve capacity ('04 - '07) 1.1 liter (0.29 US gal, 0.24 Imp gal)
(After '07) 0.7 liter (0.18 US gal, 0.15 Imp gal)
ENGINE Bore and stroke 53.0 x 45.0 mm (2.09 x 1.77 in)
Displacement 99.2 cm 3 (6. 1 cu-in)
Compression ratio 9.4 : 1
Valve train Silent, multi-link chain drive and OHC with
rocker arm
Intake valve opens at 1 mm (0.04 in) lift 10° BTDC
closes at 1 mm (0.04 in) lift 35° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 40° BBDC
closes at 1 mm (0.04 in) lift 5° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
, ra f10n
A1r flt 0·1
1ed po Iyuret h ane f oam
Crankshaft type Assembled type
Engine dry weight 21.4 kg (47.18 lbs)
Cylinder arrangement Single cylinder inclined 15° from vertical
- CARBURETOR Carburetor type Piston valve type I
Throttle bore 20 mm (0.8 in) I
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Mechanical type
Transmission 5 speeds
Primary reduction 4.437 (7 1/16)
Fina l reduction 3.571 (50/14)
Gear ratio 1st 3.083 (37 /12)
2nd 1.882 (32/17)
3rd 1.400 (28/20)
4th 1.130 (26/23)
5th 0.923 (24/26)
Gearshift pattern Left foot operated return system,
1-N - 2-3-4-5
ELECTRICAL Ignition system Condenser Discharged Ignition
I Starting system Kickstarter
1-6
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in )
ITEM STANDARD SERV ICE LIMIT
Engine oi l CRF100F At draining l0.9 liter (1.0 US qt, 0.8 Imp qt) - -
capacity At disassemb ly 11.1 liter (1.2 US qt, 1.0 Imp qt) -
CRF80F L_J\t draining 0.9 liter (1.0 US qt, 0.8 Imp qt) -
I -At disa ssemb ly 1.1 liter (1 .2 US qt, 1.0 Imp qt) -
I
Recommended engine oi l Pro Honda GN4 4-stroke oil (U.S.A and
Canada) or equivalent motor oil
API service classification: SG or higher -
JASO T 903 standard : MA
Viscosity: SAE 10W-30
Oil pump Tip clearance 0. 15 (0.006) 0.20 (0.008}
rotor Body clearance _ '- 0.15 - 0.21 (0.006 - 0.008) 0.40 (0.016)-
Side clearance 0.02 - 0.07 (0.001 - 0.003) 0.25 (0.010)
FUEL SYSTEM SPECIFICATIONS (CRF100F)

SPECIFICATIONs
-
ITEM
- Carburetor identification number ('04 and '05) I PDC3L
Carburetor identification number ('06 and '07) PDCBF
Carburetor identification number (After '07) PDCBL_
-- -
t Carburetor type Piston valve
Main jet #98
Main jet (High altitude setting) #92
Slow jet #35 X #35
__________
Jet needle clip position ('04 and '05)
..;;._ 3rd groove from t op
Pilot screw opening See page 5-18
Float level 12.5 mm (0.49 in )
-
Engine id le speed _ _ _ _ _ _1..:.,4_0_0 ± 100 rpm ~
Throttle grip free play _ _ _ _ _2_-_ 6 _m_m 4 _m....:.)_ _ _ _ _ _ ~

_ (1 /12 - 1_/_
FUEL SYSTEM SPECIFICATIONS (CRF80F)

ITEM -
SPECIFICATIONS
I
Carburetor identificatio n number ('04 and '05) PC20M
Carburetor identificatio n number ('06 and '07) PC20P '
Carburetor identificatio n number (After '07) PC200 I
Carburetor type Piston valve I
M ain jet #95
#90
..
M ain jet (High altitudesetting)
Slow jet #35
Jet needle clip position ('04 and '05) 3rd groove from top
A ir screw opening" - - - See page 5- 19
Float level 21.5 mm (0.85 in)
Engine idle _s,__
pe_e_d_ __ _ __ 1,500 ± 100 rpm
Throttle grip fre_e~p_la~y_ _ _ _ _ __ - -- -- -=---- ___ __2_-_6_ m_m_ (1/ 12 - 1/4 in)
1-7
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
Cylinder CRF100F 1,176 kPa (12.0 kgf/cm 2 , 171 psi)
compression at 1,000 rpm -
CRF80F 1,176 kPa (12.0 kgf/cm 2 , 171 psi)
at 1,000 rpm
-
Cylinder head warpage - 0.10 (0.004)
Valve and Valve clearance IN 0.05(0.002) -
valve guide EX 0.05(0.002) -
Valve stem 0.0. IN 5.450 - 5.465 (0.2145 - 0.2151) 5.420 (0.2134)
EX 5.430 -5.445 (0.2137 - 0.2143) 5.400 (0.2126)
Valve guide I.D. IN 5.475 - 5.485 (0.2155 - 0.2159) 5.50 (0.217)
EX 5.475 - 5.485 (0.2155 - 0.2159) 5.50 (0.217)
Stem to guide IN 0.010 - 0.035 (0.0004 - 0.0013) I 0.08 (0.003)
clearance EX 0.030- 0.055 (0.0012 - 0.0022) 0.10 (0.004)
Valve seat width IN/EX 1.70(0.06) 2.1 (0.08)
Valve spring Inner IN/EX 28.05 (1.104) I 27.6 (1.09)
free length Outer IN/EX 34.80 (1.370) 33.7 (1.33)
Rocker arm/ Rocker arm I.D. IN/EX 10.000 - 10.015 (0.3937 - 0.3943) 10.1 (0.40)
shaft Rocker arm shaft
IN/EX 9.978 - 9.987 (0.3928 - 0.3932) 9.91 (0.390)
O.D.
I Rocker arm to
IN/EX 0.013- 0.037 (0.0005 - 0.0014) 0.08 (0.003)
shaft clearance
Camshaft Cam lobe height CRF100F IN 27.860 - 28.040 (1.0968 - 1.1039) 27.80 (1.094)
EX 27.776 - 27.950 (1.0935 - 1.1004) 27.70 (1.091)
CRF80F IN 28.007 - 28.207 (1.1026 - 1.1105) 27.95 (1.100)
EX 27.825 - 28.025 (1.0955 - 1.1033) 27.75 (1.093)
Journal O.D. CRF100F IN 19.950 - 19.968 (0.7854 - 0.7861) 19.90(0. 783)
EX 19.950 -19.968 (0.7854- 0.7861) 19.90(0.783)
CRF80F IN 19.950 - 19.968 (0.7854- 0.7861) 19.90(0. 783)
EX 19.950 -19.968 (0.7854 - 0.7861) 19.90(0.783)
Runout - 0.03 (0.001)
Camshaft holder I.D. CRF100F 20.008- 20.063 (0.7877 - 0.7899) 20.15(0.793)
CRF80F 20.008- 20.063 (0.7877 - 0.7899) 20.15(0.793)
Oil clearance CRF100F 0.040 - 0.113 (0.0016 - 0.0044) 0.20(0.008)
CRF80F 0.040 - 0.113 (0.0016 - 0.0044) 0.20(0.008)
1-8
GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS (CRF100F)
Unit· mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder 1.0. 53.000 - 53.010 (2.0866 - 2.0870) 53.1 (2 .09)
Taper - 0.10 (0.004)
Out of round I - 0.10 (0.004)
Warpage - 0.10 (0.004)
Piston, piston Piston mark direction "IN" mark facing toward the intake side -
ring Piston 0.0. 52.960 - 52.990 (2.0850 - 2.0862) 52.90 (2.083)
I
Piston 0.0. measurement point 10 mm(0.4 in) from the bottom of skirt -
Piston pin bore 1.0. 14.002 - 14.008 (0.5513 - 0.5515) 14.04 (0.553)
Piston pin 0.0. 13.994 - 14.000 (0.5509 - 0.5512) 13.96 (0.550)
Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.020 (0.0008)
Piston ring to ring Top 0.015 - 0.045 (0.0006- 0.0018) 0.10 (0.004)
groove clearance Second 0.015 - 0.045 (0.0006 - 0.0018) 0.10 (0.004)
Piston ring end Top ring 0.05 - 0.20 (0.002 - 0.008) 0.4 (0.02)
gap .__second ring 0.05 - 0.20 (0.002 - 0.008) 0.4 (0.02)
Oil ring 0.9 (0.04)
0.20 - 0.70 (0.01 - 0.03)
(side rail)
! Cylinder-to-pisto n clearance
- - -- 0.010 - 0.050 (0.0004 - 0.0020) 0.10 (0.004)
Connecting rod small end 1.0. 14.012-14.030 (0.5517 - 0.5523) 14.05 (0.553)
I
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006- 0.0016) 0.09 (0.003)
CYLINDER/PISTON SPECIFICATIONS (CRF80F)

Unit: mm (in)
Cylinder 1.0. 47.500 - 47.510 (1.8701 -1.8705) 47.6 (1.87)
Taper - 0.10 (0.004)
....... Out of round
'-
- 0.10 (0.004)
Warpage - I 0.10 (0.004)
Piston, piston Piston mark direction "EX" mark facing toward the exhaust
ring side
-
Piston 0.0. 47.465 - 47.490 (1.8686 - 1.8697) 47.40 (1.866)
~
Piston pin bore 1.0. 13.002 - 13.008 (0.5119 - 0.5121) 13.04 (0.513)
Piston pin 0.0. 12.994- 13.000 (0.5116 - 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.020 (0.0008)
Piston ring to ring ._ Top 0.015 - 0.045 (0.0006- 0.0018) 0.10 (0.004)
Piston ring end ,__Top ring 0.10 - 0.25 (0.004 - 0.010) 0.4(0.02)
gap Second ring 0.10 - 0.25 (0.004 - 0.010) 0.4 (0.02)
Oil ring 0.9 (0.04)
0.20 - 0.70 (0.01 - 0.03)
(side rail)
Cylinder-to-piston clearance 0.010 - 0.045 (0.0004 - 0.0018) 0.10 (0.004)
Connecting rod small end 1.0. 13.016 - 13.034 (0.5124 - 0.5131) 13.04 (0.513)
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.09 (0.003)
1-9
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
Clutch lever free play 10 - 20 (3/8 - 3/4) -
Clutch spring free length CRF100F 31.9 (1.25) 29.5 (1.16)
CRF80F 27.6 (1.09) 25.5 (1.00)
Clutch disc thickness CRF100F 2.92-3.08 (0.115-0.121) 2.7(0.11)
CRF80F 2.90 - 3.00 (0.114 - 0.118) 2.5 (0.10)
Clutch plate warpage - 0.20 (0.008)
CRANKSHAFT /TRANSMISSION/KICKSTARTER
SPECIFICATIONS (CRF100F)
Unit: mm (in)
ITEM STAN DARD SERVICE LIMIT
Crankshaft Runout Right 0.035 (0.0014) 0.085 (0.0033)
Left 0.020 (0.0008) 0.070 (0.0028)
Connecting rod big end radial
clearance
.___
Connecting rod big end side
0 - 0.008 (O - 0.0003)
I 0.010 (0.0004)
0.10 - 0.35 (0.0039 - 0.0138) 0.60 (0.024)

clearance
Transmission Gear I.D. I M4, M5 17.016 -17.034 (0.6699- 0.6706) 17.05 (0.671)
Bushing O.D.
E
ri;f C1
20.662 - 20.643 (0.8135 - 0.8127)
19.520 - 19.541 (0.7685- 0.7693)
18.016 - 18.034 (0.7093 - 0.7100)
20.559 - 20.580 (0.8094- 0.8102)
20.66 (0.813)
19.56 (0.770)
18.05 (0.711)
20.54 (0.809)
Gear to bushing clearance (C1) 0.042 - 0.084 (0.0017 - 0.0033) 0.12 (0.005)
1--
Mainshaft O.D. I M4,M5 16.966 - 16.984 (0.6680 - 0.6687) 16.95 (0.667)
Countershaft O.D. C2 19.459 -19.480 (0.7661 - 0.7669) 19.44 (0.765)
C3 17.966 -17.984 (0.7073 - 0.7080) 17.95 (0.707)
Gear to shaft M4 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
clearance C2 0.040 - 0.082 (0.0016 - 0.0032) 0.12 (0.005)
C3 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
Shift fork, Shift fork shaft O.D. 11.976- 11.994 (0.4715 - 0.4722) 11.96 (0.471)
shift fork shaft Shift fork I.D. 12.000 - 12.018 (0.4724- 0.4731) 12.05 (0.474)
Shift fork claw thickness 4.93 - 5.00 (0.194- 0.197) 4.70 (0.19)
Kickstarter Spindle O.D. 17.959 - 17.980 (0.7070 - 0.7079) 17.88 (0.704)
Pinion I.D. 18.020 - 18.041 (0.7094- 0.7103) 18.06 (0.711)
1-10
GENERAL INFORMATION
CRANKSHAFT/TRANSMISSION/KICKSTARTER
Unit: mm (in)
ITEM STANDARD- - - - - r - - =s=E~ RVICE LIMIT
1--,-"=-----!-
Left 0.020 (0.0008) 0.070 (0.0028)
clearance 0 - 0.008 (0 - 0.0003) 0.010 (0.0004)
clearance 0.10 - 0.35 (0.0039 - 0.0138) 0.60 (0.024)
Transmission Gear ID M4 M5
'
17016 - 17034(06699 - 06706) 1705(067 1)
C1 17.022 - 17.043 (0.6702 - 0.6710) 17.06 (0.672 )
C2 19.520-19.541 (0.7685 - 0.7693) 19.56(0.7~
C3 17.016-17.034 (0.6699 - 0.6706) I 17.05 (0.671 )
B ushing O.D. C1 20.559 - 20.580 (0.8094 - 0.8102) 20.54 (0.809 )
Gear to bushing clearance (C1 ) 0.042 - 0.084 (0.0017 - 0.0033) 0.12 (0.005)
Mainshaft O.D. M4,M5 16.966 - 16.984 (0.6680 - 0.6687) 16.95 (0.667)
Countershaft 0.D. C2 19.459 - 19.480 (0.7661 - 0.7669) 19.44 (0.765)
C3 16.966 - 16.984 (0.6680 - 0.6687) 16.95 (0.667)
Gear to shaft M4 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
clearance C2 - 0.040 - 0.082 (0.0016 - 0.0032)
C3 0.032 - 0.068 (0.0013 - 0.0027)
-· - -0.12
- (0.005)
0.10 (0.004)
Shift fork, shift Shift fork shaft O.D. 11.976- 11.994 (0.4715 - 0.4722) ,,.-96( 0.471)
fork shaft Shift fork 1.D. 12.000 - 12.018 (0.4724 - 0.4731) I 12.05 (0.474) •
Shift fork claw thickness 4.93-5.00 (0.194-0.197) 4.70 (0.19)
Kicksta rter Spind le 0 .D. 17.959 - 17.980 (0.7070 - 0.7079) 17.88 (0.704)
Pinion I.D. 18.020 - 18.041 (0.7094 - 0.7103) 18.06 (0.711 )
FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)
Front wheel Cold t ire pressure 100 kPa (1 .00 kgf/cm 2, 14 psi) -
F·ront wheel rim I Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel hub-to-rim distance 12.0 ± 1.0 -- -
1--
Front axle runout - 0.20 (0.008)
Brake Lining thickness 4.0 (0.16) 2.0 (0.08)
Drum I.D. 95.0 (3.74) 96.0 (3.78)
Fork Spring free I CRF100F 546.0 (21.50) j 535.0 (21.06)
length J_ CRF80F 531.2 (20.91) I
520.7 (20.50)
I Fork pipe runout - 0.20 (0.008)
Recommended fork fluid Pro Honda suspension Fluid SS-8 -
(10W)
Fluid level ~ FW_OF 20I O (8.15) -
RF80F -1- 177.0 (6.97) - I
Fluid capacity CRF100F 84 ± 2.5 cm 3
-
I (2.8 ± 0.08 US oz, 3.0 ± 0.09 Imp oz)
I CRF80F 85 ± 2.5 cm 3
(2.9 ± 0.08 US oz, 3.0 ± 0.09 Im p oz)
-
1-11
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS
Unit: mm (in)
Rear wheel Cold tire pressure 100 kPa (1.00 kgf/cm 2 , 14 psi) I -
Rear wheel Radial - 2.0 (0.08)
rim runout Axia l - 2.0 (0.08)
Wheel hub-to-rim distance 11.0 ± 1.0 -
Rear axle runout - 0.20 (0.008)
Drive chain Slack 25 - 35 (1.0 - 1.4) 0.2 (0.01)
Size/link CRF100F RK RK428FDZ-118RJ -
I CRF80F RK RK420MSZ1-110RJ -
DID DID420MBK1-110RB -
I Shock Drum I.D.
Spring free CRF100F
95.0 (3.74)
123.5 (4.86)
96.0 (3.78)
121.0 (4.76)
absorber length CRF80F 137.0 (5.39) 134.3 (5.29)
Shock linkage Bushing I.D. 18.000 -18.052 (0.7087 - 0.7107) 18.25 (0.719)
Collar 0.D. 17.941 -17.968 (0.7063 - 0.7074) 17.91 (0.705)
Swingarm Bushing I.D. 14.990 - 15.030 (0.5902 - 0.5917) 15.20 (0.598)
Collar O.D. 14.966 - 14.984 (0.5892 - 0.5899) 14.94 (0.588)
Brake pedal Pedal hole I.D. 17.300 - 17.327 (0.6811 - 0.6822) 15.20 (0.598)
Collar O.D. 17.294- 17.298 (0.6809- 0.6810) 17.27 (0.680)
ELECTRICAL SYSTEM SPECIFICATIONS

ITEM SPECIFICATION
Spark plug Standard NGK CR7HSA
DENSO U22FSR-U
For cold climate/below NGK CR6HSA
(5°C/41 °F) DENSO U20FSR-U
For extended high speed NGK CR8HSA
riding DENSO U24FSR-U
Spark plug gap 0.6 - 0.7 (0.024 - 0.028)
Ignition coil primary peak voltage 100 V minimum
Alternator exciter coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F" mark) 15.5° BTDC / at 1,400 rpm
1-12
GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N ·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm hex bolt and nut 10 ( 1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm f lange bolt (8 mm head) 9 (0.9, 6.5)
10 mm hex bolt and nut 34 (3.5, 25) 6 mm f lange bolt (10 mm head) and nut 12 (1.2, 9)
12 mm hex bolt and nut 54 (5.5, 40) 8 mm f lange bolt and nut 26 (2.7, 20)
~
10 mm fl ange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
NOTE:
1. U-nut
2. Apply a locking agent to the threads.
3. Apply grease to the sliding surface
4. Apply oil to the t hreads and seat ing surface.
5. Loosen the bolt 1/8 to 1/4 turns after tightening it to the specified torque, then tighten the pivot nut.
ENGINE
MAINTENANCE
-
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N ·m (kgf·m, lbf·ft)
I Spark plug 1 10 14 (1.4, 10)
Oil drain bolt 1 12 24 (2.5, 18)
Side stand pivot bolt 1 10 10 (1.0, 7) NOTE 5
Side stand pivot nut 1 10 39 (4.0, 29)
Valve adjusting screw lock nut 2 5 10 (1.0, 7) NOTE4
Cam chain tensioner adj usting bolt lock nut 1 8 12(1.2,9)
Spoke 36 - 3 (0.3., 2)
Rim rock 1 8 12 (1.2, 9)
LUBRICATION
THREAD TORQUE
ITEM Q'TY
DIA. (mm) N ·m (kgf·m, lbf·ft)
REMARKS
I
I Oil pump plate screw 2 4 3 (0.3, 2) I
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
I Float chamber screw 3
DIA. (mm )
4
N ·m (kgf·m, lbf·ft)
2.1 (0.2, 1.4)
Carburetor drain screw (CRF100F) 1 6 1.5 (0. 15, 1.1)
Carburetor drain screw (CRF80F) 1 6 2.5 (0.25, 1.8)
I Choke lever set plate screw (CRF100F only) 1 5 3.4 (0.35, 2.5)
CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf,m , lbf·ft)
Cylinder head cover bolt 2 6 12(1.2,9)
Camshaft holder nut 4 8 20 (2.0, 14)
Cam sprocket bolt 2 6 12(1.2,9)
C:~r!]Chain tensioner adjusting b olt lock nut 1 8 12 (1.2, 9)

THREAD TORQUE
ITEM Q'TY REMARKS
DIA.(mm) N·m (kgf·m , lbf·ft)
Primary drive gear lock n ut 1 14 39 (4.0, 29) NOTE4
Stopper arm pivot bolt 1 6 13 (1.3, 9)
Shift ret urn spring pin 1 8 30 (3.0, 22)
1-13
GENERAL INFORMATION
ALTERNATOR
ITEM Q'TY
THREAD I TORQUE
REMARKS
DIA.(mm} N ·m (kgf·m, !bf.ft}
Flywheel nut 1 10 64 (6.5, 47) NOTE 1
I Pulse generator mounting bolt 2 5 I 6 (0.6, 4.3) NOTE 2
FRAME
FRAME/ BODY PANELS/ EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA.(mm) N ·m (kgf,m, lbf,ft)
Exhaust pipe/m uffler mounting bolt 3 8 26 (2.7, 20)
Exhaust pipe jo int nut 2 6 12 (1.2, 9)
Exhaust pipe p rotector bolt 2 6 14 (1 .4, 10)
Front fender boIt/nut 3 6 12(1.2, 9)
Fuel tank moun t ing bolt 2 6 12 (1.2, 9)
- ~
ENGINE REMOV AL/INSTALLATION

THREAD TORQUE
ITEM Q'TY REMARKS
I Gearshift pedal pinch bolt 1
DIA.(mm)
6
N ·m (kgf·m , lbf·ft)
10 (1.0, 7)
Kickstarter pedal pinch bolt 1 6 12 (1.2, 9)
Front engine hanger nut 2 8 34 (3.5, 25) NOTE 1
Rear engine hanger nut 2 8 44 (4.5, 33) NOTE 1
Engine hanger plate nut 2 8 34 (3.5, 25) NOTE 1 I
FRONT WHEEL/BLAKE/SUSPENSION/STEERING
THREAD I TORQUE
ITEM Q'TY REMARKS
DIA.(mm} N ·m (kgf·m, lbf·ft}
Handlebar upper holder bolt 4 6 I 12(1.2,9)
Front axle nut 1 12 62 (6.3, 46) NOTE1
Front brake arm pinch bolt 1 6 10 ( 1.0, 7) NOTE 2
Steering stem lock nut 1 22 74 (7.5, 54) See page
12-29
Steering stem bearing adjusting nut 1 22
I
- See page
12-29
Fork bottom bridge pinch bolt 2 8 26 (2.7, 20)
Fork top bridge pinch bolt 2 7 18 (1.8, 13)
Fork socket bolt 2 8 20 (2.0, 14) NOTE 2
Spoke 36 - 3 (0.3., 2)
Rim lock 1 8 12 (1.2, 9)
Fork bolt 2 22 23 (2.3, 17)
Fender stay bolt 3 6 . 12 ( 1.2, 9) I
REAR WHEEL/BRAKE/SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA.(mm} N·m (kgf·m, lbf·ft)
Rear axle nut 1 12 62 (6.3, 46) NOTE 1
Driven sprocket nut 4 8 32 (3.3, 24) NOTE 1
Swingarm pivot nut
Shock absorber mounting nut (upper)
1
1
12
10
I
I
64 (6.5, 47)
44 (4.5, 33)
NOTE
NOTE
1
1
Shock absorber mounting nut (lower) 1 8 34 (3.5, 25) NOTE 1
Shock absorber arm nut (swingarm side) 1 10 44 (4.5, 33) NOTE 1
Shock absorber connecting rod nut 2 10 44 (4.5, 33) NOTE 1
Rear brake arm nut 1 6 10 ( 1.0, 7) NOTE 1
Spoke 36 - 3 (0.3, 2)
Rim lock 1 8 12(1.2,9)
Foot peg mounting bolt 4 10 55 (5.6, 41)
1-14
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION
f
MATERIAL REMARKS
Crankshaft connecting rod small end Engine oil
Crankshaft connecting rod big end
Piston ring grooves
Piston outer surface
Piston pin bore
Cam chain whole surface
Valve adjusting screw lock nut
Oil pump rotor
Primary drive gear teeth
Flywheel nut
Clutch outer sliding surface
Clutch friction disk whole surface
Each oil seal lip
Each bearing rotating area
Each 0 -ring
Other rotating and sliding surfaces
Piston pin whole surface Molybdenum disu lfide oil
Camshaft whole surface (a mixture of 1/2 engine
Rocker arm shaft whole surface oil and 1/2 molybdenum
Valve stem sliding surface disulfide grease)
Transmission gear rotating surface
Transmission gear teeth and shift fork groove
Pulse generator mo unting bolt threads Locking agent
- -- - - - - - - ' - - ---'~,e_---------''-----------------'
1-15
GENERAL INFORMATION
FRAME
LOCATION MATERIAL REMARKS
Steering stem upper/lower bearing Urea based mu lti-purpose Apply 3-5 g
Steering stem upper/lower dust seal lips grease for extreme pres-
sure (example: EXCELITE
EP2 manufactured by
KYODO YUSHI, Japan) or
equivalent
Brake cam (sliding surface and shoe contacting area) Multi-purpose grease Apply 0.5 - 1 g
Brake anchor pin Apply 0.5 - 1 g
Brake cam dust seal
Wheel hub dust seal lips
Swingarm pivot thrust bush rolling area
Swingarm pivot sliding surface
Swingarm pivot dust sea l lips
Side stand pivot
Brake lever pivot bolt sliding surface
Rear brake pedal pivot sliding surface
Throttle grip pipe sliding surface and cable rolling area
Clutch lever pivot bolt sliding surface
Kickstarter pedal joint movable area
Shock absorber arm bush rolling area Molybdenum disulfide
paste
Shock absorber arm dust seal lips surface
Shock absorber connecting rod bush rolling area
Shock absorber connecting rod dust seal lips surface
Fork oil seal lips and dust seal lips Fork fluid
Damper oil seal lips
Handlebar grip inner surface Honda Bond A or Honda
Hand Grip Cement (U.S.A.
only)
Front brake arm pinch bolt threads Locking agent
Fork socket bolt threads
1-16
GENERAL INFORMATION
CABLE & HARNESS ROUTING
BREATHER HOSE
FRONT BRAKE CABLE
1-17
GENERAL INFORMATION
ENGINE STOP BUTION WIRE W IRE CLAMP ALTERNATOR/

IGNITION PULSE
GENERA OR WIRE
IGNITION CONTROL
MODULE WIRE CRANKCASE
BREATHER HOSE
CARBURETOR DRAIN HOSE

tJ
CRANKCASE WIRE BAND
~
BREATHER HOSE
SPARK
CARBURETOR
PLUG WIRE
AIR VENT HOSE
1-18
GENERAL INFORMATION
ENGINE STOP BUTION WIRE
IGNITION CONTROL ALTERNATOR/

MODULE WIRE IGNITION PULSE
GENERATOR WIRE
After '07 CRANKCASE

BREATHER HOSE

ALTERNATOR/ IGNITION
PULSE GENERATOR WIRE
1-19
GENERAL INFORMATION
AIR VENT HOSE
1-20
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), and the California Air Resources Board (CARB) require that off-road
motorcycles comply with applicable exhaust emissions standards during its useful life, when operated and maintained
according to the instructions provided.
SOURCE OF EMISSIONS
The combustion process produces oxides of nitrogen, carbon monoxide and hydrocarbons. Control of oxides of nitrogen
and hydrocarbons is very important because, under certain conditions, they react to form photochemicai smog when
subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide and
hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of appropriate carburetor settings, no adjustment should be made
except for high altitude setting and idle speed adjustment with the throttle stop screw. The exhaust emission control
system is separate from the crankcase emission control system.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.
CARBURETOR
CRANKCASE BREATHER SEPARATOR
~ FRESHAIR
~ BLOW-BY GAS
BREATHER HOSE
1-21
GENERAL INFORMATION
SERVICING THE HONDA
U.S.A. Only
Maintenance, replacement or repair of the emission control devices and systems may be performed by any motorcycle
repair establishment or individual using parts that are "certified" to EPA standards.
PROHIBITED ACTIONS
The following prohibitions apply to everyone with respect to the engines emission control system.
You may not remove or disable any device or element of design that may affect an engine's emission levels. This
restriction applies before and after t he engine in placed in service.
Vehicles that are used only for competition are exempt from t his prohibition.
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROH IBITED: U.S. Federal law prohibits, or Canadian provincial law
may prohibit the following acts or the causing t hereof: (1) the removal or rendering inoperative by any person, other than
for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle
for purpose of noise control prior to its sale or delivery to the ultimate purchaser or whi le it is in use; or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles,header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of t he vehicle, or parts of the exhaust or int ake system, wit h parts other than those
specified by the manufacturer.
FUEL PERMEATION EMISSION CONTROL SYSTEM
This motorcycle complies with the Fuel Permeation Emission Control regu lations of the U.S. Environmental Protection
Agency (EPA), California Air Resources Board (CARS), and Environment Canada (EC) . The fuel tank, fuel hoses, and fuel
vapor charge hoses used on this motorcycle incorporate fuel permeation control technologies. Tempering with the fuel
tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is
prohibited by federal regulations.
REBUILT ENGINE
When you rebuild your engine including a major overhau l in wh ich you replace the engine's pistons or power assemblies
or make other changes that sign ifi cantly increase the service life of the engine, your Honda wi ll continue to comply with all
emissions regulations if you :
- Make sure you are technical ly qualified to rebuild the engine and have the proper tools
- Use only Genuine Honda parts or equivalents
- Make sure to maintain all specif ications as described in this Service Manual
1-22
2. FRAME/BODY PANELS/EXHAUST SYSTEM
1111
SERVICE INFORMATION ........................... 2-2 NUMBER PLATE ····· .................................... 2-5
TROUBLESHOOTING ..... ·· .......................... 2-2 FRONT FENDER ......................................... 2-5
BODY PANEL LOCATIONS ........................ 2-2 REAR FENDER ............................................ 2-5
SIDE COVER, ............................................... 2-3 MUD GUARD .............................................. 2-6
SEAT, ........................................................... 2-3 CRANKCASE PROTECTOR ........................ 2-6
TANK SHROUD ........................................... 2-3 MUFFLER/EXHAUST PIPE ........................ 2-7
FUEL TANK ................................................. 2-4
2-1
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels, fuel tank and exhaust system.
• Serious burns may result if the exhaust system is not al lowed to cool before components are removed or serviced.
• Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely instal l all of the exhaust pipe fasteners first. Always tighten the exhaust
clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not
seat properly.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Exhaust pipe/muffler mounting bolt 26 N·m (2.7 kgf·m, 20 lbf·ft)
Exhaust pipe joint nut 12 N·m (1.2 kgf·m, 9 lbf·ft)
Exhaust pipe protector bolt 14 N·m (1.4 kgf·m, 10 lbf·ft)
Front fender bolt/nut 12 N·m (1.2 kgf·m, 9 lbf·ft)
Fuel tank mounting bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Front engine hanger nut 34 N·m (3.5 kgf·m, 25 lbf·ft) U-nut
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
BODY PANEL LOCATIONS

FUEL TANK
SIDE COVER
CRANKCASE
PROTECTOR
2-2
FRAME/ BODY PANELS/EXHAUST SYSTEM
SIDE COVER
REMOVAL/INSTALLATION
Remove the bolt and side cover.
HOLE
Installation is in the reverse order of remova l.
NOTE:
Align the boss on the side cover with the hole.
SIDE COVER
SEAT
Remove the nuts and collars.
Remove the seat.
Installation is in the reverse order of removal.
NOTE:
When instal ling the seat, align the seat hook wit h
the screw on the fuel tank, and also align the prong
with the frame clamp.
TANK SHROUD
Remove the bolt and trim clip.
Remove the tank shroud from the fuel tank.
NOTE:
Align the hole in the shroud with the boss on the
fuel tank.
2-3
FRAME/BODY PANELS/EXHAUST SYSTEM
FUEL TANK
REMOVAL/ INSTALLATION
Turn the fuel valve OFF.
Remove the seat (page 2-3).
Remove the tank shroud (page 2-3).
Disconnect the fuel hose from the fuel valve.
Disconnect the fuel tank breather hose from the
number plate.
Remove t he fuel tank holder band.
Remove the fuel tank mounting bolts and fuel tank.
TORQUE:
Fuel tank mounting bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft)
BREATHER HOSE SCREW

STRAP
/
BOLT
FUEL HOSE
BOLT
COLLARS
2-4
NUMBER PLATE
Unfasten the number plate from the handlebar.
NUMBER
Remove the bolt and number plate. PLATE
NOTE:
During installation, align the lower grooves with the
bracket tabs on the steering stem.
FRONT FENDER
Remove the bolt, nuts, collars and front fender.
Install ation is in the reverse order of removal.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) FENDER
REAR FENDER
Remove the seat and side covers (page 2-3).
Remove the bolts and rear fender.
2-5
MUDGUARD
Remove the two bolts and mud guard.
CRANKCASE PROTECTOR
REMOVAL
Remove the two crankcase protector bolts.
Remove the front engine hanger bolt/nut and crank- 1BOLT/

case protector.
Inspect the stopper rubber for wear or damage,

replace if necessary.
RUBBER
2-6
INSTALLATION
Place the crankcase protector and install the front
engine hanger bolt from the left side.
Tempo rari ly install the two crankcase protector
bolts.
Tighten the front engine hanger nut to the specified
torque.
TORQUE: 34 N ·m (3.5 kgf·m, 25 lbf·ft)
Tighten the two crankcase protector bolts.
MUFFLER/EXHAUST PIPE
REMOVAL
Remove the right side cover (page 2-3).
Remove the exhaust pipe joint nuts.
Remove the exhaust pipe/muffler mounting bolts

and exhaust pipe/muffler assembly.
2-7
FRAME/ BODY PANELS/EXHAUST SYSTEM
INSTALLATION
SPARK ARRESTER
GASKET ~
MOUNTING BOLT
26 N·m (2.7 kgf·m ,
20 lbf·ft)
~ --- e@
____....~ EXHAUST PIPE JOINT NUTS
12 N·m (1.2 kgf·m, 9 lbf,ft)
14 N·m (1.4 kgf·m, 10 lbf·ft)
Always replace the Instal l a new exhaust pipe gasket onto t he exhaust
exhaust pipe gasket port of t he cylinder head.
with a new one.
Install the exhaust pipe, temporari ly install the

exhaust pipe joint nuts and mounting bolts.
First tighten the exhaust pipe joint nuts to the speci-
fied torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
2-8
FRAME/BODY PANELS/EXHAUST SYSTEM
Tighten the exhaust pipe/muffler mounting bolts to
the specified torque.
TORQUE: 26 N ·m (2.7 kgf,m, 20 lbf·ft)

Install the side cover (page 2-3).
2-9
3. MAINTENANCE
•
SERVICE INFORMATION ................... ···· .... 3-2 DRIVE CHAIN,, .......................................... 3-17
MAINTENANCE SCHEDULE ...................... 3-5 DRIVE CHAIN SLIDER .. ............................ 3-19
FUEL LINE ................................................... 3-9 BRAKE SHOE WEAR ......... ·· .................... · 3-20
THROTILE OPERATION ... ,......................... 3.9 BRAKE SYSTEM ............. ·................... ·..... 3-20
AIR CLEANER ............................................ 3-10 CLUTCH SYSTEM ·.. ·.... · .... ·......... · .. ·..... ·... 3-22
SPARK PLUG ............................................ 3-11 SIDE STAND ............................................. 3-23
VALVE CLEARANCE., ............................... 3-12 SUSPENSION ·· · ··· .. ··· ·· ·· ·· ··... · ··· .. ··· ·· .. ·· ··.. ·· 3-23
ENGINE OIL ............................................... 3-13 SPARK ARRESTER ................................... 3-24
ENGINE OIL STRAINER SCREEN ............ 3-15 NUTS, BOLTS, FASTENER$, ................... 3-25
CAM CHAIN TENSION ............................. 3-15 WHEELS/TIRES ........................................ 3-25
ENGINE IDLE SPEED ................................ 3-16 STEERING HEAD BEARINGS ··· ····· .......... 3-26
3-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the motorcycle on a level surface before starting any work.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
SPECIFICATIONS
CRF100F:
ITEM SPECIFICATIONS
- 2 - 6 mm (1/ 12 -1/4 in)
Throttle grip free_play
Spark plug NGK DENSO
Standard CR7HSA -1 U22FSR-U
For cold climate (below 5°C/41 °F) CR6HSA I U20FSR-U
For extended high speed riding CR8HSA l U24FSR-U
I Valve
Spark plug gap
clearance IN
0.6-0.7 mm (0.024 - 0.028 in)
0.05 mm (0.002 in)
_LE~ 0.05 mm (0.002 in)
Engine oil capacity At draining 0.9 liter (1.0 US qt, 0.8 Imp qt)
I Recommended engine oil At disassembly 1.1 liter (1.2 US qt, 1.0 Imp qt)
Pro Honda GN4 4-stroke oil (U.S.A and Canada) or
equivalent motor oil
API service classification: SG or higher
JASO T 903 standard: MA
Engine idle speed 1,400 ± 100 rpm
-- -
Drive chain slack 25- 35 mm (1.0- 1.4 in)
Drive chain size/link RK RK428FDZ-118RJ
Brake lever free play 20- 30 mm (3/4 -1-1/4 in)
Brake pedal free play 20 - 30 mm (3/4-1-1/4 in)
Clutch lever free play 10 - 20 mm (3/8 - 3/4 in)
Tire size Front 70/100-19 M/C 42M
Rear 90/100-16 M/C 51M
Tire brand Front Cheng shin
Rear Cheng shin
Cold tire pressure I Front 100 kPa (1.00 kgf/cm~, 14 psi)
Rear 100 kPa (1.00 kgf/cm 2 , 14 psi)
3-2
MAINTENANCE
CRF80F:
ITEM SPECIFICATIONS
Throttle grip free play 2 - 6 mm ( 1/ 12 - 1/4 in)
Spark plug NGK DENSO
Standard CR7HSA U22FSR-U
For cold climate (below 5°C/41 °F) CR6HSA U20FSR-U
For extended high speed riding_ CR8HSA U24FSR-U
Spark plug gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Valve clearance iN 0.05 mm (0.002 in)
EX 0.05 mm (0.002 in)
Engine oil capacity At draining 0.9 liter (1.0 US qt, 0.8 Imp qt)
~
At disassembly 1.1 liter IT.2 US qt, 1.0 Imp qt)
I
Recommended engine oil Pro Honda GN4 4-=stroke oii (U.S.A and Canada) or
equivalent motor oil
API service classification: SG or higher
JASO T 903 standard: MA
Engine idle speed 1,500 ± 100 rpm I
Drive chain slack -- 25 - 35 mm (1.0 - 1.4 in) I

Drive chain size/link
-- RK RK420MSZ1-110RJ I
DID DID420MBK1 -110RB
Brake lever free play 20 - 30 mm (3/4- 1-1 /4 in) - I
Brake pedal free play 20 - 30 mm (3/4-1-1 /4 in)
Clutch lever free play 10 - 20 mm (3/8 - 3/4 in)
Tire size Front 2.50-16 4PR
I Rear 3.60-14 4PR
Tire brand Front IRC
-
Rear IRC
Cold tire pressure Front 100 kPa (1.00 kgf/cm 2, 14 psi)
Rear 100 kPa (1.00 kgf/cm 2 , 14 psi)
TORQUE VALUES
Spark plug 14 N·m (1.4 kgf-m , 10 lbf.ft)
Oil drain bolt 24 N·m (2.5 kgf·m, 18 lbf·ft)
Rear axle nut 62 N·m (6.3 kgf·m, 46 lbf·ft) U-nut
Side stand pivot bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Loosen the bolt 1/8 to 1/4 turns after
tightening it to the specified torque,
then tighten the pivot nut.
Side stand pivot nut 39 N·m (4.0 kgf·m, 29 lbf·ft)
Valve adjusting screw lock nut 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply oil to the threads and seating sur-
face
Cam chain tensioner adjusting bolt lock 12 N·m (1.2 kgf·m, 9 lbf·ft)
nut
Spoke 3 N·m (0.3 kgf·m, 2 !bf.ft)
Rim rock 12 N·m (1.2 kgf·m, 9 lbf·ft)
3-3
MAINTENANCE
TOOLS
Valve adjusting wrench, 8 x 9 mm Va lve adjuster 8 Spoke wrench, 4.5 x 5.1 mm
07708-0030100 07908-KE90000 07701-0020200
or equivalent commercially avai l- or 07908-KE90200 (U.S.A. only) or equivalent commercially avail-

able in U.S.A able in U.S.A.
3-4
MAINTENANCE
MAINTENANCE SCHEDULE
CRF100F ('04 AND '05):
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanica l knowledge. Certain items (particu larly those marked * and **) may require
more technical information and tools. Consult an authorized Honda dealer.
INITIAL
WHICHEVER REGULAR MAINTENANCE
MAINTE-
COMES FIRST INTERVAL
NANCE REFER TO
~ y
mi 100 600 1,200 1,800 2,400 PAGE
¢ km 150 1,000 2,000 3,000 4,000
I NOTE MONTH 1 6 12 18 24
(/)
* FUEL LINE I I 3-9
~ FUEL STRAINER SCREEN
UJ ** C C 3-9
t: * THROTILE OPERATION I I 3-9
0 AIR CLEANER NOTE 1 C C C C 3-11
UJ
~
....J
SPARK PLUG I I I I 3-11
UJ * VALVE CLEARANCE I I I I I 3-12
ex: ENGINE OIL R R R R R 3-13
z ** ENGINE OIL STRAINER SCREEN I C C 3-15
0
<ii * CAM CHAIN TENSION A A A A A 3-15
(/)
~ ** ENGINE IDLE SPEED I I I I I 3-16
UJ
(/) NOTE 1 I, L I, L: Every 300 mi (500 km) 3-17
~ DRIVE CHAIN
UJ
or 3 month
t: DRIVE CHAIN SLIDER I I I I 3-19
0 BRAKE SHOE WEAR I I I I 3-20
UJ
BRAKE SYSTEM I I I I I 3-20
~
UJ
CLUTCH SYSTEM I I I I I 3-22
ex: SIDE STAND I I I 3-23
z * SUSPENSION I I 3-23
0
<ii * C: Every 1,000 mi (1,600 km) or every 3-24
SPARK ARRESTER
(/)
100 operating hours
~
UJ * NUTS, BOLTS, FASTENERS I I I 3-25
z0 ** WHEELS!flRES I I I I I 3-25
z ** STEER ING HEAD BEARINGS I I I 3-26
* Should be serviced by an authorized Honda dea ler, unless the owner has proper tools and service data and is
mechanically qualified.
** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer.
NOTES:
1. Service more frequently when ridden in wet or dusty conditions.
3-5
MAINTENANCE
CRF100F (AFTER '05):
Perform the Pre-ride inspection in the Owner's Manual at each schedu led maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A : Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require
FREQUE NCY INITIAL
WHICHEVER
COMES FIRST
MAINTE-
REG ULAR MAINTENANCE
INTERVAL
I
NANCE REFER TO
I ¢ I
mi 100 600 1,200 1,800 2,400
1,000 2,000 3,000 4,000
PAGE
km 150
ITEMS NOTE M ONTH 1 6 12 18 24 I
* FUEL LINE I I 3-9
** FUEL STRAINER SCREEN C C 3-9
* THROTILE OPERATION I I 3-9
AIR CLEANER NOTE 1 C C C C 3-11
SPARK PLUG I I I I 3-11
* VALVE CLEARANCE I I I I I 3-12
ENG INE OIL R R R R R 3-13
** ENGINE OIL STRAINER SCREEN C C 3-15
* CAM CHAIN TENSION A A A A A 3-15
** ENGINE IDLE SPEED I I I I I 3-16
NOTE 1 I, L I, L: Every 300 m i (500 km) 3-17
DRIVE CHAIN
or 3 month
DRIVE CHAIN SLIDER I I I I 3- 19
BRAKE SHOE WEAR I I I I 3-2~
I BRAKE SYSTEM I I I I I 3-20
SIDE STAND I I 3-23
* SUSPENSION
-- - f- - -
I I 3-23
* C: Every 1,000 mi (1 ,600 km) or every 3-24
SPARK ARRESTER
100 operating hours
* NUTS, BOLTS, FASTENERS I I I 3-25
** WHEELS/TIRES I I I I I I 3-25
I ** STEERING HEAD BEARINGS I I I I 3-26
* Should be serviced by an aut horized Honda dealer, unless the owner has proper tools and service data and is
mechanica lly qualified.
NOTES:
1. Service more frequently when ridden in wet or d usty cond itions.
3-6
MAINTENANCE
CRFSOF ('04 AND '05):
Perform the Pre-ride inspection i n the Owner's Manua l at each scheduled maintenance period.
The following items require some mechanical knowledge. Certain items (particu larly those marked * and **) may require
FREQUENCY INITIAL i
WH ICH EVER REGULAR MAINTENANCE
MAINTE- INTERVAL
COMES FIRST
NANCE REFER TO
mi 100 600 1 1,200 1,800 2,400 PAGE
¢ km 150 1,000 2,000 3,000 4,ooo I
ITEMS NOTE MONTH 1 6 12 18 24
* FUEL LIN E I I 3-9
I~ * * FUEL STRAINER SCREEN
!:::: * THROTILE OPERATION
C
I
C
I
I 3-9
3-9
I
0 AIR CLEANER NOTE 1 C C C I C 3-11

I
w
3-11
~ SPARK PLUG I I I I
3-12
...J
* VALVE CLEARANCE I I I I I I
w
R R R 3-13
-
0: ENGINE OIL R R
z ** ENGINE OIL STRAINER SCREEN c C
-
3-15
0
3-15
-
vi
(f)
* CAM CHAIN TENSION ' A
I
A
I
A
I
A
I
A
I 3-16
** ENGINE IDLE SPEED
~
U.J I I, L I, L: Every 300 mi (500 km) 3-17
(f) NOTE l
~ DRIVE CHAIN or 3 month
UJ -
!:::: DRIVE CHAIN SLIDER I I I I 3-19
0 BRAKE SHOE WEAR I I I I 3-20
UJ
I I I I I 3-20
~
....J
BRAKE SYSTEM
CLUTCH SYSTEM I I I I I I 3-22
UJ
a: SIDE STAND I I 3-23
z * SUSPENSION I I 3-23
-
0 3-24
vi * C: Every 1,000 mi (1,600 km) or every
SPARK ARRESTER
(f)
~
I 100 operating hours
* NUTS, BOLTS, FASTENERS I I I I 3-25
LI,J
z * * WHEELSfrlRES I I I I I I 3-25
0
z ** STEERING HEAD BEARINGS : I I I I
I 3-26
I
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
NOTES:
3-7
MAINTENANCE
CRFSOF (AFTER '05):
Perform the Pre-ride inspection in the Owner's Manual at each schedu led maintenance period.
The following items require some mechanical knowledge. Certain items (particularly those marked* and * * ) may require
l~ y WHICHEVER
COMES FIRST
¢ mi
km
INITIAL
MAINTE-
NANCE
100
150
REGULAR MAINTENANCE
INTERVAL
600 1,200 1,800 2,400
1,000 2,000 3,000 4,000
REFER TO
PAGE
ITEMS NOTE MONTH 1 6 12 18 24

-
* FUEL LINE I I 3-9
** FUEL STRAINER SCREEN C C 3-9
* THROTILE OPERATION I I 3-9
AIR CLEANER NOTE 1 C C C C 3-11
SPARK PLUG
- -- - - I I I I 3-11
* VALVE CLEARANCE I I I I I 3-12
ENGINE OIL R R R R R 3-13
* * ENGINE OIL STRAINER- SCREEN C C 3-15
* CAM CHAIN TENSION A A A A A 3-15
** ENGINE IDLE SPEED I I I I I 3-16
NOTE 1 I, L I, L: Every 300 mi (500 km) 3-17
DRIVE CHAIN
or 3 month
DRIVE CHAIN SLIDER I I I I I I 3-19
BRAKE SHOE WEAR I I I I 3-20
BRAKE SYSTEM I I I I I 3-20
SIDE STAND I I 3-23 -
* SUSPENSION I I 3-23
* SPARK ARRESTER C: Every 1,000 mi (1,600 km) or every 3-24
100 operating hou rs
* NUTS, BOLTS, FASTENERS I I I 3-25
** WHEELSfTIRES I I I I I 3-25
** STEERING HEAD BEARINGS I I I 3-26
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
NOTES:
3-8
MAINTENANCE
FUEL LINE
Check the fuel line for deterioration, damage or
leakage.
Replace the fuel line if necessary.
FUEL STRAINER SCREEN

Turn the fuel va lve to "OFF" position and disconnect
the fuel hose from the carburetor.
Place a drain pan under the fuel hose and turn the
fuel valve ON to drain the fuel tank.
After the tank has drained completely, remove the
two bolts, fuel valve and fuel strainer screen.
Wash the fuel strainer screen in non-flammab le or

high flash solvent.
Install a new 0-ring to the fuel valve.
Install the fuel valve/strainer screen, collars and
mounting bolts.
Tighten the fuel va lve mounting bolts.
After installation, check for fuel leaks.
THROTTLE OPERATION
Check for smooth throttle grip full opening and
automatic full closing in all steering positions. 2 - 6 mm (1/12-1/4 in)
Check the throttle cable and replace it if deterio-
rated, kinked or damaged.
Lubricate the throttle cables if throttle operation is
not smooth.
Measure the free play at the throttle grip flange.
FREE PLAY: 2- 6 mm (1/12- 1/4 in)
3-9
MAINTENANCE
Throttle grip free play can be adjusted at the throttle
housing adjuster. LOCK NUT
Remove the dust cover from the adjuster.

Adjust the free play by loosening the lock nut and
turning the adjuster.
Recheck the throttle operation.
Replace any damaged parts if necessary.
AIR CLEANER
Remove the left side cover (page 2-3).
Remove the air cleaner housing cover band and
housing cover.
Release the air cleaner element holder band and air

cleaner element from the housing.
Wash the element in non-flammable or high flash

point solvent and let it dry thoroughly.
SQUEEZE
Squeeze out the solvent thoroughly, and allow the SQUEEZE OUT OUT
element to dry. SOLVENT EXCESS
Soak the element in Pro Honda Foam Filter Oil or THOROUGHLY OIL
~·t ·@·t
equivalent and squeeze out any excess oil.
I PRO I
WASH IN
HONDA
SOLVENT
FOAM
FILTER OIL
3-10
MAINTENANCE
SPARK PLUG
Disconnect the spark p lug cap.
Clean around the Remove t he spark plug using a spark plug wrench
spark plug bases or equivalent.
with compressed
air before remov-
Inspect or replace as described in the maintenance
schedule (page 3-5).
,ng, and be sure
that no debns is
allowed to enter the
combustion cham-
ber.
INSPECTION
Check the following and replace if necessary
(recommended spark plug: page 3-2): CENTER ELECTRODE
• Insulator for damage
• Electrodes for wear
• Burning condition, coloration;
- Da rk to light brown indicates good condition.
- Excessive lightness indicates malfunctioning
ignition system or lean m ixture.
- Wet or black sooty deposit indicates over-rich
mixture.
SPECIFIED SPARK PLUG :
NGK: CR7HSA
DENSO: U22FSR-U
INSULATOR SIDE ELECTRODE
Clean the spark plug electrodes with a wire brush or

special plug cleaner. 0.6-0.7 mm J
(0.024 - 0.028 in) ~
Check the gap between the center and side elec-
trodes with a w ire-type feeler gauge .
lf necessary, adjust the gap by bending the side 1
electrode carefully.
SPARK PLUG GAP: 0.6 - 0.7 mm (0.024 - 0.028 in)
Install and hand tighten the spark plug to the cylin-

der head, then tighten the spark plug to the speci-
fied torque.
TORQUE: 14 N-m (1.4 kgf·m, 10 !bf.ft)
Insta ll the spark plug cap.
3-11
MAINTENANCE
VALVE CLEARANCE
INSPECTION
Inspect and ad1ust Remove the following .
the valve clearance
- Side cover (page 2-3)
while the engine is
- Seat (page 2-3)
cold /below 35 °C/
- Fuel tank (page 2-4)
95°F)
Remove the two cylinder head cover bolt and cylin-
der head cover.
Remove the left crankcase cover (page 10-4).

Turn the crankshaft counterclockwise and align the
"T" mark on the flywheel with the index notch on
the left crankcase cover.
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
Check the valve clearance by inserting a feeler

gauge between the valve adjusting screw and valve
stem.
VALVE CLEARANCE:
IN/ EX:0.05 mm (0.002 in)
3-12
MAINTENANCE
ADJUSTMENT
Adjust by loosening the lock nut and turning the
adjusting screw until there is a slight drag on the
feeler gauge.
Hold the adjusting screw and tighten the lock nut to
TOOLS:
Valve adjusting wrench,
8x9mm 07708-0030100 or
equivalent com-
mercially avail-
able in U.S.A.
Valve adjuster B 07908-KE90000 or
07908-KE90200
FEELER GAUGE
(U.S.A. only)
TORQUE: 10 N ,m (1.0 kgf·m, 7 lbf·ft)

After tightening the valve adjuster lock nut, recheck
the valve cl earance.
Install the following:
- Cylinder head cover (page 7-20)
- Seat (page 2-3)
- Side cover {page 2-3)
- Left crankcase cover (page 10-8)
ENGINE OIL
ENGINE OIL LEVEL CHECK
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait 2 - 3 minutes.
Support the motorcycle in an upright position on
level ground.
Remove the fil ler cap/dipstick and wipe it clean.
Reinstall the oil filler cap/dipstick, but do not screw
in.
3-13
MAINTENANCE
Remove the filler cap and check the oil level.
If the oil level is below the lower level line on the
dipstick, fill the crankcase with the recommended
oi l.
0-RING
- - UPPER LEVEL
-.--- LOWER LEVEL

Other viscosities RECOMMENDED ENGINE OIL:
shown in the charr Pro Honda GN4 4-stroke oil (U.S.A and Canada) or
may be used when equivalent motor oil
the average rem- API service classification: SG or higher
perature in your JASO T 903 standard: MA
nding area 1s within Viscosity: SAE 10W-30
the indicated range.
Check that the 0-ring is in good condition, replace if
necessary.
Reinstall the oil filler cap/dipstick.
-30 -20 -10 o 10 20 30 40 so·c
-20 0 20 40 60 80 100 120°F
ENGINE OIL CHANGE

Change the engine Warm up the eng ine.
oil with the engine
Stop the engine and remove the oil fi ller cap/dip-
warm and the
stick and drain bolt and sealing washer.
motorcycle on level
ground to assure Drain the oil completely.
complete draining.
After the oil has drain completely, install the drain

bolt with a new sealing washer.
Tighten the drain bolt to the specified torque.
TORQUE: 24 N ,m (2.5 kgf·m, 18 !bf.ft)
3-14
MAINTENANCE
Fil l the crankcase with the recommended engine oil.
OIL CAPACITY:
0.9 litter (1.0 US qt, 0.8 Imp qt} after draining
Install the oil filler cap/dipstick.

Start the engine and let it idle for 2 to 3 minutes.
Stop the engine and recheck the oil level.
Check the engine oil level (page 3-13) and make
sure there are no oil leaks.
ENGINE OIL STRAINER SCREEN

Perform this mam- Remove the right crankcase cover (page 9-5) .
tenance before fill- Remove the oil strainer screen and clean it.
ing the engine with
oil. Reinstall the oil strainer screen and right crankcase
cover (page 9-14).
Fill the crankcase with recommended engine oil
(page 3-14).
CAM CHAIN TENSION

Stop the engine.
Loosen the cam chain adjuster set plate bolt.
Turn the adjuster and set the punch mark at 45

degree downside (tension side) from the standard
position.
Tighten the set plate bolt.
NOTE:
Do not turn the adjuster over 45 degree downside
from the standard position to prevent the tensioner
being too tensile.
Loosen the lock nut and the cam chain tensioner
adjust screw.
NOTE:
I
The cam chain tension will be adjusted automati- MARK
cally by the tensile force of the cam chain tensioner
spring when loosening the cam chain tensioner ' - - - - -- - - -- - - - - -- - -
adjust screw.
3-15
MAINTENANCE
Tighten the cam chain tensioner adjust screw.
Tighten the lock nut to the specified torque with
holding the adjust screw.
TORQUE: 12 N-m (1.2 kgf·m , 9 lbf.ft)
Loosen the cam chain tensioner adjuster set plate

bolt and turn the adjuster and set punch mark to the
standard position.
Tighten the cam chain tensioner adjuster set plate
bolt.
Start the engine and check the chain noise.
If the cam chain is too tensile, turn the adjuster to
the slack side and fine adjust.
After adjustment, tighten the cam chain tensioner
adjuster set plate bolt.
TENSIONER
ENGINE IDLE SPEED

• Inspect and adjust the idle speed after all other
engine maintenance items have been performed
and are within specifications.
• The engine must be warm for accurate idle
speed inspection and adjustment.
Connect a tachometer.
Warm up the engine for about 10 minutes.
Turn the throttle stop screw as required to obtain
the specified idle speed.
IDLE SPEED:
CRF100F: 1,400 ± 100 rpm
CRF80F: 1,500 ± 100 rpm
THROTILE STOP SCREW
3-16
MAINTENANCE
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Never inspect and Turn the ignition switch OFF, place the motorcycle
ad1ust the dnve on its side stand and shift the transmission into neu-
chain while the tral.
engine is running.
Check the slack in the drive chain lower run midway
between the sprockets.
CHAIN SLACK: 25 - 35 mm (1.0 - 1.4 in)
I NOTICE I
Excessive chain slack, 50 mm (2.0 in) or more, may
damage the frame.
ADJUSTMENT
Loosen the rear axle nut.
Turn both chain adjusting nuts equally until the
chain slack is correct.
Make sure the index marks on both adjusters are

aligned with the index marks on the swingarm.
Tighten the rear axle nut to the specified torque.
TORQUE: 62 N ·m (6.3 kgf-m, 46 lbf-ft)
Tighten both adjusting nuts.
Recheck the drive chain slack and free wheel rota-
tion.
Check the rear brake pedal free play (page 3-21),
adjust if necessary.
Lubricate the drive chain with #80-90 gear oil or
drive chain lubricant.
Wipe off any excess gear oi l or drive chain lubricant.
3-17
MAINTENANCE
CLEANING INSPECTION AND
LUBRICATION
If the drive chain becomes extremely dirty, it shou ld
be removed and cleaned prior to lubrication.
Remove the left crankcase cover (page 10-4) .
Carefully remove the retaining clip with pliers.
Remove the master link and drive chain.
Clean the chain with non-flammable or high flash

point solvent and wipe it dry. SOFT BRASH
Be sure the chain has dried completely before lubri-

cating .
Inspect the drive chain for possible damage or wear.
CLEANING
Replace any chain that has damaged rollers, loose
fitting links, or otherwise appears unserviceable.
Instal ling a new chain on badly worn sprockets wil t WIPE AND DRY
cause the new chain to wear quickly.
Inspect and replace sprocket if necessary.
LUBRICATE ~
Lubricate the drive chain with #80- 90 gear oil or LUBRICATE ·.

drive chain lubricant.
Wipe off any excess gear oil or drive chain lubricant.
PRO HONDA CHAIN LUBE

OR EQUIVALENT
Measure the drive chain distance between a span of
41 pins from pin center to pin center with the chain 41 PINS
held taut and any kinked joint st raightened.
SERVICE LIMIT: 511 mm (20.1 in)
3-18
MAINTENANCE
SPROCKETS INSPECTION
Inspect the drive and driven sprocket teeth for wear
or damage, replace if necessary.
Never use a new drive chain on worn sprockets.
Bot h chain and sprockets must be in good condi-
tion, or the new replacement chain wil l wear rap-
idly.
Check the attaching bolts and nuts on the drive and NORMAL
driven sprockets.
If any are loose, torque them.
Install the drive chain onto the sprockets.

MASTER LINK
Install the master link and link plate.
Install the retaining clip with the open end opposite
the direction of chain travel.
DRIVE CHAIN SLIDER

UPPER DRIVE CHAIN SLIDER
Check the upper drive chain slider for wear or dam-
age. CHAIN SLIDER
Replace the drive chain sl ider if it is worn to the ser-
vice limit or if it has been damaged.
SERVICE LIMIT: 6.0 mm (0.23 in)
LOWER DRIVE CHAIN SLIDER

Check the lower drive chain slider for wear or dam-
age.
Replace the lower drive chain slider if it is worn to
the wear limit or if it has been damaged.
3-19
MAINTENANCE
BRAKE SHOE WEAR
FRONT BRAKE SHOES
Check the brake shoes and brake drum if the arrow
on the indicator plate aligns with the "6.'' mark on
t he brake panel when the brake lever is applied.
Refer to page 12-15 for brake shoe replacement.
REAR BRAKE SHOE

Check the brake shoes and brake drum if the arrow
on the indicator plate al igns with t he "6.'' mark on
the brake panel when the brake pedal is appl ied.
Refer to page 13-12 for rear brake shoe replace-
ment.
BRAKE SYSTEM
FRONT BRAKE
Measure the front brake lever free play at the tip of
the lever.
FREE PLAY: 20 - 30 mm (3/4 - 1-1/ 4 in)

_J_
3-20
MAINTENANCE
Minor adjustments can be made with the upper
adjuster.
Loosen the lock nut and turn the adjuster until the
free play is within specification.
After adjustment, tighten the lock nut.
Major adjustments can be made with the lower

adjuster on the brake panel.
Loosen the lock nut and turn the adjusting nut until
the free play is within specification.
After adjustment, tighten the lock nut.
REAR BRAKE
Pedal Height
Adjust the rear Loosen the lock nut and adjust the brake pedal
brake free play after height by turning the adjusting bolt.
adjusting the brake
Retighten the lock nut.
pedal height
Pedal Free Play

Check the brake pedal free play.
FREE PLAY: 20 - 30 mm (3/4-1-1/4 in)
t
20 - 30 mm (3/4-1-1 /4 in)
3-21
MAINTENANCE
Make sure the cut- Adjust the brake pedal free play by turning the
out on the adJusting adjusting nut.
nur 1s seated on the
brake arm pin after
making the final
free play adjust-
ment.
CLUTCH SYSTEM
Measure the clutch free play at the tip of the clutch
lever.
FREE PLAY: 10 - 20 mm (3/8 - 3/4 in)
Minor adjustments can be made with the upper

adjuster.
Loosen the lock nut, turn the adjuster and retighten
the lock nut.
Check the clutch operation.
Major adjustment can be made with the lower

adjuster.
Loosen the lower adjuster lock nut and turn the
adjuster all the way in.
3-22
MAINTENANCE
Loosen the adjusting screw lock nut on the right
crankcase. Turn the adjusting screw counterclock-
w ise until resistance is felt. Then turn the screw
clockwise 1/8-1/4 of a turn. Hold the adjusting screw
and tighten the lock nut.
Turn the lower adjuster out until the free play at the
lever end is 10 - 20 mm (3/8 - 3/4 in).
Tighten the lock nut.
Then turn the upper adjuster to obtain the specified
free play (page 3-22).
SIDE STAND
Support the motorcycle on a level surface.
Check the side stand spring for damage or loss of
tension.
Check the side stand assembly for freedom of
movement and lubricate the side stand pivot if nec-
essary.
Check that the side stand pivot bolt is tightened to
the correct torque value.
Tighten the pivot bolt to the specified torque.
Loosen the pivot bolt 1/8 to 1/4 turns, then tighten
SIDE STAND
the side stand pivot lock nut to the specified torque.
TORQUE: 39 N ·m (4.0 kgf·m, 29 !bf.ft}
SUSPENSION
FRONT SUSPENSION INSPECTION
Check t he action of the front suspension by operat-
ing the front brake and compressing the forks sev-
eral times.
Check the entire fork assembly for signs of leaks,
damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer t o page 12-18 for fork service.
MAINTENANCE
REAR SUSPENSION INSPECTION
Support the motorcycle securely and raise the rear
wheel off the ground by placing a work stand or a
box under the engine.
Check for worn swingarm bushings by grabbing the
rear end of the swingarm and attempting to move
the swingarm side to side.
Replace the bushings if any are looseness is noted.
Check the action of the shock absorber by com-

pressing it several times.
Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to page 13-18 for shock absorber service.
SPARK ARRESTER
INSPECTION/CLEANING
Remove the three SH bolts, spark arrester and gas-
ket from the muffler.
Check the screen mesh, replace if necessary.

Use a soft brush to remove carbon deposits from
the spark arrester screen.
Be careful not to avoid damaging the spark arrester
screen .
The spark arrester must be free of breaks and holes,
3-24
MAINTENANCE
Install the new gasket to the spark arrester.
Install the spark arrester and tighten the three bolts
securely .
9~ GASKET • • •, . 1
NUTS,BOLTS,FASTENERS
Check t hat al l chassis nuts and bolts are tightened to
their correct torque values (page 1-13).
Check that all safety clips, hose clamps and cable
stays are in place and properly secured.
WHEELS/TIRES
RECOMMENDED TIRE PRESSURE AND TIRE SIZE:
,re pressure
kpa (kgf/cm 2 , psi)
Tire CRF100F
size
Tire CRF100F
brand
CRF80F
Check the tires for cuts, embedded nails, or other

damage.
Check the front and rear wheels for trueness (refer r----:~!Z..-~
to Sections 12 and 13).
Tire pressure Check the cold tire pressure.
should be checked
when the ttres are
cold.
Maintenance of spoke tension and wheel trueness

are crit ical to safe motorcycle operation. During the
first 150 km (100 miles), spoke will loosen more rap-
idly due to initial seating of parts. Excessively loose
spokes may result in high speed instabi lity and pos-
sible loss of control.
Inspect the wheel rims and spokes for damage.
Tighten any loose spokes to the specified torque.
TOOL:
Spoke wrench, 4.5 x 5. 1 mm 07701 - 0020200 or
equivalent com-
m ercially avail-
able in U .S.A.
TORQUE: 3 N ·m (0.3 kgf·m, 2 lbf·ft )
3-25
MAINTENANCE
Tighten the rim lock to t he specif ied torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft}
STEERING HEAD BEARINGS

Raise the front wheel off the ground by placing a
work stand or box under the engine.
Check chat the con- Check that the handlebar moves freely from side to
trol cables do not side.
interfere with han-
dlebar rotation. If the handlebar moves unevenly, binds, or has ver-
tical movement, inspect the steering head bearings
(page 12-26).
3-26
4. LUBRICATION SYSTEM
Ill
LUBRICATION SYSTEM DIAGRAM ........ ,. 4-2 CYLINDER HEAD OIL CHECK BOLT .......... 4-5
SERVICE INFORMATION ........................... 4-3 OIL PUMP ................... ·· .............................. 4-5
TROUBLESHOOTING ................................. 4-4
4-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
CAMSHAFT
ROCKER ARM
PISTON
''
CONNECTING ROD ' ' '
MAINSHAFT
COUNTERSHAFT
4-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
SPECIFICATIONS
Unit: mm (in)
~ ngineoi l CRF100F At draining 0.9 liter (1.0 US qt, 0.8 Imp qt) -
capacity At disassembly 1.1 liter (1.2 US qt, 1.0 Imp qt) -
CRF80F At draining 0.9 liter (1.0 US qt, 0.8 Imp qt) -
I Recommended engine oil At disassembly 1.1 liter (1.2 US qt, 1.0 Imp qt)
Pro Honda GN4 4-stroke oil (U.S.A and
-
Canada) or equivalent motor oil
API service classification: SG or higher -
I JASO T 903 standard: MA
I Viscosity: SAE 10W-30
0.15 (0.006) I 0.20 (0.008)
I Oil pump
rotor
Tip clearance
Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.40 (0.016)
Side clearance 0.02 - 0.07 (0.001 - 0.003) 0.25 (0.010)
-
TORQUE VALUES
Oil pump plate screw 3 N·m (0.3 kgf·m, 2 lbf·ft)
4-3
LUBRICATION SYSTEM
TROUBLESHOOTING
Engine oil level too low, high oil consumption
• Oil consumption
• External oil teaks
• Worn piston rings
• Improperly installed piston rings
• Worn cylinder
• Worn valve guide
• Worn valve stem sea ls
• Faulty head gasket
Low oil pressure
• Oil level low
• Clogged oil strainer
• Internal oil leak
• Incorrect oil being used
• Oil not change often enough
• Oil pump drive gear broken
No oil pressure
• Oil level too low
• Damaged oil pump
• Oil pump drive gear broken
• Internal oil leak
High oil pressure
• Clogged oil strainer.
• Incorrect oil being used
Engine oil contamination
• Oil not changed often enough
• Faulty head gasket
• Worn piston rings
Oil emulsification
• Entry of water
4-4
LUBRICATION SYSTEM
CYLINDER HEAD OIL CHECK BOLT
Start the engine and let it idle.
SEALING WASHER
Do not remove the Loosen, but do not remove, the cylinder head oil '
oil check bolt when check bolt and make sure oil comes out of the oil I
the engme ,s run- bolt hole. ~
ning.
If do not flow the engine oil from the oil check bolt
hole, inspect the related oil passage clogging.
Retighten the oil check bo lt and check for no oil
leaks.
If engine oi l leaks from the oil check bolt hole, stop
the engine and replace the sealing washer with a
new one.
OIL PUMP
REMOVAL
Drain the engine oil (page 3-14).
Remove the following:
- Right crankcase cover (page 9-5)
- Oil through
Turn the crankshaft and align the holes on the oil

pump drive gear with oi l pump mounting screws (or
bolts).
CRF100F: Remove the two screws, oil pump and 0-rings.
CRFBOF: Remove the two bolts, oil pump and 0 -rings.
INSPECTION
Remove the two screws and oi l pump plate.
OIL PUMP PLATE
4-5
LUBRICATION SYSTEM
Temporarily insta ll the outer and inner rotors into
If any portion of the
oil pump is wornthe oil pump body.
beyond the speci- Install the oil pumps shaft.
tied service ltm,ts.
replace the oil Measure the tip clearance between the inner and
pump as an assem- outer rotors.
bly. SERVICE LIMIT: 0.20 mm {0.008 in)
Measure the pump body clearance between the

outer rotor and pump body.
Measure t he side clearance using a straight edge

and feeler gauge.
DISASSEMBLY
Remove the two screws and oil pump plate. SCREWS
Remove t he gasket.
OIL PUMP PLATE
4-6
LUBRICATION SYSTEM
Remove the inner rotor and outer rotor.
OUTER ROTOR
INNER ROTOR
Remove the two bolts and oi l pump gear cover.
BOLTS
GEAR COVER
Remove the oil pump drive shaft and drive gear.
DRIVE SHAFT
Check the drive gear and shaft for wear or damage.
DRIVE GEAR
4-7
LUBRICATION SYSTEM
ASSEMBLY
OUTER ROTOR SCREWS
DRIVE GEAR
INNER ROTOR
SCREW (CRF100Fl
BOLTS BOLT (CRF80F)
GEAR COVER
Install the oil pump drive shaft and drive gear in the
body by aligning the cut-outs of the oi l pump drive DR IVE SHAFT
shaft and gear.
DRIVE GEAR
Install the oil pump gear cover and tighten the bolts BOLTS
securely.
GEAR COVER
4-8
LUBRICATION SYSTEM
Install the outer rotor and inner rotor. ~~ GASKET
Install a new gasket and oil pump plate. lliijjjll
OUTER ROTOR
Insta ll the oil pump plate by aligning the boss on the

plate with the cutout in the pump body.
Tighten the two oil pump plate screws to the speci-
fied torque.
TORQUE: 3 N ·m (0.3 kgf·m , 2 !bf.ft)
Check the oil pump operation by rotating the pump

gear by hand.
PLATE
INSTALLATION
Apply oil to new 0 -rings, then install them onto the
right crankcase.
Turn the crankshaft and align the holes on the oi l

pump drive gear with oil pump mounting screws.
(or bolts)
CRF100F Tighten the two screws.
CRFBOF· Tighten the two bolts.
4-9
LUBRICATION SYSTEM
Install the oi l through align the cutout to the drive
pin.
Install the right crankcase cover (page 9-14).
After installation, fi ll the crankcase with recom-
mended oil (page 3-13) and check that there are no
oil leak.
4-10
5. FUEL SYSTEM
Ill
COMPONENT LOCATION .......................... 5-2 CARBURETOR ASSEMBLY ..................... 5-12
SERVICE INFORMATION · · ···· ·· ···· ····· ····· · ··· · 5-3 CARBURETOR INSTALLATION ............... 5-15
TROUBLESHOOTING ................................. 5-5 PILOT SCREW ADJUSTMENT

(CRF100F)······ 00
•• • ••• • ................................... 5-18
AIR CLEANER HOUSING ........................... 5-6
AIR SCREW ADJUSTMENT
CARBURETOR REMOVAL .......................... 5-6 (CRF80F) .................................................... 5-19
CARBURETOR DISASSEMBLY .................. 5-8 HIGH ALTITUDE ADJUSTMENT ............. 5-20
5-1
FUEL SYSTEM
COMPONENT LOCATION
12 N·m (1.2 kgf,m, 9 lbf·ft)
5-2
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
• Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting
in loss of vehicle control.
• Work in a well vent ilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• When disassembling fuel system parts, note the locations of the 0 -rings. Replace them with new ones on reassembly.
• Before removing the carburetor, place an approved gasoline container under the carburetor drain hose, loosen the
drain screw and drain the carburetor.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to
prevent any foreign material from dropping into the engine.
• Refer to page 2-4 for fuel tank removal and installation.
• If the vehicle is to be stored for more than one month, drain the float bowl. fuel left in the float bowl may cause clogged
jets, resulting in hard starting or poor driveability.
SPECIFICATIONS (CRF1 OOF)

- ITEM
Carburetor identification number ('04 and '05)
-
- SPECIFICATIONS
PDC3L
PDCBF-
Carburetor identification number (After '07) PDCBL
Carburetor type Piston valve
Main jet #98
Slow jet #35 X #35
Jet needle clip position ('04 and '05) --- - 3rd groove from top
- j
Pilot screw opening See page 5-18
Float level 12.5 mm (0.49 in) 1
Engine idle speed 1,400 ± 100 rpm
Throttle grip free play 2 - 6 mm (1/12 - 1/4 in)
SPECIFICATIONS (CRFSOF)
,-
I Carburetor identificationITEM SPECIFICATIONS

I number ('04 and '05)
- -- PC20M
PC20P
Carburetor identification number (After '07) PC200
Carburetor type Piston valve
Main jet #95
Slow jet #35
-
Jet needle clip position ('04 and '05)
- l r9 groove from top
- -
-----Air screw opening - - -
Float level
Engine idle speed
See page 5-19
21.5 mm (0.85 in)
1,500 ± 100 rpm
Throttle grip free play 2 - 6 mm (1/12 - 1/4 in)
TORQUE VALUES
Float chamber screw 2.1 N·m (0.2 kgf·m, 1.4 lbf·ft)
Carburetor drain screw (CRF100F) 1.5 N· m ( 0.15 kg f· m, 1.1 Ibf·ft)
Carburetor drain screw (CRF80F) 2.5 N·m (0.25 kgf·m, 1.8 lbf.ft)
Choke lever set plate screw 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) CRF100F only
5-3
FUEL SYSTEM
TOOLS
Carburetor float level gauge Pilot screw wrench (D type) Pilot screw wrench guide
07401-0010000 07KMA-MS60101 07PMA-MZ20110
or 07KMA-MN9A100 (U.S.A. on ly)
5-4
FUEL SYSTEM
TROUBLESHOOTING
Engine cranks but won't start
• No fuel to carburetor
- Fuel strainer clogged
- Fuel hose clogged
- Float level misadjusted
- Fuel tank breather hose clogged
• Too much fuel getting to the engine
- Flooded carburetor
- Clogged air cleaner
• Fuel contaminated/deteriorated
• No spark at plug (ignition system faulty)
• Intake air leak
• Improper choke operation
• Improper throttle operation
Engine idles roughly, runs poorly or stalls
• Fuel line restricted
• Improper choke operation
• Ignition ma lfunction
• Fuel contam inated/deteriorated
• Intake air leak
• Incorrect idle speed
• Incorrect float level
• Pilot or air screw miss adjustment
• Low cylinder compression
• Rich mixt ure
• Lean mixture
• Clogged carburetor
Backfiring or misfiring during acceleration
• Ignition system faulty
• Fuel mixtu re too lean
Afterburn when engine braking is used
• Lean mixture in slow circuit
Poor performance (driveability) and poor fuel economy
• Fuel system clogged
• Ignition system faulty
• Air cleaner clogged
Lean mixture
• Clogged fuel jets
• Fau lty float valve
• Float level too low
• Blocked fuel fill cap air vent hose
• Clogged fuel st rainer screen
• Restricted fuel line
• Clogged carburetor air vent hose
• Intake air leak
• Throttle valve faulty
Rich mixture
• Clogged ai r cleaner
• Worn jet needle or needle jet
• Faulty float valve
• Float level too high
• Choke lever in CLOSE position
• Air jets clogged
• Flooded carburetor
5-5
FUEL SYSTEM
AIR CLEANER HOUSING
Refer to page 3- 70 Remove the following:
for air cleaner ele- _ Side cover (page 2_3 )
ment service. - mud guard (page 2-6)
Disconnect the crankcase breather hose from the
connecting tube.
Disconnect the air vent hose from the air cleaner
housing groove.
Loosen the connecting tube band screw.
Remove the air cleaner housing mounting bolt.
Remove the two air cleaner housing mounting

bolts, then remove the air cleaner housing from the
left side of t he frame.
Make sure the car- Install the air cleaner housing in the reverse order of
buretor connecting removal.
tube band is tight-
ened securely.
CARBURETOR REMOVAL
THROTTLE VAL VE
Loosen the carburetor top and pull the throttle valve
out.
Remove the throttle cable from the throttle valve

while compressing the throttle valve spring.
5-6
FUEL SYSTEM
Remove the jet needle retainer and jet needle.
JET NEEDLE
Check the throttle valve and jet needle for scratches,

wear or damage. THROTILE VALVE
RETAINER
IV'
JET NEEDLE
CARBURETOR BODY
Turn the fuel valve OFF.
Remove the throttle valve (page 5-6).
Place an approved gasoline container under the
drain hose and loosen the drain screw to drain the
fuel.
Disconnect the fuel hose from the carburetor.
Remove the air vent hose from the air cleaner hous-
ing groove.
5-7
FUEL SYSTEM
Loosen the connecting tube band screw.
Remove the carburetor mounting nuts, then remove
the carburetor to the right.
Remove the 0 -ring from the carburetor body.
CARBURETOR DISASSEMBLV
Disconnect the air vent hose and drain hose.
SET PLATE SCREW
CRF700F.· Remove the screw, set plate, choke lever and
washer.
DRAIN HOSE
CRFIOOF: Remove t he three screws and f loat chamber.

SCREWS
FLOAT CHAMBER
5-8
FUEL SYSTEM
CRFBOF: Remove the two screws and float chamber.
---...
Remove the 0-ring from the float chamber.
FLOAT CHAMBER
Remove the float pin, float and float valve. FLOAT PIN
FLOAT VALVE
Inspect the float for deformation or damage.
Inspect the float valve seat for scores, scratches,

clogging and damage.
Check the tip of the float valve where it contacts the
valve seat for stepped wear or contamination.
Replace the valve if the tip is worn or contaminated.
Check the operation of the float valve.
5-9
FUEL SYSTEM
CRF100F
Remove the following: NEEDLE JET
- Jet holder HOLDER
Main jet SLOW JET
Needle jet holder
Needle jet
Slow jet
Throttle stop screw/spring
Turn the pilot screw in and record the number of HOLDER
Damage co the pilot
screw seat will turns it takes before it seats lightly.
occur if che pi/oc
Remove the pilot screw, spring, washer and 0 -ring.
screw is tightened
against the seat.
THROTILE
After '05: TOOLS: STOP SCREW
Pilot screw wrench (D t ype) 07KMA-MS60101 or
07KMA-MN9A 100
(U.S.A. only)
Pilot screw w rench guide 07PMA-M Z20110
Inspect each jet for wear or damage and replace if
NEEDLE JET SPRING
necessary.
HOLDER
Clean each jet with non-flammable or high flash
point solvent and blow open with compressed air. JET
HOLDER
Check the pilot screw for stepped wear or damage.
Check the spring for damage.
Replace these parts if necessary.
~/ -_; .,
MAIN / ../'\ 0 -RING
JET / ,, SPRING THROTILE
SLOW JET PILOT SCREW STOP SCREW
CRF80F
- Jet holder
Main jet
Needle jet holder SLOW JET
Needle jet
Slow jet
Throttle stop screw/spring
Damage co the air Turn the air screw in and record the number of turns
screw seat will it takes before it seats lightly.
occur if the air
Remove the air screw and spring.
screw is tightened
against the seat.
After '05: TOOLS:

Pilot screw wrench (D t ype) 07KMA-MS60101 or
07KMA-MN9A 100
(U.S.A. only)
Pilot screw wrench guide 07PMA-MZ20110
5-10
FUEL SYSTEM
Inspect each jet for wear or damage and replace if
necessary.
Clean each jet with non-flammable or high f lash NEEDLE JET
point solvent and blow open with compressed air. SPRING
HOLDER
Check the air screw for stepped wear or damage.
Check the spring for damage.
Replace these parts if necessary.
) :
THROL<\,NG
STOP : \
JET HOLDER
SCREW A IR SCREW
5-11
FUEL SYSTEM
CARBURETOR ASSEMBLV
CRF100F:
AIR VENT HOSE
CARBURETOR TOP
\
THROTILE
VALVE SPRING
AFTER '05 N [
)'
DRAIN SCREW
0-RING
FLOAT CHAMBER
DRAIN HOSE
CRF80F: CHOKE LEVER
CARBURETOR TOP
AFTER'05
MAIN JET
.~. DRAIN HOSE
THROTILE VALVE
FLOAT CHAMBER
5-12
FUEL SYSTEM
Blow open each air and fuel passage in the carbure-
tor body with compressed air.
CAF100F: Install the following:
Handle all 1ets w,th - Throttle stop screw/spring SPR ING

care. They can eas- - Slow jet
ily be scored or - Needle jet
scratched. - Needle jet holder JET
- Main jet HOLDER
- Jet holder
Install the pilot screw with 0-ring, washer and
spring, and then return it to its original position as
noted during removal.
After '05. TOOLS:
MAIN
Pilot screw wrench (0 type) 07KMA-MS60101 or
07KMA-M N9A 100
(U.S.A. only)
Perform the pilot screw adjustment procedure if a
new pilot screw is insta lled (page 5-18).
CRFBOF: Insta ll the fol lowing:
Handle all jets with - Throttle stop screw/spring

care. They can eas- - Slow jet
ily be scored or - Needle jet SPRING
scratched. - Needle jet holder
- Main jet
- Jet holder
Install the air screw with spring, and then return it to
its original position as noted during removal.
After '05: TOOLS:
Pilot screw wrench (0 type) 07KMA-MS60101 or
07KMA-MN9A100
(U.S.A. only)
AIR SCREW
Perform the air screw adjustment procedure if a
new air screw is installed (page 5-19).
5-13
FUEL SYSTEM
Install the float and float va lve in the carburetor FLOAT PIN
FLOAT VALVE
body, then install the float pin through the body and
float.
FLOAT LEVEL INSPECTION

With the float valve seated and the float arm just
touching the valve, measure the float level with the
special tool as shown.
FLOAT LEVEL:
CRF100F: 12.5 mm (0.49 in)
CRFSOF: 21 .5 mm (0.85 in)
TOOL:
Carburetor float level gauge 07401-0010000
To adjust the float level, bend the float arm carefully
until the float tip just contacts the float valve.
Install a new 0-ring in the float chamber groove.

FLOAT CHAMBER OVERFLOW PIPE
Install the float chamber, aligning the overflow pipe
with the cut-out on the jet holder.
CRF100F· Instal l the three float chamber screws and tighten

SCREWS
them to the specified torque.
TORQUE: 2.1 N,m (0.2 kgf·m, 1.4 lbf.ft)
FLOAT CHAMBER
5-14
FUEL SYSTEM
CRFBOF: Insta ll the two f loat chamber screws and tighten
them to the specified torque.
TORQUE: 2.1 N -m (0.2 kgf·m , 1.4 lbf.ft)
CRF100F: Install the washer, choke lever and set plate, then
SET PLATE SCREW
tighten the screw.
TORQUE: 3.4 N-m (0.35 kgf·m , 2.5 lbf.ft)
Refer to page 1-17 Connect t he air vent hose and drain hose.
for carburetor hose
routing.
CARBURETOR INSTALLATION
CARBURETOR BODY
Install the new 0 -ring into the carbu retor body
groove.
Install the carburetor body to the intake manifold

and tighten the nuts securely.
Install the connecting tube and tighten t he connect-
ing band screw secu rely.
5-15
FUEL SYSTEM
Install the air vent hose into the air cleaner housing
groove.
Connect the fuel hose to the carburetor.
THROTILE VALVE
Install the needle clip on the jet needle groove.
NEEDLE CLIP
·04 and '05: STANDARD POSITION: 3rd groove from top
/
After '05: After '05 model can not adjust the needle clip posi-
tion.
JET NEEDLE
/
Install the jet needle into the throttle valve and
secure it with a jet needle retainer. THROTILE VALVE
RETAINER
JET NEEDLE
L
5-16
FUEL SYSTEM
Install the throttle valve spring
cable.
Connect the throttle cable to the throttle va lve while

compressing the throttle valve spring.
Install the throttle valve into the carburetor body,

aligning its cut-out with the throttle stop screw.
Tighten the carburetor top securely.

After installation, route the cables and hoses prop-
erly.
After installing the carburetor, check the following :
- Tighten the drain screw
- Throttle grip free play (page 3-9)
- Engine idle speed (page 3-16)
- Pi lot or air screw adjustment
CRF100F: (page 5-18)
CRF80F: (page 5-19)
5-17
FUEL SYSTEM
PILOT SCREW ADJUSTMENT
(CRF100F)
IDLE DROP PROCEDURE
• The pilot screw is factory pre-set Adjustment is
not necessary unless the carburetor is over-
hau led or pilot screw is replaced.
• The engine must be warm for accurate adjust-
ment. Ten minutes of stop-and-go riding is suffi-
cient.
• Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate 50 rpm
change.
After '05: Adjust the pi lot screw using following tools.
TOOLS:
Pilot screw w rench (D type) 07KMA-MS60101 or
07KMA-MN9A 100
(U.S.A. only)
Pilot screw w rench guide 07PMA-MZ20110
Damage to the pilot 1. Turn the pilot screw clockwise until it seats
screw seat will lightly, then back it out to specification given.
occur if the pdot This is an initial setting prior to the final pilot
screw 1s tightened screw adjustment.
against the seat.
INITIAL OPENING: 2-3/8 turns out
2. Warm up the engine to operating temperature.

Stop and go riding for 10 m inutes is sufficient.
3. Stop the engine and connect a tachometer

according to the tachometer manufacturer's
instructions.
4. Start the engine and adjust the idle speed to the

specified rpm with the throttle stop screw.
IDLE SPEED: 1,400 ± 100 rpm
5. Turn the pil ot screw in or out slowly to obtain the
highest engine speed.
6. Readjust the idle speed with the t hrottle stop

screw.
7. Turn the pilot screw in gradual ly until the engine

speed drops 100 rpm.
8. Turn the pilot screw counterclockwise the speci-

fied number of turns.
FINAL OPENING: 3/ 4 turns out from step 7
9. Readjust the idle speed with the th rottle stop
screw.
5-18
FUEL SYSTEM
AIR SCREW ADJUSTMENT (CRF80F)
IDLE DROP PROCEDURE
• The air screw is factory pre-set Adjustment is not
necessary un less the carburetor is overhauled or
air screw is replaced.
• The engine must be warm for accurate adjust-
ment. Ten minutes of stop-and-go riding is suffi-
cient.
• Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate 50 rpm
change.
After '05: Adjust the air screw using following tools.
'04 AND '05
TOOLS: / !. I
Pilot screw wrench (D t ype} 07KMA-M S60101 or AIR SCREW
07KMA-MN9A 100 / ' /
11
(U.S.A. only}
Pilot screw w rench guide 07PMA-M Z20110
Damage to the air

screw seat w ill
occur if the air
screw 1s tightened
against the seat.
1. Turn the air screw clockwise unti l it seats lightly,

then back it out to specification given. This is an
initial setting prior to the fina l air screw adjust-
ment.
INITIAL OPENING: 2-1/8 turn s out
THROTTLE STOP SCREW
2. Warm up the engine to operating temperature.

Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect a tachometer

according to its manufacturer's instructions.
4. Start the engine and adjust the id le speed to the

specified rpm with the throttle stop screw.
IDLE SPEED: 1,500 ± 100 rpm
5. Turn the air screw in or out slowly to obtain the
highest engine speed.
5-19
FUEL SYSTEM
6. Readjust the id le speed with the throttle stop
screw.
7. Turn the air screw out gradually until the engine

speed drops 100 rpm.
8. Turn the air screw clockwise the specified num-

ber of turns.
FINAL OPENING: 1/ 2 turns out from step 7
9. Readjust the idle speed with the throttle stop
screw.
THROTILE STOP SCREW
HIGH ALTITUDE ADJUSTMENT

At high altitude, the standard carburetor air-fuel
mixture wi ll be too rich. Performance wi ll decrease,
and fuel consumption wi ll increase. A very rich mix-
ture will also foul the spark plug and cause hard
starting. Operation at an altitude that differs from
that at which this engine was certified, for extended
periods of time, may increase emissions.
High altitude performance can be improved by spe-
cific modifications to the carburetor. If your cus-
tomer always operates the motorcycle at altitudes
above 6,500 feet (2,000 meters), you should perform
this carburetor modification.
Even with carburetor modification, engine horse-
power will decrease about 3.5% for each 1,000-foot
(300-meter) increase in altitude. The effect of alti-
tude on horsepower will be greater than this if no
carburetor modification is made.
This engine, when operated at high altitude with the
carburetor modifications for high altitude use, wi ll
meet each emission standard throughout its useful
life.
The high altitude carburetor adjustment is per- CRF OOF SHOWN:
formed as follows: 1 MAIN JET
Remove the carburetor (page 5-6) and float cham-
ber.
Replace the standa rd main jet with the high altitude
type.
HIGH ALTITUDE MAIN JET:
CRF100F:#92
CRFSOF:#90
Install the f loat chamber and carburetor (page 5-12).
5-20
FUEL SYSTEM
Turn out the air screw the specified number of turns
from the initial setting. CRF80F SHOWN:
HIGH ALTITUDE PILOT OR AIR SCREW OPENING:

CRF100F: 3/ 4 turns in from factory preset
CRF80F: 1/ 2 turns out from factory preset
After '05: TOOLS:

Pilot screw w rench (D type) 07KMA-MS60101 or
07KMA-MN9A 100
(U.S .A. only)
Pilot screw w rench guide 07PMA-MZ20110
Start the engine and adjust the idle speed to the

high altitude setting to ensu re proper high alt itude
operation (page 5-20).
1 1 1 -----------
I NOTICE I
When the carburetor has been modified for high
altitude operation, the air-fuel mixture will be too
lean for low altitude use. Operation at altitudes
below 5,000 ft. (1,500 m) with a modified carburetor
may cause the engine overheat, resulting in serious
engine damage and increased exhaust emissions.
For use at low altitudes, you should return the car-
buretor to original factory specifications.
Replace the main jet with the standard main jet, and
screw in the air screw the specified number of t urns
from the high altitude setting.
STANDARD MAIN JET:

CRF100F:#98
CRFSOF:#95
LOW ALTITUDE PILOT OR AIR SCREW OPENING :

CRF100F: 3/ 4 turns out from factory preset
CRF80F: 1/ 2 turns in from factory preset
After '05: TOOLS:

Pilot screw wrench (D type) 07KMA-MS60101 or
07KMA-MN9A 100
(U.S.A. only)
Warm up the engi ne and adjust the idle speed at

low altit ude with t he t hrottle stop screw
5-21
6. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION .......................... 6-2
SERVICE INFORMATION ........................... 6-3

ENGINE REMOVAL .................................... 6-4
ENGINE INSTALLATION .... , ....................... 6-7

•
6-1
ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
44 N-m (4.5 kgf·m, 33 !bf.ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
55 N·m (5.6 kgf·m,

41 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
6-2
SERVICE INFORMATION
GENERAL
• During engine removal and installation, support the motorcycle securely using a hoist.
• Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal.
• The fol lowing components can be serviced with the engine installed in the frame
- Alternator (Section 10)
- Camshaft (Section 7)
- Clutch (Section 9)
- Gearshift linkage (Section 9)
- Oi l pump (Section 4)
• The following components require engine removal for service.
- Cylinder head/valves (Section 7)
- Cylinder/piston (Section 8)
- Crankshaft/transmission (Section 11)
- Shift forks/shift drum (Section 11)
SPECIFICATION
ITEM SPECIFICATIONS
Engine oil capacity CRF100F 1.1 liter (1.2 US qt, 1.0 Imp qt)
(At disassembly) CRFSOF 1.1 liter (1.2 US qt, 1.0 Imp qt)
Engine dry weight CRF100F 21.4 kg (47.2 lbs)
CRF80F 18.9 kg (41.7 lbs)
TORQUE VALUES
Front engine hanger nut 34 N·m (3.5 kgf·m, 25 lbf·ft) U-NUT
Rear engine hanger nut 44 N·m (4.5 kgf·m, 33 lbf·ft) U-NUT
Engine hanger plate nut 34 N·m (3.5 kgf•m, 25 lbf·ft) U-NUT
Footpeg mounting bolt 55 N·m (5.6 kgf·m, 41 lbf·ft)
Gearshift pedal pinch bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Kickstarter pedal pinch bolt 12 N·m (1.2 kgf·m, 9 lbf.ft)
Exhaust pipe mounting bolt 26 N·m (2.7 kgf·m, 20 lbf·ft)
Exhaust pipe joint nut 12 N·m (1.2 kgf·m, 9 lbf·ft)
6-3
ENGINE REMOVAL
Support the motorcycle securely with a hoist or
equivalent.
- Right and left side cover (page 2-3)
- Seat (page 2-3)
- Muffler (page 2-7)
- Carburetor (page 5-6)
Disconnect the spark plug cap.
Remove the tank setting rubber.
Disconnect the ignition pulse generator connector

and alternator connector.
Remove the bolt and kickstarter pedal.
6-4
ENGINE REMOVAL/ INSTALLATION
Disconnect the clutch cable.
Remove the two bolts and right footpeg.
Loosen the rear axle nut and drive chain adjusting

nuts.
Push the rear wheel forward to maximize slack in
the drive chain.
Remove the fixing plate bolts, fixing plate, drive

sprocket and drive chain.
6-5
ENGINE REMOVAL/ INSTALLATION
Disconnect the crankcase breather hose from the
crankcase. iREATHER HOSE
Remove the front engine hanger bolt/nut.
Remove the crankcase protector bolts and crank-

case protector.
Remove the two bolts and left footpeg.
6-6
Remove the front engine hanger bolt/nut.
Remove the two engine hanger plate bolts/nuts and
engine hanger plate.
Loosen the rear engine hanger bolts/nuts.

Support the engine using a jack or other adjustable
support to ease of engine hanger bolts removal.
Remove the engine hanger bolts, col lars and engine
from the frame.
ENGINE INSTALLATION
• Note the direction of the right engine hanger col-
lar (clutch cable stay), left engine hanger collar
and hanger bolts.
• Use a f loor jack or other adjustable support to
-
ENGINE HANGER COLLAR
carefu lly maneuver the engine into place.
Place the engine into the frame, and install the rear
engine hanger bolts from the left side.
Install the nuts, then tighten them loosely.
6-7
Place the front engine hanger plate and install the
three bolts from the left side.
Place the crankcase protector and insta ll the hanger
bolt from the left side.
Install the crankcase protector bolts, then tighten
them loosely.
Install the hanger nuts, then tighten them loosely.
Tighten the front engine hanger nuts to the speci-

fied torque.
Tighten the engine hanger plate nuts to the speci-

fied torque.
Tighten the rear engine hanger nuts to the specified

torque.
TORQUE: 44 N ·m (4.5 kgf·m, 33 lbf-ft)
Tighten the crankcase protector bolts.
6-8
Install the left footpeg and tighten the two bolts to
Install the right footpeg and tighten the two bolts to

TORQUE: 55 N ·m (5.6 kgf·m , 41 lbf·ft)
Connect the clutch cable.
Install the kickstarter pedal and tighten the bolt to

TORQUE: 12 N ·m (1 .2 kgf·m, 9 lbf·ft)
6-9
Install the drive sprocket onto the counter shaft.
Instal l the fixing plate and tighten the bolts.
Connect the alternator and ignition pulse generator

connector.
IGNITION PULSE
GENERATOR CONNECTOR ........
Install the tank setting rubber against the rubber
stopper. RUBBER
Connect the crankcase breather hose to the crank-

case. iREATHER HOSE
6-10
- Muffler (page 2-7)
- Seat, Side cover (page 2-3)
Connect the spark plug cap.
Pour the recommended engine oil to the proper
level (page 3-14).
Adjust the drive chain slack (page 3-17).
Adjust the clutch lever free play (page 3-22).
6-11
7. CYLINDER HEAD/VALVES
COMPONENT LOCATION .......................... 7-2 CYLINDER HEAD INSPECTION ............... 7-11 •
SERVICE INFORMATION ........................... 7-3 VALVE GUIDE REPLACEMENT ,.............. 7-13
TROUBLESHOOTING ................................. 7-5 VALVE SEAT INSPECTION/

REFACING ,................................. ............... 7-13
CYLINDER COMPRESSION TEST .. ,........... 7-6
CYLINDER HEAD ASSEMBLY ................. 7-16
CAMSHAFT REMOVAL , ............................. 7-6
CYLINDER HEAD INSTALLATION·,......... 7-17
CYLINDER HEAD REMOVAL ................... 7-10
CAMSHAFT INSTALLATION ................... 7-18
CYLINDER HEAD DISASSEMBLy ............ 7-10
7-1
COMPONENT LOCATION
12 N·m (1.2 kgf·m, 9 lbf.ft)
/
10 N·m (1.0 kgf·m , 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
14 N·m (1.4 kgf·m, 10 lbf·ft)
7-2
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, and camshaft.
• The camshaft can be removed with the engine in the frame, but the engine must be removed from the frame to perform
other service.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
tions.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
• Rocker arm lubricating oil is fed through the oil passage in the cylinder head. Clean the oil passage before assembling
the cylinder head.
• Be carefu l not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
SPECIFICATIONS
Unit: mm (in)
,_=
c ·y- l~i-n-d~e-r - - - ~ I -C
~R~F~1-0-0·F
~ 1,176 kPa (12.0 kgf/cm2 , 171 psi)
compression I at 1,000 rpm
-
1,176 kPa (12.0 kgf/cm 2 , 171 psi)
1-~,~~-~-'---
~ RF80F
I at 1,000 rpm
-
Cylinder head warpage - 0. 10 (0.004)
Valve and I Valve clearance IN 0.05(0.002) -
valve guide EX 0.05(0.002) -
I Valve stem O.D. IN 5.450 - 5.465 (0.2145 - 0.2151) 5.420 (0.2134)
EX 5.430 -5.445 (0.2137 - 0.2143) 5.400 (0.2126)
I Valve guide I.D. IN 5.475 - 5.485 (0.2155 - 0.2159) 5.50 (0.217)
EX 5.475 - 5.485 (0.2155 - 0.2159) 5.50 (0.217)
Stem to guide IN 0.010 - 0.035 (0.0004 - 0.0013) 0.08 (0.003)
I clearance
Valve seat width
EX
IN/EX
0.030 - 0.055 (0.0012 - 0.0022)
1.70(0.06}
0.10 (0.004)
2.1 (0.08)
Valve spri ng Inner IN/EX 28.05 (1 . 104) 27.6 (1.09)
free length Outer IN/EX 34.80 (1.370) 33.7 (1.33)
Rocker arm/ Rocker arm I.D. IN/EX 10.000 - 10.015 (0.3937 - 0.3943) 10.1 (0.40)
shaft Rocker arm shaft 9.91 (0.390)
IN/EX 9.978 - 9.987 (0.3928 - 0.3932)
O.D.
Rocker arm to 0.013 - 0.037 (0.0005- 0.0014) 0.08 (0.003)
IN/EX
shaft clearance
Camshaft Cam lobe height CRF100F IN 27.860 - 28.040 (1.0968 - 1.1039) 27.80 (1.094)
EX 27.776 - 27.950 (1.0935 - 1.1004) 27.70 (1.091)
CRF80F IN 28.007 - 28.207 (1. 1026 - 1.1105) 27.95 (1.100)
EX 27.825- 28.025 (1.0955-1.1033) 27.75 (1.093)
Journal 0 .D. CRF100F IN 19.950 - 19.968 (0.7854 - 0.7861) 19.90(0.783)
E X 19.950 - 19.968 (0.7854 - 0.7861) 19.90(0. 783)
CRF80F IN 19.950 - 19.968 (0.7854 - 0.7861) 19.90(0.783)
E X 19.950- 19.968 (0.7854- 0.7861) 19.90(0.783)
Runout - 0.03 (0.001)
Camshaft holder I.D. CRF100F 20.008 - 20.063 (0.7877 -0.7899) 20.15(0.793)
CRF80F 20.008 - 20.063 (0.7877 - 0.7899) 20.15(0.793)
Oil clearance CRF100F 0.040 - 0.113 (0.0016 - 0.0044) 0.20(0.008)
CRF80F 0.040 - 0.113 (0.0016 - 0.0044) 0.20(0.008)
TORQUE VALUES
Cylinder head cover bolt 12 N·m (1.2 kgf·m , 9 lbf.ft)
Camshaft holder nut 20 N·m (2.0 kgf·m, 14 lbf·ft)
Cam sprocket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Cam chain tensioner adjusting bolt lock nut 12 N·m (1.2 kgf,m, 9 lbf·ft)
Spark plug 14 N·m (1.4 kgf·m, 10 lbf·ft)
Valve adjusting screw lock nut 10 N·m (1.0 kgf·m, 7 lbf·ft)
7-3
TOOLS
Valve spring compressor Seat cutter, 24.5 mm (EX, 45°) Seat cutter, 27.5 mm (IN, 45°)
07757-0010000 07780-0010100 07780-0010200
or equivalent commercial ly avai l- or equivalent commercial ly avail-

able in U.S.A. able in U.S.A.
Flat cutter, 22 mm (EX, 32°) Flat cutter, 25 mm (IN, 32°) Interior cutter, 22 mm (IN/EX, 60°)
07780-0012601 07780-0012000 07780-0014000
~
u
or equivalent commercially avail- or equivalent commercially avail- or equivalent commercially avai l-
able in U.S.A. able in U.S.A. able in U.S.A.
Valve guide driver, 5.5 mm Valve guide reamer, 5.485 mm Cutter holder, 5.5 mm
07742-0010100 07984-0980001 07781-0010101
or 07984-0980000 (U.S.A. only) or equivalent commercial ly avail-

able in U.S.A.
7-4
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or
by tracing engine noises to the top-end with a sounding rod stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky,
check for a seized piston ring (page 8-5).
Low compression
• Valves:
- Incorrect valve adjustment
- Burned or bent valve
- Incorrect valve timing
- Weak valve spring
- Uneven valve seating
• Cylinder head:
- Leaking or damaged head gasket
- Warped or cracked cylinder head
• Worn cylinder, piston or piston rings (page 8-6)
High compression
• Excessive carbon build-up on piston crown or on combustion chamber
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Worn cylinder, piston or piston rings (page 8-6)
Excessive noise
• Cylinder head:
- Incorrect valve adjustment
- Sticking valve or broken valve spring
- Damaged or worn camshaft
- Loose or worn cam chain
- Worn or damaged cam chain
- Worn or damaged cam chain tensioner
- Worn cam sprocket teeth
- Worn rocker arm and/or shaft
• Worn cylinder, piston or piston rings
Rough idle
• Low cylinder compression
Overheating
• Excessive carbon build-up on the piston head or combustion chamber
Knocking or abnormal noise
• Excessive carbon build-up
7-5
CYLINDER COMPRESSION TEST
Warm up the engine.
Stop the engine and remove the spark plug.
Connect a compression gauge.
open the throttle grip fu lly and crank the engine
with the kickstarter until the gauge reading stops
rising.
Operate the kickstarter pedal several times.
COMPRESSION PRESSURE:
CRF100F: 1,176 kPa (12.0 kg/cm 2 , 171 psi) at 1,000
rpm
CRFSOF: 1,176 kPa (12.0 kg/cm 2, 171 psi) at 1,000
rpm
Low compression can be caused by:

- Blown cylinder head gasket
- Improper valve adjustment
- Valve leakage
- Worn piston ring or cylinder (Section 8)
High compression can be caused by:
- Carbon deposits in combustion chamber or on
piston head
CAMSHAFT REMOVAL
Remove the following .
- Side cover (page 2-3)
- Seat (page 2-3)
Remove the two bolts and cylinder head cover.
Loosen the cam chain tensioner adjusting bolt lock

nut and adjusting bolt.
7-6
Release the cam chain tension by pushing the chain
tensioner with a screwdriver, then tighten the
adjusting bolt and lock nut.
If you will be remove the cylinder head, remove the

cam chain tension adjuster set plate bolt, set plate
and adjuster to release the cam chain tension at this
time.
l oosen the cam sprocket bolt, turn the crankshaft

counterclockwise one full turn (360°) and Loosen
the other cam sprocket bolt.
Turn the cam sprocket with its bolt holes in parallel

to the cylinder head surface and "O " mark facing
up.
7-7
Remove the four camshaft holder nuts and washers
in a crisscross pattern in 2 • 3 steps.
Remove the camshaft holder.
Remove the camshaft and dowel pins.

Suspend the cam chain with a piece of wire to keep
it from falling into the crankcase.
Remove the cam sprocket from the camshaft.
CAM LOBE HEIGHT

Inspect the rocker Inspect the cam lobe surfaces for wear, scoring or
arm sliding surface evidence of insufficient lubrication.
if the cam lobe is Measure each cam lobe height using a micrometer.
worn or damaged.
SERVICE LIMITS:
CRF100F: IN: 27.80 mm (1.094 in}
EX: 27.70 mm (1.091 in)
CRFSOF: IN: 27.95 mm (1 .100 in)
EX: 27.75 mm (1 .093 in)
CAMSHAFT JOURNAL
Inspect the 01/ pas- Inspect the camshaft journal surfaces for wear, scor-
sages and camshaft ing or evidence of insufficient lubrication.
holder for wear or Measure the 0 .0 . of each camshaft journal using a
damage if the 1our- micrometer.
nal surface is worn
or damaged.
7-8
CAMSHAFT HOLDER
Tap the camshaft holder with a plastic hammer to
remove the intake rocker arm shaft. ROCKER ARMS "EX" SHAFT
Temporarily instal l an 8 mm bolt into the exhaust

rocker arm shaft and pull the shaft out of the holder.
Remove the rocker arms.
If anv rocker arms Inspect the rocker arms and shafts for wear or dam-
require servicing or age. "EX" SHAFT
Jf.j.
replacement, Measure the rocker arm I.D.
inspect the cam
lobes for scoring, SERVICE LIMIT: 10.1 mm (0.40 in)
chipping or flat
spots. Measure the rocker arm shaft O.D.
Calculate the rocker arm-to-shaft clearance.
CAMSHAFT OIL CLEARANCE

Wipe any oil from the journals of the camshaft, cyl-
inder head and camshaft holders.
Lay a strip of plastigauge lengthwise on top of each
camshaft journal.
Do not the cam- Install the camshaft holder and tighten the nuts in a
shaft when using crisscross pattern in 2 - 3 steps.
ptast,gauge.
TORQUE: 20 N ·m (2.0 kgf·m , 14 lbf.ft)
7-9
Remove the camshaft holder and measure the
width of each plastigauge.
The widest thickness determines the oil clearance.
When the service limits are exceeded, replace the
camshaft and recheck the oil clearance.
Replace the cylinder head and camshaft holders as
a set if the clearance still exceeds the service limit.
CYLINDER HEAD REMOVAL

Remove the following: SET PLATE ADJUSTER
- Engine (page 6-4)
- Camshaft (page 7-6)
Remove the carburetor intake pipe.
Remove the cam chain tensioner set plate bolt, set
plate and adjuster.
Do not allow the Remove the cylinder head mounting bolt and the
cam chain to fall cylinder head.
mto the crankcase;
hold the cam cham
with a piece of
wire.
Remove the gasket and dowel pins.
CYLINDER HEAD DISASSEMBLY

To prevent Joss of Remove the valve spring cotters using a valve
tension. do not spring compressor.
compress the valve
springs more than TOOL:
necessary to Valve spring compressor 07757-0010000
remove the cotters.
7-10
Mark all parts dur- Remove the following:
ing disassembly so
- Spring retainer SPRING SEATS
they can be placed
- Outer and inner va lve springs
back m their ongmal
- Valve
locations.
- Stem seal INNER SPRING\
- Valve spring seat
RETAINER\ Q
~ VALVE
~ STEM SEAL
• OUTER SPRING
.....___ COTTERS
SPRING SEATS
IN NER SPRING\
RETAINER\ © ~=e~=
\ i I .,_____ VALVE
'~ ~ STEM SEAL

~ OUTER SPRING
COTTERS
CYLINDER HEAD INSPECTION

CYLINDER HEAD
Avoid damaging the Remove the carbon deposits from the combustion
gasket surface. chamber.
Clean off any gasket material from the cylinder head
surface.
Check the spark plug hole and valve area for cracks.
Check the cylinder head for warpage using a

straight edge and feeler gauge.
7-11
VALVE SPRING
Check the valve springs for fatigue or damage.
Measure the free length of the inner and outer va lve
springs.
SERVICE LIMITS:
Inner: 27.6 mm (1.09 in)
Outer: 33.7 mm (1.33 in)
Replace the springs if they are shorter than the ser-
vice limits.
OUTER INNER
VALVE/VALVE GUIDE
Inspect each valve for bending, burning, scratches
or abnorma l stem wear. VALVE STEM
~
Check the va lve movement in the gu ide.
Measure and record the va lve stem 0.0.
SERVICE LIMITS:
IN: 5.420 mm (0.2134 in)
EX: 5.400 mm (0.2126 in)
Ream the guides to remove any carbon deposits

before checking clea ranees.
Insert the reamer from the camshaft side of the
head and always rotate the reamer clockwise.
TOOLS:
Valve guide reamer, 5.485 mm 07984-0980001 or
07984-098000D
(U.S.A. only)
Measure and record each valve guide 1.0.

SERVICE LIMITS:
IN: 5.50 mm (0.217 in)
EX: 5.50 mm (0.217 in)
Calculate the stem-to-guide clearance.
SERVICE LIMITS:
IN: 0.08 mm (0.003 in)
EX: 0.10 mm (0.004 in)
Reface the valve If the stem-to-guide clearance exceeds the service

seats whenever the li mits, determine if a new guide with standard
valve guides are dimensions would bring the clearance w ith in toler-
reptaced(page 7-13) ance. If so, replace any guides as necessary and
ream to fit.
If the stem-to-guide clearance exceeds the service
limits with new guides, also replace the valves and
guides.
7-12
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Heat the cylinder head to 100 -150°C (212 - 300°F)
with a hot plate or oven.
To avoid burns, wear heavy gloves when handl ing
the heated cylinder head.
Support the cylinder head and drive out the valve
guides from the combustion chamber side of t he
cylinder head.
TOOL:
Valve guide driver, 5.5 mm 07742-0010100
Drive in the guides from the top of the head. VALVE GU IDE DRIVER
TOOL:
Valve guide driver, 5.5 mm 07742-0010100
Let the cylinder head cool to room temperature.
Ream the new valve gu ide after installation.

Use cutting oil on Insert the reamer from the combustion chamber
the reamer during side of the cylinder head and always rotate the
this operation. reamer clockwise.
TOOLS:
Valve guide reamer, 5 .485 mm 07984-0980001 or
07984-098000D
(U.S.A . only)
Clean the cylinder head thorough ly to remove any

metal particles.
Reface the valve seat (page 7-13).
VALVE SEAT INSPECTION/REFACING

Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to each va lve
seat .
Lap the va lves and seats using a rubber hose or
other hand-lapping tool.
7-13
Remove the valve and inspect the valve seat face.
The valve seat contact should be within the speci-
fied width and even all around the circumference.
STANDARD: 1.70 mm (0.06 in)
If the seat width is not within specification, reface
+
the valve seat(page 7-14). t
' ~
~
SEAT WIDTH
Inspect the valve seat face for:

• Uneven seat width:
- Replace the valve and reface the valve seat.
• Damaged face:
- Replace the valve and reface the valve seat.
DAMAGED FACE UNEVEN SEAT WIDTH
The valves cannot • Contact area (too high or too low)

be ground. If a - Reface the valve seat.
valve face is burned
or badly worn or if it
comacts the seat
unevenly, replace
the valve.
TOO LOW TOO HIGH
VALVE SEAT REFACING

Follow the refacing
manufacturer's
operating instruc-
tJOnS.
Valve seat cutters/grinders or equivalent valve seat
refacing equipment are recommended to correct
worn valve seats. c )/\32°
~ ~ 45'
~ 6 0'
7-14
If the contact area is too high on the valve, the seat
must be lowered using a 32° flat cutter.
If the contact area is too low on the valve, the seat
CONTA~CTTOO
HIGH ::3~~g,siAT
must be raised using a 60° interior cutter.
- .
L___:__32°
CONTACT TOO LOW
~-
" ' ~LDSEAT
""'~ WIDTH
L soo
Reface che seat Use a 45° cutter to remove any roughness or irregu-
ROUGHNESS
with a 45-degree larities from the seat.
cutter whenever a
valve guide is TOOLS:
replaced. Seat cutter, 27.5 mm (45° IN) 07780-0010200
Seat cutter, 24.5 mm (45° EX) 07780-0010100
Cutter holder, 5.5 mm 07781-0010101
or equivalent commercially available in U.S.A.
Use a 32° cutter to remove the top 1/4 of the existing

valve seat material.
TOOLS:
Flat cutter, 25 mm (32° IN) 07780-0012000
Flat cutter, 22 mm (32° EX) 07780-0012601
32° !...__
· _ _
Use a 60° cutter to remove the bottom 1/4 of the old

seat.
TOOLS:
Interior cutter, 22 mm (60° IN/EX)07780-0014000
7-15
Using a 45° seat cutter, cut the seat to the proper
width.
Make sure that all pitting and irregu larities are
removed.
Refinish if necessary. ~ - 7 mm (0.06 in)
45o L
After cutting the seat, apply lapping compound to

the va lve face, and lap the valve using light pres-
sure.
• Excessive lapping pressure may deform or dam-
age the seat.
• Change the ang le of lapping tool frequently to
prevent uneven seat wear.
• Do not allow lapping compound to enter the
guides.
After lapping, wash all residual compound off the
cylinder head and valve.
CYLINDER HEAD ASSEMBLV

Clean t he cylinder head assembly w ith solvent and
blow out all oil passages with compressed air. CRF100F SHOWN:
Install the valve spring seats and new stem seals.

Lubricate each valve stem and valve guide inner
surface with molybdenum disulfide oil.
Install the valves into the valve gu ides while turn ing
it slowly to avoid damage to the stem seal.
Install the valve springs.
Insta ll the valve spring retainers.

Grease the cotters Install the valve cotters using the special tool as
to ease mstallation. shown.
NOTE:
To prevent Joss of tension, do not compress the
valve spring more than necessary.
TOOL:
Valve spring compressor 07757-0010000
7-16
Support the cylin- Tap the valve stems gently with two plastic ham-
der head above the mers as shown to seat the valve cotters firmly.
work bench sur·
face to prevent pos-
sible valve damage.
CYLINDER HEAD INSTALLATION

Clean off any gasket material from the cylinder sur-
face.
Install the new gasket and dowel pins.
Loosen t he tensioner adjusting bolt lock nut and

adjusting bolt.
Push down on the tensioner rod with a screwdriver
and retighten the bolt (page 7-7).
Tighten the lock nut.
Install the cylinder head.

Install the cam chain tension adjuster with a new 0 -
ring.
7-17
CAF100F: Install the intake pipe with a new 0-ring and gasket. -
INTAKE PIPE
CAFBOF. Install the intake pipe with a new gasket.
Tighten the two intake pipe bolts securely.

SET PLATE BOLTS
Install the cam chain tensioner adjuster set plate
and bolt.
Install the cylinder head mounting bolt, but do not
tighten.
The cam chain tension adjuster has an eccentric

cam to control the tension of cam chain. PUNCH MARK
To loosen the cam chain tension:

- Loosen the cam chain tension adjuster set plate
bolt.
- Turn to the adjuster to the punch mark facing up.
ADJUSTER
ADJUSTER
CAMSHAFT INSTALLATION
Install the rocker arms and rocker arm shafts to the "IN" SHAFT
camshaft holder. CAMSHAFT
Align the cutout of the intake rocker arm shaft with
the bolt hole as shown.
Push the exhaust rocker arm shaft in completely.
"'~ BOLT HOLE
HOLDER
~
"EX" SHAFT
"IN" SHAFT
7-18
Coat the camshaft journals with molybdenum
disulfide grease.
Install the cam sprocket to the camshaft with its "O"
mark facing up and camshaft lobes facing down .
Install the dowel pins.
Make sure that the cam chain tension adjuster is set

to the loosen setting ( page 7-18).
Turn the crankshaft counterclockwise and align the
"T" mark on the flywheel with the index mark on the
left crankcase.
Install the cam chain onto the cam sprocket with

cam sprocket bolt holes in paralle l to the cylinder
head surface and " O " mark facing up.
Insta ll the camshaft holder assembly and washers
over the cylinder head, then tighten the camshaft
holder mounting nuts to the specified torque.
TORQUE: 20 N ·m (2.0 kgf,m, 14 lbf.ft)
Tighten the cylinder head mounting bolt.
Install the dowel Tighten the cam sprocket bolts to the specified
bolt (black) on the torque.
intake side.
TORQUE: 12 N ·m (1.2 kgf·m, 9 lbf.ft)
7-19
Loosen the lock nut and adjusting bolt.
The cam chain adjuster sets automatically when the
adjusting bolt is loosened.
When nghtening After adjustment, tighten the lock nut to the speci-
the lock nut. hold fied torque.
the adJusting bolt to TORQUE: 12 N ·m (1.2 kgf·m, 9 lbf·ft)
prevent it from turn-
ing with the lock
nut.
Pour clean engine oi l into the cylinder head oi l

pocket.
Adjust the va lve clearance (page 3-12).
Install a new gasket into the groove of the cylinder

head cover.
Install the cylinder head cover and new mounting

rubbers then tighten the two bolts to the specified
torque.
TORQUE: 12 N ·m (1.2 kgf· m, 9 lbf·ft)

- Seat (page 2-3)
- Side cover (page 2-3}
7-20
Do notrun rhe Start the engine and let it idle.
engine at high- Check the cam chain tension (page 3-15), adjust if
speed. This will pre·
vem engme dam· necessary.
age. if rhe o,! Loosen, but do not remove, the cylinder head oil
passages is check bolt and make sure oi l flows from the oil
clogged. check bolt hole.
If do not flow the engine oil from the oil check bolt
hole, inspect the related oil passage clogging.
Retighten the oil check bolt and check for no oil
leaks.
If the engine oil leaks from the oil check bolt hole,
stop the engine and replace the sealing washer w ith
a new one.
7-21
8. CYLINDER/PISTON
COMPONENT LOCATION .......................... 8-2 PISTON REMOVAL ····· .............................. · 8-6
SERVICE INFORMATION ··· ········· ··········· ···· 8-3
TROUBLESHOOTING ································· 8-4

PISTON/PISTON RING INSPECTION········ 8-7
PISTON INSTALLATION ............................ 8-9

•
CYLINDER REMOVAL ................................ 8-5 CYLINDER INSTALLATION ...................... 8-10
CYLINDER INSPECTION .. ,.......................... 8-5
8-1
CYLINDER/ PISTON
COMPONENT LOCATION
12 N·m (1.2 kgf·m, 9 lbf.ft)
8-2
CYLINDER / PISTON
SERVICE INFORMATION
GENERAL
• The engine must be removed from the frame to perform the operations in this section.
• Camshaft lubricating oil is fed to the cylinder head through an orifice in the cylinder head, cylinder and crankcase. Be
sure that this orifice is not clogged and that the 0-rings and dowel pins are in place before installing the cylinder.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
Unit: mm (in)
ITEM STANDARD S ERVICE LIMIT
Cylinder 1.0. 53.000 - 53.010 (2.0866 - 2.0870) ' 53.1 (2.09)
Taper - 0.10 (0.004) -
Out of round - 0.10 (0.004)
-
Piston, piston
- Warpage
Piston mark direction "IN" mark facing toward the intake side
0.10 (0.004)
-
ring Piston 0.0. 52.960 - 52.990 (2.0850 - 2.0862) 52.90 (2.083) I
I Piston pin bore I.D. 14.002 -14.008 (0.5513-0.5515) 14.04 (0.553)
I Piston pin 0.0.
Piston-to-piston pin clearance
13.994 - 14.000 (0.5509 - 0.5512)
0.002 - 0.014 (0.0001 - 0.0006)
13.96 (0.550)
0.020 (0.0008)
Piston ring to ring Top 0.015 - 0-:-045 (0.0006 - 0.0018) 0.10 (0.004)
- Piston ring end Top ring 0.05 - 0.20 (0.002 - 0;008) 0.4 (0.02)
-
gap ~ condring 0.05 - 0.20 (0.002 - 0.008) 0.4 (0.02)
Oil ring
-
0.20 - 0.70 (0.01 - 0.03) 0.9 (0.04)
(side rail)
Cylinder-to-piston clearance 0.010 - 0.050 (0.0004 - 0.0020) 0.10 (0.004)
Connecting rod small end 1.0. 14.012 - 14.030 (0.5517 - 0.5523) 14.05 (0.55_3_)_
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.09 (0.003)
SPECIFICATIONS (CRFSOF)
Unit: mm (in)
Cylinder 1.0. 47.500 - 47.510 (1.8701 - 1.8705) 47.6 (1.87)
- 0.10 (0.004)
-
Taper I
Out of round - 0.10 (0.004)
Warpage - 0.10-((l.004)
Piston, piston Piston mark direction "EX" mark facing toward the exhaust
ring side -
- Piston 0.0. 47.465 - 47.490 (1.8686 - 1.8697) I 47.40 ( 1.866)
Piston pin bore 1.0. 13.002 - 13.008 (0.5119 - 0.5121) 13.04 (0.513)
Piston pin 0.0. 12.994-13.000 (0.5116- 0.5118) 12.96 (0.510)
PTston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.020 (0.0008)
Piston ring to ring Top 0.015 - 0.045 (0.0006 - 0.0018) 0.10 (0.004)
groove clearance Second 0.015 - 0.045 (0.0006- 0.0018) I 0.10 (0.004)
Piston ring end Top ring 0.10 - 0.25 (0.004 - 0.010) 0.4 (0.02)
gap Second ring 0.10 - 0.25 (0.004 - 0.010) 0.4 (0.02)
Oil ring 0.20- 0.70 (0.01 - 0.03) 0.9 (0.04)
(side rail)
Cylinder-to-piston clearance 0.010 - 0.045 (0-:0004 - 0.0018) 0.10 (0.004)
Connecting rod small end 1.0. 13.016 - 13.034 (0.5124 - 0.5131) 13.04 (0.513)
Connecting rod-to-piston pin clearance 0.016- 0.040 (0.0006- 0.0016) 0.09 (0.003)
8-3
CYLINDER/ PISTON
TROUBLESHOOTING
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky,
check for a seized piston ring.
Cylinder compression is too low, or engine is hard to start
• Brown cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder or piston
Cylinder compression is too high, or engine overheats
• Excessive carbon bui ld-up on the piston head or combustion chamber
Knocking or abnormal noise
• Worn cylinder, piston and/or piston ring
• Excessive carbon build-up
• Worn piston pin hole and piston pin
• Worn connecting rod small end
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper insta llation of piston rings
• Scored or scratched piston or cylinder wall
8-4
CYLINDER/ PISTON
CYLINDER REMOVAL
Remove the cylinder head (page 7-10).
CYLINDER CAM CHAIN GUIDE
Remove the cam chain guide.
/
\
Prevent rhe cam
chain from falling Remove the cylinder.
mto the crankcase
when removing the
cylinder.
Remove the cylinder gasket and dowel pins.
Loosen the lock nut and remove the adjusting bolt.

Remove the cam chain tensioner and spring .
LOCK NUT
CYLINDER INSPECTION
Inspect the cylinder bore for scratches or wear.
Measure the cylinder I.D. at three levels in an X and
Yaxis.
Take the maximum reading to determine the cylin-
der wear.
SERVICE LIMITS:
CRF100F: 53.1 mm (2.09 in)
CRFSOF: 47.6 mm (1.87 in)
Calculate the piston-to-cylinder clearance.
Take a maximum reading to determine the clear-
ance.
Refer to page 8-7 for measurement of the piston
O.D.
8-5
CYLINDER/PISTON
Calculate the cylinder for taper and out of round at
three levels in an X and Y axis. Take the maximum y
reading to determine the taper and out of round.
SERVICE LIMITS:
Taper: 0.10 mm (0.004 in ) TOP X
Out-of-round:0.10 mm (0.004 in)
The cylinder must be rebored and an oversize pis-

MIDDLE
ton fitted if the service limits are exceeded.
The following oversize pistons are available:
CRF100F: 0.25 mm (0.010 in) BOTIOM
0.50 mm (0.020 in)
CRF80F: 0.25 mm (0.010 in)
0.50 mm (0.020 in)
0.75 mm (0.030 in)
1.00 mm (0.039 in)
The piston-to-cylinder clearance for the oversize pis-
ton must be: 0.010 - 0.040 mm (0.0004- 0.0016 in)
Inspect the top of the cylinder for warpage by plac-
ing a straight edge and a feeler gauge.
SERVICE LIMIT: 0.10 mm (0.004 in )
PISTON REMOVAL
Place clean shop towels in the crankcase to keep the
piston pin clips, or other parts from falling into the
crankcase.
Remove the piston pin clip with pliers.
Remove the piston pin out, and then remove the
piston.
8-6
CYLINDER/ PISTON
PISTON RING REMOVAL
Do not damage the Spread each piston ring and remove it by lifting it
PISTON RING
piston rings by up at a point opposite the gap.
spreading the ends
too far.
PISTON/PISTON RING INSPECTION

Remove any carbon deposits from the piston ring
grooves, using the old piston ring as shown.
Inspect the piston for damage.
Temporarily instal l the piston rings to their proper

position with the mark facing up.
Measure the piston ring-to-ring groove clearance
with the rings pushed into the grooves.
SERVICE LIMITS:
Top: 0.10 mm (0.004 in)
Second: 0.10 mm (0.004 in)
Inspect the piston ring grooves for wear or damage.
M easure the pis- Measure the piston diameter at specification given

ton diameter per· from the bottom and 90 degrees to the piston pin CRF100F:
pendicular to the hole. 10mm(0.4in)
piston pin hole. CRF80F:
PISTON O.D.MEASUREMENT POINTS: 7 mm (0.3 in)
CRF100F: 10 mm (0.4 in)
CRF80F: 7 mm (0.3 in)
+
SERVICE LIMITS:
CRF100F: 52.90 mm (2.083 in)
CRF80F: 47.40 mm (1.866 in)
Calculate the cylinder-to-piston clearance (cyl inder
I.D.; See page 8-5).
8-7
CYLINDER/PISTON
Measure and record the piston pin bore 1.0.
SERVICE LIMITS:
CRF100F: 14.04 mm (0.553 in)
CRFSOF: 13.04 mm (0.513 in)
Measure and record the piston pin 0.0. at three
points.
SERVICE LIMITS:
CRF100F: 13.96 mm (0.550 in)
CRFSOF: 12.96 mm (0.510 in)
Calculate the piston-to-piston pin clearance by sub-
tracting the piston pin 0.0. from the piston pin bore
1.0.
Measure and record the connecting rod small end
1.0.
SERVICE LIMITS:
CRF100F: 14.05 mm (0.553 in)
CRFSOF: 13.04 mm (0.513 in)
Calculate the connecting rod-to-piston pin clearance
by subtracting the piston pin 0.0. from the connect-
ing rod small end 1.0.
Push the rings into Insert the piston ring squarely into the bottom of the
the cylinder with cylinder and measure the ring end gap.
the top of the pis-
ton to be sure they SERVICE LIMITS:
are squarely in the Top: 0.4 mm (0.02 in)
cylinder. Second: 0.4 mm (0.02 in)
Oil (side rail): 0.9 mm (0.04 in)
8-8
CYLINDER / PISTON
PISTON INSTALLATION
PISTON RING INSTALLATION
SECOND RING TOP RING

("T" MARK) ("T" MARK)
SIDE R A l j -
SPACER OIL RING
SIDE RAI L
CRF100F SHOWN:
Clean the piston ring grooves thoroughly and instal l

the piston rings.
• Apply oil to the piston rings.
• Avoid piston and piston ring damage during
installation.
• Install the piston rings with the marking facing
up.
EACH PISTON RING MARK TABLE:
TOP RING I SECOND RING
CRF100F T T
CRF80F R I RN
• Do not mix the top and second rings.

• To install the oil ring, insta ll the spacer first, then
install the side rails.
Do not align the gaps in the oil rings (side rails).

Space the piston ring end gaps 120 degrees apart.
After instal lation, the piston rings should rotate
freely in the piston ring grooves.
8-9
CYLINDER/PISTON
PISTON INSTALLATION
Place a clean shop towel over the crankcase to pre-
vent the gasket material, piston pin clip or other
parts falling into the crankcase.
Be careful not to Clean the gasket surface of the crankcase thor-
damage the gasket oughly
mating surface
Apply molybdenum oil solution to the connecting

rod small end inner surfaces and piston pin outer
surfaces.
Install the piston and piston pin, using a new piston
pin clip.
Remove the shop towel.
CRF100F: • Install the piston with its "IN" mark facing the
intake side.
CRFBOF: • Install the piston with its "EX" mark facing the
exhaust side.
• Make sure that the piston pin clips are seated
securely.
• Do not align the piston pin clip's end gap with
the piston cut-out.
• Do not let the clip fall into the crankcase.
CYLINDER INSTALLATION
Install the cam chain tensioner rod into the hole in
the cylinder and hook the spring end on the cylinder
spring groove.
Install a new 0-ring on the cam chain tensioner

adjusting bolt and lock nut.
8-10
CYLINDER/ PISTON
Pul l the tensioner down, then tighten the adjusting
bolt and lock nut.
Clean off any gasket materials from the crankcase

surface.
Install the dowel pins and new gasket.
Do not fer the cam Coat the cylinder bore, piston outer surface and pis-
chain fa/I 1mo the ton ring grooves with clean engine oil.
crankcase.
Install the cylinder while compressing the piston
rings.
Avoid piston ring damage during installation.
Do not let the cam Insta ll the cam chain guide.

chain fa/1 ,nto the
Insta ll the fol lowing:
crankcase.
- Cylinder head (page 7-17)
- Camshaft (page 7-18)
- Cylinder head cover (page 7-20)
- Engine (page 6-7)
Seat, side cover (page 2-3)
8-11
9. CLUTCH/GEARSHIFT LINKAGE
COMPONENT LOCATION .......................... 9-2 CLUTCH ................. ..................................... 9-7
•
SERVICE INFORMATION .......................... · 9-3 PRIMARY DRIVE GEAR ............................ 9-10
TROUBLESHOOTING ................................. 9-4 GEARSHIFT LINKAGE .............................. 9-12
RIGHT CRANKCASE COVER REMOVAL···9-5 RIGHT CRANKCASE COVER

INSTALLATION ........................................ 9-14
9-1
COMPONENT LOCATION
30 N·m (3.0 kgf·m, 22 Ibf.ft)
39 N·m (4.0 kgf·m,

29 lbf•ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
9-2
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the clutch, gearshift linkage and right crankcase cover. These services can be per-
formed with the engine installed in the frame.
SPECIFICATIONS
Unit: mm (in)
~ tch lever free play 10 - 20 (3/8 - 3/4) -
Clutch spring free length CRF100F 31.9 (1.25) 29.5 (1.16)
CRF80F 27.6 (1.09) 25.5 (1.00)
Clutch disc thickness CRF100F 2.92 - 3.08 (0.115 - 0.121) 2.7(0.11)
CRF80F 2.90 - 3.00 (0.114 - 0.118) 2.5 (0.10)
Clutch plate warpage - 0.20 (0.008) I
TORQUE VALUES
Primary drive gear lock nut 39 N·m (4.0 kgf.m, 29 lbf·ft) Apply oil to the threads and seating surface.
Stopper arm pivot bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
Shift return spring pin 30 N·m (3.0 kgf·m, 22 lbf·ft)
Foot peg mounting bolt 55 N·m (5.6 kgf.m, 41 lbf·ft)
Kickstarter pedal pinch bolt 12 N·m (1.2 kgf·m, 9 lbf-ft)
TOOL
Gear holder, M1.5

07724-0010200
or 07724-001A200 (U.S.A. only)
9-3
CLUTCH/GEARSHIFT LINKAGE
TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the clutch lever free play.
Clutch lever hard to pull in
• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Fau lty clutch lifter plate bearing
Clutch w ill not disengage or motorcycle creeps with clutch disengaged
• Too much clutch lever free play
• Clutch plate warped
• Oil level too high, improper oil viscosity, or additive used
Clutch slips
• Clutch lifter sticking
• Worn clutch discs
• Weak clutch springs
• No clutch lever free play
• Check for oil additive
Hard to shift
• Misadjusted clutch cable
• Damaged or bent shift fork
• Bent shift fork shaft
• Incorrect engine oi l viscosity
• Incorrect gearshift spindle assembly
• Damaged shift drum cam grooves
Transmission jumps out of gear
• Worn shift drum stopper arm
• Worn or broken gearshift spindle return spring
• Worn gear dogs or slots
Gearshift pedal will not return
• Weak or broken gearshift spind le return spring
• Bent gearshift spindle
9-4
RIGHT CRANKCASE COVER REMOVAL
Remove the bolt and kick starter pedal.
Disconnect the clutch cable.
Remove the two bolts and right foot peg.
Loosen che nght Remove the nine bolts and ri ght crankcase cover.
crankcase cover
bolt in a crisscross
pattern ,n 2 - 3
steps.
9-5
Remove the oil strainer screen and clean it (page 3-
15).
DISASSEMBLY
Remove the clutch adjusting screw lock nut.
Remove the clutch adjusting lever, 0-ring and

clutch adjusting screw.

- Cotter pin
- Clutch lifter cam
- Clutch lever spring
- Clutch lever
- 0-ring
9-6
CLUTCH
REMOVAL
- Clutch lifter pin
Loosen the clutch - Clutch spring bolts
spring bolts ma - Clutch lifter plate
crisscross pattern - Clutch springs
in 2 - 3 steps.
- Snap ring
- Clutch center
- Clutch discs
- Clutch plates
- Clutch pressure plate
- Spline washer
- Clutch outer
INSPECTION
Clutch lifter bearing
Turn the inner race of the lifter bearing with your
LIFTER PLATE
finger.
The bearing should turn smoothly and freely with-
out excessive play.
Also check that the bearing fits tightly in the clutch
outer cover.
If necessary replace the bearing.
LIFTER BEARING
9-7
Clutch spring
Measure the clutch spring free length .
SERVICE LIMITS:
CRF100F: 29.5 mm (1.16 in)
Clutch disc
Replace the clutch Replace the clutch discs if they show signs of scor-
d,scs and plates as ing or discoloration.
a set. Measure the thickness of each disc.
SERVICE LIMITS:
CRF100F: 2.7 mm (0.11 in)
Clutch plate
Replace the clutch Check the plates for discoloration.
discs and plates as
Check each clutch plate for warpage on a surface
aser.
plate using a feeler gauge.
• Warped clutch plates prevents the clutch from
disengaging properly.
• Clutch plates should be replaced as a set.
Clutch outer
Check the slots in the clutch outer for nicks, cuts or CLUTCH OUTER
damage caused by the clutch discs.
Check the gear teeth of the primary driven gear for
wear or damage.
Replace if necessary.
SLOTS
9-8
Clutch center
Check the grooves of the clutch center for damage
CLUTCH CENTER
or wear caused by the clutch plates.
Replace if necessary.
INSTALLATION
Install the clutch outer and spline washer.
Coat the clutch discs with clean engine oil.

PRESSURE PLATE
CRF700F. Assemble the pressure plate, four clutch discs, three
clutch plates and clutch center, then install them in
t he clutch outer.
CRFBOF. Assemble the pressure plate, three clutch discs, two
clutch plates and clutch center, then install them in
the clutch outer.
CLUTCH PLATES
CRF100F SHOWN:
Install the snap ring.
9-9
Install the clutch springs and lifter plate.
Tighten the lifter Install and tighten the clutch spring bolts.
plate bolts in a Install the lifter plate bearing and clutch lifter pin.
crisscross pattem
,n 2 or 3 steps. Install the right crankcase cover (page 9-14).
PRIMARY DRIVE GEAR

REMOVAL
- Oil pump (page 4-5)
Remove the oil through and spring from the crank-
shaft.
Attach the gear holder between the primary drive

and driven gear as shown.
TOOLS:
Gear holder, M1.5 07724-0010200 or
07724-001A200
(U.S.A. only)
Remove the lock nut.
Remove the clutch assembly (page 9-7).

- Oil through drive pin
- Washer
- Primary drive gear
9-10
Remove the collar.
INSTALLATION
Install the collar.

- Primary drive gear
- Washer
- Oil through drive pin
Install the clutch assembly (page 9-9).
Attach the gear holder between the primary drive

and driven gear as shown.
TOOL:
Gear holder, M1 .5 07724-0010200 or
07724-001 A200
(U.S.A. only)
Apply oil to the Install and tighten the lock nut to the specified
threads and seat- torque.
mg surface
TORQUE: 39 N ·m (4.0 kgf,m, 29 lbf.ft)
9-11
Install the oil through and spring.
Install the following.
- Right crankcase cover(page 9-14)
GEARSHIFT LINKAGE
REMOVAL
Remove the nut, bolt and gearshift pedal.
- Clutch assembly (page 9-7)

- Stopper plate bolt
- Stopper arm pivot bolt
- Stopper arm
- Return spring
Remove the shift drum stopper plate and dowel

pins.
9-12
Pull the gearshift spindle out of the crankcase.
INSPECTION
Check the gearshift spindle for wear, damage or
GEARSH IFT SPINDLE
bends and replace if necessary.
Check the return spring for fatigue or damage and
INSTALLATION
Install the gearshift spindle into the crankcase, so
that the shift return spring pin is positioned
between the spring ends.
If you remove the shift return spring pin, tighten it
to the specified torque.
TORQUE: 30 N ·m (3.0 kgf,m, 22 lbf·ft)
Install the dowel pins into the shift drum holes.

Install the shift drum stopper plate aligning the
stopper plate holes with the dowel pins as shown.
9-13
Install and tighten the shift drum stopper plate bolt.
Install the stopper arm, return spring and tighten
the stopper arm pivot bolt to the specified torque.
Install the gearshift pedal, bolt and tighten the nut.

- Clutch (page 9-9)
- Right crankcase cover
RIGHT CRANKCASE COVER

INSTALLATION
ASSEMBLY
Insta ll the new 0-ring onto the clutch lever.
CLUTCH LEVER
\
0-RING "

- Clutch lever
- Clutch lever spring
- Clutch lifter cam
Install the new cotter pin into th e clutch lever.
9-14
Insta ll the new 0-ring onto the clutch adjusting
screw.
Install the clutch adjusting lever to the right crank-
case cover.
Install the clutch adjusting screw lock nut.
INSTALLATION
Be careful not toClean off any gasket material from the right crank-
damage the gasket case cover mating surface.
mating surface. Install the dowel pins and new gasket.
Install the right crankcase cover.

Tighten the right crankcase cover nine bolts in a
crisscross pattern in 2 or 3 steps.
9-15
Install the right foot peg and tighten the foot peg
mounting bolts to the specified torque.
Connect the clutch cable.
Install the kickstarter pedal and tighten the bolt to

TORQUE: 12 N·m (1.2 kgf·m , 9 lbf·ft)
Pour the recommended engine oil (page 3-13) and
make sure there are no oil leaks.
Adjust the clutch (page 3-22).
9-16
10. ALTERNATOR
COMPONENT LOCATION ........................ 10-2 STATOR .................................................... 10-5
SERVICE INFORMATION························· 10-3 STATOR BASE·········································· 10-7
LEFT CRANKCASE COVER REMOVAL ... 10-4
FLYWHEEL ................................................ 10-4

~i~;~t.Trfit~~.~-~-~~~····· ················· 10-8 Ill
10-1
ALTERNATOR
COMPONENT LOCATION
6 N·m (0.6 kgf·m,

4.3 lbf.ft)
64 N·m (6.5 kgf·m, 47 lbf.ftl
10-2
ALTERNATOR
SERVICE INFORMATION
GENERAL
• This section covers the remova l and installation of the flywheel, alternator and ignition pulse generator. These services
can be done with the engine installed in the frame.
• For alternator inspection and troubleshooting, refer to section 14.
TORQUE VALUES
Flywheel nut 64 N·m (6.5 kgf·m, 47 lbf·ft) Apply oil to the threads and seating sur-
face.
Pulse generator mounting bolt 6 N·m (0.6 kgf·m, 4.3 lbf.ft) Apply a locking agent to the threads.
TOOLS
Universal holder Flywheel pu ller

07725-0030000 07733-0010000
or 07933-0010000
10-3
ALTERNATOR
LEFT CRANKCASE COVER REMOVAL
Loosen the left Remove the fi ve SH bolts and left crankcase cover.
crankcase cover
bolts in a cnss·
cross pattern in
several steps.
Remove the gasket.
FLYWHEEL
REMOVAL
Remove the left crankcase cover.
Hold the flywheel with the universal holder, then
remove the flywheel nut and washer.
TOOL:
Universal holder 07725-0030000
Remove the flywheel using the flywheel puller.
TOOLS:
Flywheel puller 07733-0010000or
07933-0010000
10-4
ALTERNATOR
INSTALLATION
Clean any oil from the crankshaft and flywheel
tapered areas.
Instal l t he flywheel by aligning the woodruff key on
the crankshaft with the flywheel keyway.
Apply engine oil to the flywheel nut threads and

seating surface.
Hold the f lywheel with the universal holder and
install the washer and flywheel nut.
TOOL:
Universal holder 07725-0030000
Tighten the flywheel nut to the specified torque.
TORQUE: 64 N ,m (6.5 kgf,m, 47 lbf·ft)
Install the left crankcase cover (page 10-8).
STATOR
REMOVAL
Remove the fuel tank (page 2-4).
Remove the tank setting rubber.
Disconnect the ignition pu lse generator connector

and alternator connector.
Remove the fl ywheel(page 10-4).
10-5
ALTERNATOR
Remove the two stator mounting bolts.
Release the wire grommet from the crankcase

groove.
CRFIOOF' Remove the pu lse generator mounting bolt, stator
and pulse generator.
CRFBOF: Remove the two pulse generator mounting bolts,
stator and pulse generator.
INSTALLATION
Apply a locking agent to the pulse generator mount-
ing bolt threads.
CRFIOOF: Install the pu lse generator and tighten the bolt to
the specified torque, then set the wi re grommet into
the crankcase groove.
CRFBOF: Install the pu lse generator and tighten the two bolts
to the specified torque, then set the wire grommet
into the crankcase groove.
TORQUE: 6 N ·m (0.6 kgf·m, 4 .3 lbf.ft)
Instal l the stator and tighten the stator mounting

bolts.
Instal l the flywheel (page 10-5).
10-6
ALTERNATOR
Connect the alternator and ignition pulse generator
connector.
Install the tank setting rubber against the rubber

stopper.
Install the fuel tank (page 2-4).
STATOR BASE
REMOVAL
Remove the flywheel (page 10-4).
Remove the stator (page 10-5).
Remove the woodruff key from the crankshaft.
CRFIOOF: Remove the three screws and stator base .
CRF80F: Remove the two screws and stator base.
OIL SEAL REPLACEMENT

(CRF100F ONLY)
Remove the 0 -ring and oil seal from the stator base.
Apply oil to the new oil seal and 0-ring, and install $'~
them. OIL SEAL
'STATOR BASE
10-7
ALTERNATOR
INSTALLATION
CRFIOOF: Install the stator base and tighten the three screws.
CRFBOF: Install the stator base and tighten the two screws.
Install the woodruff key.
Instal l the stator (page 10-6).
Install the flywheel (page 10-5).
LEFT CRANKCASE COVER INSTALLATION

Install the new gasket to the left crankcase.
Install the left crankcase cover and tighten the five

SH bolts in a crisscross pattern in several steps.
10-8
11. CRANKSHAFT/TRANSMISSION/KICKSTARTER
COMPONENT LOCATION ····· ········ .... ······· 11-2 TRANSMISSION REMOVAL/

DISASSEMBLY ............. ··············· ............ · 11 -9
SERVICE INFORMATION ......................... 11-3
CRANKCASE BEARING
TROUBLESHOOTING ............................... 11-6 REPLACEMENT ······································ 11-12
CRANKCASE SEPARATION ········· ............ 11-7
CRANKSHAFT ........................................... 11-8

KICKSTARTER ........................................ 11 -18
CRANKCASE ASSEMBLY ...................... 11-19
11-1
COMPONENT LOCATION
11-2
CRANKSHAFT/ TRANSMISSION/ KICKSTARTER
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the crankshaft, transmission and kickstarter.
• The following parts must be removed before separating the crankcase.
- Alternator (page 10-4)
- Clutch/gearshift linkage (page 9-7)
- Cylinder head (page 7-1O)
- Cylinder/piston (page 8-5)
- Engine (page 6-4)
SPECIFICATIONS(CRF1 OOF)
Unit: mm (in)
I Crankshaft Runout -'-= Right

Left
0.035 (0.0014)
0.020 {0.0008)
0.085 (0.0033) '
0.070 (0.0028)
<-connecting rod big end radiai- 0.010 (0.0004)
0 - 0.008 (0 - 0.0003)
clearance
Connecting rod big end side 0.60 (0.024)
0.10 - 0.35 (0.0039 - 0.0138)
clearance
Transmission Gear I.D. M4,M5 17.016 - 17.034 (0.6699 - 0~6706) 17.05 (0.671)
C1 20:-662 - 20.643 (0.8135 - 0.8127) 20.66 (0.813)
C2 19.526 - 19.541 (0.7685 - 0.7693) 19.56 (0.776i
C3 18.016 - 18.034 (0.7093 - 0.7100) 18.05 (0.71, r - l
Bushing O.D. C1
- 20.559 - 20.580 (0.8094 - 0.8102) 20.54 (0.809)
0.042 - 0.084 (0.0017 - 0.0033)
- 0.12 (0.005)
Gear to bushing clea~ce (C1)
Mainshaft 0.0. M4,M5 16.966 - 16.984 (0.6680 - 0.6687) 16.95 (0.667)
'"countershaft 0.D. C2 19.459 - 19.480 (0.7661 - 0.7669) I 19.44 (0.765)-
C3 17.966 -17.984 (0.7073 - 0.7080) I 17.95 (0.707)-
Gear to shaft M4 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
I
clearance C2 0.040 - 0.082 (0.0016 - 0.0032) 0.12 (0.005)
C3 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
Shift fork, Shift fork shaft 0.D. 11.976 - 11.994 (0.4715 - 0.4722) 11.96 (0.471)
I shift fork shaft Shift fork l.D. 12.000 - 12.018 (0.4724- 0.4731) 12.05 (0.474)
Shift fork claw thickness 4.93 - 5.00 (0.194 - 0.197) I 4.70 (0.19)
Kickstarter Spindle 0.0. 17.959 - 17.980 (0.7070 - 0.7079) I 17.88 (0.704)
Pinion I.D. 18.020-18.041 (0.7094- 0.7103) 18.06 (0.711)
11-3
SPECIFICATIONS(CRFSOF)
Unit: mm (in)
Left 0.020 (0.0008) 0.070 (0.0028)
0 - 0.008 (O - 0.0003) 0.010 (0.0004)
clearance
0.10 - 0.35 (0.0039 - 0.0138) 0.60 (0.024)
clearance
Transmission Gear 1.0. M4, M5 17.016-17.034 (0.6699 - 0.6706) 17.05 (0.671)
C1 17.022 -17.043 (0.6702 - 0.67 10) 17.06 (0.672)
C2 19.520 - 19.541 (0.7685 - 0.7693) 19.56 (0.770)
C3 17.016-17.034 (0.6699 - 0.6706) 17.05 (0.671)
Bushing 0.0. C1 20.559 - 20.580 (0.8094 - 0.8102) 20.54 (0.809)
Gear to bushing clearance (C1) 0.042 - 0.084 (0.0017 - 0.0033) 0.12 (0.005)
Mainshaft 0.0. M4,M5 16.966 - 16.984 (0.6680 - 0.6687) 16.95 (0.667)
Countershaft 0.0. C2 19.459 - 19.480 (0.7661 - 0.7669) 19.44 (0.765)
C3 16.966 - 16.984 (0.6680 - 0.6687) 16.95 (0.667)
Gear to shaft M4 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
clearance C2 0.040 - 0.082 (0.0016 - 0.0032) 0. 12 (0.005)
C3 0.032 - 0.068 (0.0013 - 0.0027) 0.10 (0.004)
Shift fork, shift Shift fork shaft 0 .0. 11.976 - 11.994 (0.4715 - 0.4722) 11.96 (0.471)
fork shaft Shift fork 1.0 . 12.000 - 12.018 (0.4724 - 0.4731) 12.05 (0.474)
Shift fork claw thickness 4.93 - 5.00 (0. 194 - 0.197) 4.70 (0. 19)
Kickstarter Spi ndle 0.0. 17.959 - 17.980 (0.7070 - 0.7079) 17.88 (0.704)
Pinion 1.0. 18.020- 18.041 (0.7094 - 0.7 103) 18.06 (0.711 )
11-4
TOOLS
Bearing remover set, 12 mm Bearing remover head, 12 mm Bearing remover shaft

07936-1660101 07936-1660110 07936-1660120
07936-166010A (U.S.A. only) Not available in U.S.A. Not available in U.S.A.
Bearing remover shaft handle Bearing remover weight Driver

07936-3710100 07741-0010201 07749-0010000
or 07936-371020A
or 07936-3710200 (U.S.A. only)
Pi lot, 12 mm Pilot, 17 mm Pilot, 25 mm

07746-0040200 07746-0040400 07746-0040600
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 42 x 47 mm

07746-0010100 07746-0010200 07746-0010300
11-5
CRANKSHAFT /TRANSMISSION/KICKSTARTER
TROUBLESHOOTING
Crankshaft noisy
• Worn connecting rod big end bearing
• Bent connecting rod
• Worn crankshaft main journal bearing
Transmission jumps out of gear
• Worn gear dogs or slots
• Bent fork shaft
• Worn or bent shift forks
• Broken shift drum stopper
• Broken shift linkage return spring
Hard to shift
• Improper clutch operation
• Incorrect clutch adjustment
• Incorrect engine oil v iscosity
• Bent shift fork
• Bent shift fork claw
• Bent shift spindle
11-6
CRANKCASE SEPARATION
Refer to page 17-3 Remove the kickstarter spindle return spring and
for the parts which spring collar. RETURN SPRING
must be removed
before separating
the crankcase.
Remove the two bolts.
Place the left crankcase down.

RIGHT CRANKCASE , /
Separate the right and left crankcase halves. I
11-7
CRANKSHAFT
REMOVAL
Separate the crankcase halves (page 11-7).
Remove the crankshaft from the left crankcase.
INSPECTION
Measure the connecting rod big end side clearance
with a feeler gauge.
Measure the connecting rod big end radial clear-

ance at symmetrical points as shown.
Turn the outer race of the crankshaft bearing with

your f inger. TIMING SPROCKET
The bearing shou ld turn smoothly and quietly.

A lso check that the inner race of the bearing fits
/
tightly on the crankshaft.
Check the timing sprocket for wea r or damage.
If you replacing the timing sprocket, align the center
of the sprocket teeth with the center of woodruff key
groove.
BEARINGS
11-8
Place the crankshaft on a stand or V-blocks and
measure the runout using a dial gauge.
The measuring locations are shown in the illustra-
tion.
SERV ICE LIMITS:
Right : 0.085 mm (0.0033 in )
Left: 0.070 m m (0.0028 in)
LEFT
30.0 mm (1.18 in) 52.0 mm (2.05 in)
INSTALLATION
Be careful not to Install the crankshaft into the left crankcase.
damage rhe cam Assemble the crankcase (page 11 -19).
chain.
TRANSMISSION REMOVAL/
DISASSEMBLV
REMOVAL
Remove the kickstarter spindle from the left crank-
case (page 11-18).
Remove the shift fork shaft.
Remove the shift forks.
11-9
Remove the shift drum.
Remove the mainshaft and countershaft as an

assembly.
DISASSEMBLV
• Keep track of the disassembled parts (gears,
bushings, washers, and snap rings) by stacking
them on a tool or slipping them onto a piece of
wire.
• Do not expand the snap ring more than neces-
sary for removal. To remove a snap ring, expand
the snap ring and pull it off using the gear behind
it.
Disassemble the mainshaft and countershaft.
COUNTERS HAFT
INSPECTION
Check the gear dogs, dog holes and teeth for abnor-
mal wear or lack of lubrication.
Measure the 1.0. of each gear.
SERVICE LIMITS:
CRF100F: M4, MS: 17.0S mm (0.671 in)
C1: 20.66 mm (0.813 in)
C2: 19.S6 mm (0.770 in)
C3: 18.0S mm (0.711 in)
CRFSOF: M4, MS: 17.0S mm (0.671 in)
C1: 17.06 mm (0.672 in)
C2: 19.S6 mm (0.770 in)
C3: 17.0S mm (0.671 in)
11-10
BUSHING
CRF100F· Check the bushing for damage or excessive wear.
Measure the O.D. of C1 bushing.
Calcu late the gear to bushing clearance.
C1 BUSHING
MAINSHAFT/ COUNTERSHAFT
Check the spl ine grooves and sliding surfaces for
damage or abnormal wear. MAINSHAFT
Measure the 0 .0. of the mainshaft and countershaft

at the gear sliding area.
SERVICE LIMITS:
Mainshaft: M4, M5 gear: 16.95 mm (0.667 in)
Countershaft: C2 Gear: 19.44 mm (0.765 in )
C3 Gear:
CRF100F: 17.95 mm (0.707 in)
CRFSOF: 16.95 mm (0.667 in)
C2 GEAR C3 GEAR COUNTERSHAFT
SHIFT DRUM
Inspect the sh ift drum for scoring, scratches or evi-
dence of insufficient lubrication. SHIFT DR UM
Check the shift drum grooves for abnormal wear or

damage.
SHIFT FORK
Check the shift fork for abnormal wear or deforma-
tion .
Measure the 1.0. of the shift fork.
Measure t he shift fork claw thickness.
11-11
Check the shift fork shaft for abnormal wear or
deformation.
Measure the shift fork shaft 0.0.
CRANKCASE BEARING REPLACEMENT

Turn the inner race of each bearing with your fi nger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the crankcase.
Remove and discard the bearing if the race does not
turn smoothly, quietly or fits loosely in the crank-
case.
RIGHT CRANKCASE BEARINGS

Drive the mainshaft bearing out of the right crank-
case.
Remove the countershaft bearing using the specia l
tools as shown.
TOOLS:
Bearing remover set, 12 mm 07936-1660101
Bearing remover shaft 07936- 1660120
Bearing remover head, 12 mm 07936-1660110
Bearing remover weight 07741-0010201
TOOLS (U.S.A. only):

Bearing remover, 12 mm 07936-16601 OA
Bearing remover shaft handle 07936-3710100
Bearing remover weight 07936-371020A or
07936-3710200
Drive new mainshaft bearing into the right crank-
case using the special tools as shown.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
11-12
Drive new countershaft bearing into the right crank-
case usi ng the special tools as shown.
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
LEFT CRANKCASE BEARINGS

Remove the following.
- Crankshaft (page 11 -8)
- Kickstarter spindle (page 11-18)
- Transmission (page 11-9)
Remove the left countershaft oil seal.
Drive the countershaft bearing out of the left crank-
case.
Remove the mainshaft bearing using the special

tools as shown.
TOOLS:
Bearing remover set, 12 mm 07936-1660101
Bearing remover shaft 07936-1660120
Bearing remover head, 12 mm 07936- 1660110
Bearing remover weight 07741-0010201
TOOLS (U.S.A. only):

Bearing remover, 12 mm 07936- 166010A
Bearing remover shaft handle 07936-3710100
Bearing remover weight 07936-371020A or
07936-3710200
Drive new ma inshaft bearing into the left crankcase

using the special tools as shown.
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
11-13
CRANKSHAFT/ TRANSMISSION/ KICKST ARTER
Drive new countershaft bearing into the left crank- COUNTER ._.,
case using the special tools as shown. SHAFT ~
BEARIN G
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
Install the new countershaft oil seal on the left

crankcase.
Apply oil to the new countershaft oil seal lip.
- Crankshaft (page 11-9)
- Transmission (page 11-15)
- Kickstarter spindle (page 11-19)
- Assemble the crankcase (page 11-19)
11-14
TRANSMISSION ASSEMBLV/
INSTALLATION
TRANSMISSION ASSEMBLY
Clean al l parts in solvent.
Apply molybdenum oil solution to the gear, bushing
sliding surface and shift fork grooves to ensure ini-
tial lubrication.
Assemble all parts into their original positions.
Mainshaft:
(17\ g=r:~~~T
M2GEAR M5GEAR M3GEAR
120\
M4GEAR
123\
MAINSHAFT/ M1
GEAR: CRF1 OOF:12T
CRF80F:13T
PR IMARY STARTER
GEAR (19T)
\@fi:o \
~~~-/~Do
SPLINE WASHER SNAP RING SNAP RING SPLINE WASHER
£
THRUST WASHER
~m;~
Gear and bushing

sliding surfaces and
shift fork grooves
11-15
Countershaft:
C2 GEAR
C5 GEAR (24T) CRF100F:32T
CRF80F:31T
COUNTERSHAFT
C3 GEAR (28T)
SPLINE WASHER
GEAR BUSH ING (CRF100F ONLY)
.....___C1 GEAR
CRF1 OOF:37T
CRF80F:35T
SPLINE WASHER THRUST WASHER
THRUST WASHER
Gear and bushing

sliding surfaces and
shift fork grooves
• Always install the thrust washer and snap ring

with the chamfered (rolled) edge facing away
from the thrust load.
• Install the snap ring so that its end gap aligns
with the groove of the splines.
• Make sure that the snap ring is fully seated in the
shaft groove after installing it.
11-16
TRANSMISSION INSTALLATION
Coat each gear with molybdenum disulfide oil and
check for smooth movement. COUNTERSHAFT
Apply molybdenum disulfide oil to the shift fork

grooves in the M3, C4 and C5 gear.
Assemble the mainshaft and countershaft as
shown.
~ SHIFT FORK GROOVES

Install the mainshaft and countershaft as an assem-
bly into the left crankcase. MAINS HAFT ASSEMBLY
Install the shift drum into the left crankcase.
Install the shift Install the shift forks.

forks into the
shifter gear grooves
with their marks
facing up.
11-17
Install the shift fork shaft.
Rotate the mainshaft by hand to see if the gears
rotate freely.
- Kickstarter spindle (page 11-19).
- Assemble the crankcase (page 11 -19).
KICKSTARTER
REMOVAL/DISASSEMBLY
Separate the crankcase (page 11-7).
SPINDLE
Remove the kickstarter spindle from the left crank-
case.
Remove the two washers and kickstarter pinion.

Remove the snap ring then remove the starter
ratchet, ratchet spring and snap ring.
RATCHET
INSPECTION
Check the kickstarter spindle for straightness.
Check the return spring for fatigue.
Measure the pinion gear 1.0.
Measure the kickstarter spindle 0 .0 .

11-18
ASS EMBLY/INSTALLATION
Install the snap ring.
Install the starter ratchet aligning its punch mark
with the kickstarter spindle.
I
SNAP RING
ALIGN
SPINDLE
Insta ll the ratchet spring and snap ring.

WASHERS
Insta ll the pinion and two washers.
RATCHET
Insta ll the kickstarter spindle to the left crankcase.

Assemble the crankcase (page 11 -19).
CRANKCASE ASSEMBLY
Be careful not to Clean off any gasket material from the crankcase
damage the crank- mating surface before assembling.
case mating sur-
Dress the surfaces with an oil stone if necessary to
face.
correct any minor roug hness or irregularities.
After cleaning, lubricate the crankshaft bearings and
ot her contacting surfaces with clean engine oil.
Install the dowel pins and new gasket onto the left
crankcase.
11-19
Make sure that the Assemble the right crankcase over the left crank-
RIGHT CRANKCASV
gasket stays m case, being carefu l to align the dowel pins and
~
place. shafts.
Do not force the crankcase halves together; if there
is excessive force required, something is wrong.
Remove the right crankcase and check for mis-
aligned parts.
Install and tighten the two right crankcase bolts.
Install the return spring end into the hole on kick-

starter spindle.
Install the spring collar aligning its groove with the
return spring end.
Hook the return spring end on the crankcase boss.
Install the removed parts in the reverse order of
removal.
BOSS
11-20
12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING
COMPONENT LOCATION ........................ 12-2 FRONT WHEEL ....................................... 12-10
SERVICE INFORMATION ......................... 12-3 FRONT BRAKE ........................................ 12-15
TROUBLESHOOTING ............................... 12-5 FORK ....................................................... 12-18
HANDLEBAR ............................................. 12-6 STEERING STEM, ................................... 12-26
12-1
FRONT WHEEL/ BRAKE/SUSPENSION/ STEERING
COMPONENT LOCATION
12 N·m (1 .2 kgf·m, 9 lbf·ft)
26 N·m (2.7 kgf·m, 20 lbf·ft)
62 N·m (6.3 kgf,m, 46 lbf·ft)
12-2
FRONT WHEEL/BRAKE/ SUSPENSION/ STEERING
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regard less of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies.Use an OSHA-approved vacuum cleaner.
• Riding on damaged rims impairs safe operation of the motorcycle.

• When servicing the front wheel, brake, fork or steering stem, support the motorcycle using a safety stand or hoist.
SPECIFICATIONS
Unit: mm (in)
Front wheel Cold tire pressure 100 kPa (1.00 kgf/cm2. 14 psi) -
Front wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel hub-to-rim distance 12.0 ± 1.0 -- -
-
- Front axle runout I
- ·0.20 (0.008)
- Drum 1.0. 95.0 (3.74) 96.0 (3.78)
Fork Spring free CRF100F 546.0 (21.50) 535.0 (21.06)
length CRF80F 531.2 (20.91) I 520.7 (20.50)
Fork pipe runout - 0.20 (0.008)
Recommended fork fluid- Pro Honda suspension Fluid SS-8
(10W)
-
... -
Flu id level CRF100F 207.0 (8.15)
I CRF80F 177.0 (6.97) -
Fluid capacity CRF100F 84 ± 2.5 cm 3 -
(2.8 ± 0.08 US oz, 3.0 ± 0.09 Jmp oz)
CRF80F 85 ± 2.5 cm 3
(2.9 ± 0.08 US oz, 3.0 ± 0.09 Imp oz)
-
TORQUE VALUES
Handlebar upper holder bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Front axle nut 62 N·m (6.3 kgf·m, 46 lbf·ft) U-nut
Front brake arm pinch bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply a locking agent to the threads.
Steering stem lock nut 74 N·m (7.5 kgf·m, 54 lbf·ft)
Steering stem bearing adjusting nut See page 12-29
Fork bottom bridge pinch bolt 26 N·m (2.7 kgf·m, 20 lbf·ft)
Fork top bridge pinch bolt 18 N·m (1.8 kgf·m, 13 lbf·ft)
Fork socket bolt 20 N·m (2.0 kgf·m, 14 l bf·ft) Apply a locking agent to the threads.
Spoke 3 N·m (0.3 kgf·m, 2 lbf·ft)
Fork bolt 23 N·m (2.3 kgf·m, 17 lbf·ft)
Fender stay bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)
Front fender bolt/nut 12 N·m (1.2 kgf·m, 9 lbf·ftl
12-3
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
TOOLS
Pi lot, 12 mm Attachment, 32 x 35 mm Attachment, 37 x 40 mm

07746-0040200 07746-0010100 07746-0010200
Bearing remover shaft Bearing remover head, 12 mm Ball race remover

07746-0050100 07746-0050300 07944-1150001
Driver Steering stem driver, 24 mm Lock nut wrench

07749-0010000 07946-GC40000 07916-3710101
\S'
or 07946-MBOOOOO and or 07916-3710100 (U.S.A. only)
07946-GC4000A (U.S.A. on ly)
Fork seal driver 27 mm Spoke wrench, 4.5 x 5.1 mm

07947-1180001 07701-0020200
or equivalent commercia lly avail-

able in U.S.A.
12-4
TROUBLESHOOTING
Hard steering
• Steering stem adjusting nut too tight
• Faulty or damaged steering head bearing
• Insufficient tire pressure
• Faulty tire
Steers to one side or does not track straight
• Bent fork
• Bent front axle
• Wheel installed incorrectly
• Faulty steering head bearings
• Bent frame
• Worn wheel bearings
• Worn swingarm pivot components
• Weak front shock absorber
Front wheel wobbling
• Bent rim
• Worn front wheel bearings
• Faulty tire
• Unbalanced tire and wheel
Front wheel hard to turn
• Faulty wheel bearings
• Bent front axle
• Brake drag
Soft suspension
• Weak fork springs
• insufficient fluid in fork
• Low tire pressure
Stiff suspension
• Incorrect fork fluid viscosity
• Bent fork pipes
• Clogged f luid passage
Suspension noisy
• Low fork fluid level
• Loose fork fasteners
12-5
HANDLEBAR
REMOVAL
Remove the number plate (page 2-5).
Remove the wire bands.
Remove the two screws, holder and clutch lever

bracket.
Remove the screw, ground wire and engine stop

ENGINE STOP BUTION SCREW
button.
\
Remove the throttle housing screws and cover.
THROTILE HOUSING COVER
SCREWS
12-6
Disconnect the throttle cable end from the throttle
HOUSING THROTTLE PIPE
pipe and remove the throttle housing.
Remove the throttle pipe from the handlebar.
CABLE END
Remove the screws, holder and front brake lever

bracket.
Remove the handlebar upper holder bolts and hold-

ers.
Remove the handlebar.
INSTALLATION
Place the handlebar onto the lower holders, aligning
HOLDERS
the punch mark on the handlebar with the mating
surface of the lower holder.
Place the upper holders with the punch marks fac-
ing forward. /~.
12-7
Install the upper holder bolts, tighten the forward
bolts first, then the rear bolts.
If the handlebar grips were removed, apply Honda

Bond A or Pro Honda Hand Grip Cement (U.S.A.
on ly) to the inside of the grip and to the clean sur-
faces of the left handlebar and throttle grip.
Allow the adhesive Wait 3 - 5 minutes and insta ll the grip.
to dry for an hour Rotate the grip for even application of the adhesive.
before using.
HANDLE GRIP
Place the front brake lever bracket onto the handle-

bar.
Install the holder with its punch mark facing up.
Align the mating surface of the bracket with the
punch mark on the handlebar.
Tighten the upper screw first, then the lower screw.
Apply grease to the sliding surface of the throttle

pipe. THROTILE PIPE
Install the throttle pipe on the handlebar.
12-8
FRONT WHEEL/ BRAKE/ SUSPENSION/ STEERING
Apply oil to the th rottle cable end and sliding sur-
face.
Connect the throttle cable to the throttle pipe.
Align the mating surface of the throttle housing with PUNCH MARK COVER
the punch mark on the handlebar.
Install the throttle housing cover and tighten the
upper screw first, then the lower screw.
SCREWS
Insta ll the engine stop button and ground wire, then
ENGINE STOP BUTION GROUND WIRE
align the mating surface of the clamp with the
\
Tighten the screw securely.
SCREW
Place the clutch lever bracket onto the handlebar. HOLDER/BRACKET
Install the holder with its punch mark facing up.
Align the mating surface of the bracket w ith the
Tighten the upper screw first, then the lower screw.
SCREWS
-
PUNCH MARKS
12-9
Secure the engine stop button wire with the wire
bands.
Install the number plate (page 2-5).
FRONT WHEEL
REMOVAL
Support the motorcycle securely using a safety
stand or a hoist and raise the front wheel off the
ground.
Remove the bolt and front brake cable guide from
the left fork slider.
Remove the front axle nut, axle and front wheel.

Remove the brake panel from the front wheel.
Remove the side collar from the right wheel hub.
12-10
INSPECTION
Axle runout
Set the axle in V-blocks and measure the runout.
Actual runout is 1/2 of the total indicator reading.
Wheel rim
Check the rim runout by placing the wheel in a true-
ing stand.
Spin the wheel by hand, and read the runout using a
dial indicator.
Actual runout is 1/2 the tota l indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Wheel bearing
Turn the inner race of each bearing with your finger.
the hub.
The bearings should turn smoothly and quietly.
Replace the bear- Remove and discard the bearings if they do not turn
ings in pairs. smoothly, quietly, or if they fit loosely in the hub.
Install the new bearings into the hub using the spe-
cial tools (page 12-12).
WHEEL BEARING
DISASSEMBLY
Remove the dust seal from the right wheel hub.
Install the bearing remover head into the bearing.
From the opposite side, install the bearing remover
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
ASSEMBLY
DISTANCE COLLAR
DISTANCE COLLAR
RIGHT WHEEL BEARI NG
Replace the wheel

bearings in pairs.
Do not reuse old
bearings.
Pack the new bearing cavit ies with grease.
Drive in a new right side bearing squarely with its
sealed side facing out.
Install the distance collar, then drive in the left side
bearing with its sealed side facing out.
-~-~
BEARING
I
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 m m 07746-0010100
Pilot, 12 mm 07746-0040200
12-12
Wheel cen ter Wheel center adjustment
adjusrmenc is nec-
Place the rim on the work bench and begin lacing
essary when new
with new spokes.
spokes are
Tighten the spokes in 2 or 3 progressive steps to the
installed.
specified torque.
TOOL:
Spoke wrench, 4.5 x 5.1 mm 07701-0020200 or
equivalent com-
: ======.,2 {
mercially avail-
able in U.S.A. '-<---:::C---
'.'.===··
Adjust the hub position so that the distance from 12.0 ± 1.0mm
the right end surface of the hub center to the side of (0.47 ± 0.04 in)
rim is 12.0 ± 1.0 mm (0.47 ± 0.04 in) as shown.
Recheck the rim runout (page 12-11 ).
Apply grease to a new dust seal lips, and install the
dust seal into the right wheel hub.
INSTALLATION
Install the side collar into the right wheel hub.
Install the brake panel into the front wheel.

Install the front wheel between the fork legs whi le
aligning the brake panel groove with the boss on
the left fork slider.
Apply a thin coat of grease to the front axle surface,
then install the front axle from right side.
12-13
Hold the axle and temporarily tighten the axle nut.
Adjust the front brake lever free play (page 3-20).
With the front brake applied, pump the fork up and

down several times to seat the axle and check the
front brake operation.
Tighten the axle nut to the specified torque.
TORQUE: 62 N·m (6.3 kgf·m , 46 lbf·ft}
Instal l the brake cable guide to the left fork slider

and tighten the bolt securely.
12-14
FRONT BRAKE
REMOVAL
Remove the front wheel (page 12-10).
BRAKE CABLE
Disconnect the brake cable from the brake arm.
INSPECTION
Measure the front brake drum I.D.
Measure the brake lining thickness.
DISASSEMBLY
Remove the brake shoes and springs.
12-15
Remove the brake arm pinch bolt, nut and brake
arm.
Remove the indicator plate, brake earn and dust

seal.
ASSEMBLY
SPRINGS
s" -~ OUST SEAL

INDICATOR PLATE
~BRAKE CAM
°w BOLT
BRAKE SHOES
BRAKE PANEL NUT

BRAKE ARM
12-16
FRONT WHEEL/BRAKE/SUSPENSION/ STEERING
Apply grease to the dust seal and install it onto the
brake panel. -~
Apply grease to the anchor pin and brake cam.
Install the brake cam into the brake panel.
_-f;imw
BRAKE CAM
Insta ll the wear indicator plate on the brake cam
aligning its wide tooth with the wide groove on the
brake cam .
Install the brake arm aligning the punch marks

between the arm and brake cam.
Apply a locking agent to the brake arm pinch bolt
threads.
Install the brake arm pinch bolt and brake arm nut.
Tighten the bolt to the specified torque.
TORQUE: 10 N ·m (1.0 kgf·m, 7 !bf.ft)
Install the brake shoes and springs.

SPRINGS
12-17
FRONT WHEEL/ BRAKE/SUSPENSION/STEERING
INSTALLATION
Install the brake cable to the brake arm. BRAKE CABLE
~
Install the front wheel ( page 12-13).
Adjust the front brake lever free play (page 3-20).
FORK
REMOVAL
Remove the number plate (page 2-5).
Remove the front wheel (page 12-10).
Loosen the fork top bridge pinch bolts.
Loosen the fork bottom bridge pinch bolts.

Remove the fork leg.
When the fork is to be disassembled, lower the fork - - --

leg and tighten the bottom pinch bolt.
Loosen the fork bolt, but do not remove it yet.
Loosen the fork bottom pinch bolt and remove the
fork leg.
12-18
DISASSEMBLY
Loosen the fork boot clamp screw and remove the
BOOT
band and boot.
BAND/ SCREW
The fork bolt is Remove the fork bolt and 0 -ring.

FORK BOLT/0-RING
under spnng pres-
sure. Use care
when remov,ng it.
/
Remove the fork spring.

FORK PIPE
Pour out the fork fluid by pumping the fork pipe up
and down several times.
FORK SPRING
Hold the fork slider in a vice with soft jaws or a shop SOCKET BOLT/WASHER
towel.
If the fork piston Remove the fork socket bolt and sea ling washer
turns with the with a hex wrench.
socket bolts, tem-
porarily install the
fork spring and fork
cap.
12-19
FRONT WHEEL/BRAKE/ SUSPENSION/STEERING
Remove the dust seal from the fork slider.
DUST SEAL
Remove the stopper ring from the fork slider.
Pull the fork pipe out from the fork slider.

Remove the oi l lock piece.
Remove the fork piston and rebound spring from

FORK PIPE
t he fork pipe.
FORK PISTON
12-20
Remove the fork oil seal from the fork slider.
INSPECTION
Fork spring
Measure the fork spring free length.
SERVICE LIMITS:
CRF100F: 535.0 mm (21.06 in)
CRFSOF: 520.7 mm (20.50 in)
1~
----•7-•
Fork pipe/fork slider/piston
Check the fork pipe and fork slider for score marks FORK SLIDER
and excessive or abnormal wear. . - - - - -...
Replace the components if necessary.
FORK PIPE
Fork piston
Do not remove the Check the fork piston ring for wear or damage. REBOUND SPRING
fork piston ring Check the rebound spring for fatigue or damage.
except to replace 11
Replace the components if necessary.
with a new one.
FORK PISTON PISTON RING
12-21
Fork pipe runout
Place the fork pipe in V-blocks and measure the
runout.
Actual runout is 1/2 the total indicator reading.
FORK PIPE
ASSEMBLY
$1 . . DUST SEAL FORK PIPE

0-RING . . $1
STOPPER RING
FORK SPRING
BOOTBAND
~ F O R K BOOT
PISTON RING
q. FORK PISTON
FORK SOCKET BOLT OIL LOCK PIECE REBOUND SPRING
Before assembly, wash all parts with a high flash or

non-flammable solvent and wipe them dry.
Install the rebound spring and fork piston into the
fork pipe.
OIL LOCK PIECE
Install the oil lock peace to the end of the fork pis-
ton.
Install the fork pipe into the fork slider.
12-22
Hold the fork slider in a vise with soft jaws or a shop
towel. SEALING WASHER - ~
/
- lllliijll
Apply a locking agent to the fork socket bolt /
threads. /
L
If the fork piston Install and tighten the socket bolt with a new sealing
~
turns together w ith washer into t he fork piston.
the socket bolt,
temporarily install TORQUE: 20 N ·m (2.0 kgf·m, 14 lbf·ft)
the fork spring and
fork cap.
Wrap vinyl tape around the fork top end to avoid

pipe damaging the fork oi l sea l lips.
Coat a new fork oil seal lips w ith fork fluid and
install it over the fork pipe w ith the marking side fac-
ing up.
Drive t he fork oil seal into the fork slider using the
specia l tools.
-~
TOOL:
Fork seal driver 27 mm 07947-1180001
OIL SEAL . .
Install the oil sea l stopper ring into the fork slider
groove securely.
Apply fork fluid to a new dust seal lips and install it.
Remove the vinyl tape from t he fork pipe end.
.,
UST SEAL . .
12-23
Pour the specified amount of recommended fork
fluid into the fork pipe.
RECOMMENDED FORK FLUID:

Pro Honda Suspension Fluid 55-8 {10W)
FORK FLUID CAPACITY:
CRF100F: 84 ± 2.5 cm3
(2.8 ± 0.08 US oz, 3 .0 ± 0.09 Imp oz)
CRF80F: 85 ± 2.5 cm 3
(2.9 ± 0.08 US oz, 3.0 ± 0.09 Imp oz)
Slowly pump the fork pipe several times to remove
trapped air from the lower portion of the fork pipe.
Be sure the oil level Compress the fork leg fully and measure the oil
is the same in both level from the top of the fork pipe.
fork pipes.
FORK FLUID LEVEL:
CRF100F: 207.0 mm (8 .15 in)
CRF80F: 177.0 mm (6.97 in)
FLUID LEVEL
=- - -
-----
~
---
Pull the fork pipe up and install the fork spring with
the tightly wound coil end facing down.
DOWN
Coat a new 0-ring with fork fluid and insta ll it into

the fork bolt groove.
Install the fork bolt into the fork pipe.
12-24
Install the fork boot and tighten the boot band screw
loosely. BOOT
BAND/SCREW
INSTALLATION
Insta ll the fork pipe into the steering stem.
If the fork has been reassembled, temporarily
tighten the bottom bridge pinch bolts and tighten
the fork bolt to the specified torque.
Loosen the bottom bridge pinch bolts and pul l up

the fork pipe to the top bridge.
Align the top end of the fork pipe with the upper
surface of the top bridge as shown.
Tighten the bottom bridge pinch bolts to the speci-

fied torque.
TORQUE: 26 N -m (2.7 kgf·m, 20 lbf·ft)
12-25
FRONT WHEEL/BRAKE/ SUSPENSION/STEERING
Tighten the top bridge pinch bolt to the specified
torque.
Pull the fork boot up until it just touches the bottom

bridge.
Tighten the band screw with the band end facing
rearward.
Install the front wheel (page 12-13).
Install the number plate (page 2-5).
STEERING STEM
REMOVAL
- Handlebar (page 12-6}
- Front wheel (page 12-10)
- Front fender (page 2-5)
Loosen the steering stem lock nut, then remove the
fork legs (page 12-18), steering stem lock nut,
washer and top bridge.
Remove the steering stem bearing adj usting nut

using the special tool.
TOOLS:
Lock nut w rench 07916-3710101 or
07916-3710100
(U.S.A . only)
12-26
Hold t he bottom of steering stem to prevent it from
fall ing out of the steering head, then remove the
adjustment nut.
Remove the upper bearing inner race and upper
bearing.
Remov e t he steering stem and lower bearing.
BEARING RACE REPLACEMENT

Always replace the Remove the upper and lower bearing outer races
bearings and races using the special tools.
as a ser.
TOOL:
Ball race remover 07944- 1150001
If the motorcycle Insta ll the new upper and lower bearing outer races
has been involved using the special tool.
in an accident,
examine the area TOOLS:
around the steer- Driver 07949-0010000
ing head for cracks. Attachment, 37 x 40 mm 07746-0010200
12-27
Remove the t hree bolts and fender stay.
Temporarily install the steering stem nut onto the DUST SEAL/WASHER
stem to prevent the threads from being damaged
when removing the lower bearing inner race from
the stem.
Remove the lower bearing inner race with a chisel
or equiva lent tool, being carefu l not to damage t he
stem.
Remove the dust seal and washer.
STEM NUT INNER RACE
Install the washer over the steering stem. STEERING

Apply grease to new dust seal lips and install it over STEM DRIVER
the steering stem.
Install a new lower bearing inner race using a spe-
cial tool and a hydraulic press.
TOOLS:
Steering st em driver, 24 mm 07946-GC40000 or
Steering stem driver, 30 mm
Driver attachment, 24 mm
07946-MBOOOOO and
07746-GC4000A
... _---um
(U.S.A . only) DUSTSEAU
WASHER
Instal l the fender stay.

Tighten the three bolts to the specified torque.
FENDER STAY
12-28
INSTALLATION
LOWER OUTER RACE BEARING ADJUSTING NUT
LOWER BEARING ~ UPPER BEARING

~vlNNERRACE
~ U P P E R BEARING
~• - UPPER OUTER RACE
STEERING STEM
BEARINGS INNER/
_-ffiWII OUTER RACES
DUST SEAL
Apply grease to the lower races and lower bearing,

then insert the lower bearing into the steering stem.
Insert the steering stem into the steering head pipe.
Apply grease to the upper races and upper bearing,

then install the upper bearing and upper bearing
-
_-ffiWII ~
inner race. UPPER BEARING
12-29
Hold the steering stem and tighten the stem bearing
adjusting nut using the special tool to the initial
torque.
TOOLS:
Lock nut wrench 07916-3710101 or
07916-3710100
(U.S.A . only)
Move the steering stem to the right and left, lock-to-

lock, five times to seat the bearings.
Make sure that the steering stem moves smoothly,
without play or binding; then loosen the bearing
adjusting nut.
Retighten the bearing adjusting nut to the specified

torque.
TOOLS:
Lock nut w rench 07916-3710101 or
07916-3710100
(U.S.A . only)
TORQUE: 2.5 N ·m (0.25 kgf·m, 1.8 lbf·ft)
Install the top bridge to the steering head and tem-

porari ly instal l the fork legs.
Install the washer and stem lock nut.
Tighten the steering stem lock nut to the specified
torque.
Recheck that the steering stem moves smoothly

w ithout play or binding.
- For k legs (page 12-25)
- Front fender (page 2-5)
- Front w heel (page 12-13)
- Handlebar (page 12-7)
12-30
13. REAR WHEEL/BRAKE/SUSPENSION
COMPONENT LOCATION ··""·················· 13-2 BRAKE PEDAL ........................................ 13-15
SERVICE INFORMATION ·· ······ .. ············· ·· 13-3 SHOCK ABSORBER .. , ............................. 13-18
TROUBLESHOOTING······························· 13-5 SHOCK LINKAGE ................................... 13-19
REAR WHEEL ,, .......................................... 13.5 SWINGARM ............................................ 13-22
REAR BRAKE, .......................................... 13.12
13-1
REAR WHEEL/BRAKE/ SUSPENSION
COMPONENT LOCATION
55 N·m (5.6 kgf·m, 41 lbf·ft)
44 N·m (4.5 kgf·m, 33 lbf·ft)
64 N·m (6.5 kgf·m, 47 lbf·ft)

62 N·m (6.3 kgf·m, 46 lbf·ft) 44 N·m (4.5 kgf·m, 33 lbf·ft)
55 N·m (5.6 kgf·m, 41 lbf.ft) 44 N·m (4.5 kgf·m, 33 lbf.ft)
13-2
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health .
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• Riding on damaged rims impairs safe operation of the motorcycle.

• Raise the rear wheel off the ground by supporting the frame securely when servicing . A box or work stand is required to
support the motorcycle.
• A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated
drum with a high quality brake degreasing agent.
• Use only genuine Honda replacement bolts and nuts for al l suspension linkage and swingarm pivot mounting points;
ordinary bolts lack adequate strength for these application. Also take note of the installation direction of these bolts
since they must be instal led correctly.
• Refer to page 3-17 for drive chain information.
SPECIFICATIONS
Unit: mm (in)
Rear wheel Cold tire pressure 100 kPa (1.00 kgf/cm2. 14 psi) -
Rear wheel I Radial - 2.0 (0.08)
rim runout I Axial - 2.0 (0.08)
Wheel hub-to-rim distance 11.0 ± 1.0 -
Rear axle runout - 0.20 (0.008)
Drive chain Slack 25 - 35 (1.0 - 1.4) 0.2 (0.01)
Size/link I CRF100F RK RK428FDZ-118RJ - -
CRF80F - ' AK - RK420MSZ1-110RJ -
I DID DID420MBK1-110RB -
Brake drum I.D. 95.0 (3.74) 96.0 (3.78)
Shock Spring free I CRF100F 123.5 (4.86) 121.0 (4.76)
absorber length I CRF80F 137.0 (5.39) 134.3 (5.29}
Shock linkage Bushing I.D. 18.000 -18.052 (0.7087 - 0.7107) 18.25 (0.719)
Collar 0.D. 17.941 - 17.968 (0.7063 - 0.7074) I 17.91 (0.705)
Swingarm Bushing 1.0. 14.990 - 15.030 (0.5902 - 0.5917) I 15.20 (0.598)
Collar 0.0. 14.966 - 14.984 (0.5892 - 0.5899) 14.94 (0.588)
Brake pedal Pedal hole I.D. 17.300-17.327 (0.6811 - 0.6822) 15.20 (0.598)
Col lar O.D. 17.294 - 17.298 (0.6809 - 0.6810) 17.27 (0.680)
TORQUE VALUES
Rear axle nut 62 N-m (6.3 kgf·m, 46 lbf·ft) U -nut
Driven sprocket nut 32 N·m (3.3 kgf,m, 24 lbf.ft) U-nut
Swingarm pivot nut 64 N·m (6.5 kgf·m, 47 lbf·ft) U -nut
Shock absorber upper mounting nut 44 N·m (4.5 kgf·m, 33 lbf·ft) U-nut
Shock absorber lower mounting nut 34 N·m (3.5 kgf·m, 25 lbf·ft) U -nut
Shock absorber arm nut 44 N·m (4.5 kgf·m, 33 lbf.ft) U-nut
Shock absorber connecting rod nut 44 N·m (4.5 kgf·m, 33 lbf·ft) U-nut
Rear brake arm nut 10 N·m (1.0 kgf·m, 7 lbf·ft) U-nut
Spoke 3 N·m (0.3 kgf·m, 2 lbf·ft)
Foot peg mounting bolt 55 N·m (5.6 kgf·m, 41 lbf·ft)
13-3
TOOLS
~ poke wrench, 4.5 x 5.1 mm Bearing remover head, 12 mm Bearing remover shaft
I 01101-0020200 07746-0050300 07746-0050100
or equivalent commercial ly avai l-

able in U.S.A.
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Driver

07746-0010100 07746-0010200 07749-0010000
Pilot, 12 mm
07746-0040200
13-4
TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Worn or damaged rear wheel bearings
• Faulty rear t ire
• Loose or broken spokes
• Worn or damaged swingarm bearings or pivot bushings
• Bent frame or swingarm
• Axle fastener not tightened properly
• Unbalanced ti re and wheel
• Tire pressure too low
Wheel hard to turn
• Brake drag
• Faulty wheel bearings
• Bent axle
• Drive chain too tight (See page 3-17)
Soft suspension
• Weak shock absorber springs
• Oil leakage from damper unit
• Tire pressure too low
Stiff suspension
• Bent shock absorber damper rod
• Damaged suspension or swingarm pivot bearings
• Damaged swingarm pivot bushings
• Bent swi ngarm pivot or frame
• Tire pressure too high
Steers to one side or does not track straight
• Drive chain adjusters not adjusted equally
• Bent axle
• Bent frame
Rear suspension noise
• Loose suspension fasteners
• Worn or damaged susp ension pivot bearings
• Faulty shock absorber
13-5
REAR WHEEL
REMOVAL
wheel off the ground by placing a work stand under
the engine.
Remove the rear brake adjusting nut and disconnect
the rear brake rod from the brake arm, and remove
the joint pin and spring.
Loosen the left and right drive chain adjust nuts.

Remove the rear axle nut and drive chain adjuster.
Push the rear wheel forward.
Remove the drive chain from the driven sprocket.
Remove the rear axle and drive chain adjuster from

the right side and remove the rear wheel.
Remove the brake panel assembly from the right

wheel hub.
13-6
Remove the left side collar and dust sea l from the - - - - -- , - - -.....
left wheel hub.
INSPECTION
Axle
Set the axle on V-blocks and measure the runout.
The actual runout is 1/2 of the tota l indicator read-
ing.
Wheel bearing
Turn the inner race of each bearing with your finger.
Bearings shou ld turn smoothly and quietly.
the hub.
Replace the wheel Remove and discard the bearings if the races do not
bearings m pa,rs. turn smooth ly and quietly, or if they fit loosely in the
hub.
Install the new bearings into the hub using the spe-
cia l tools(page 13-9).
Wheel rim runout

Check the rim runout by placing the wheel in a turn-
ing stand.
Turn the wheel slowly and measure the runout
using a dial indicator.
The actual runou t is 1/2 of the total ind icator read -
ing.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
13-7
Driven sprocket
Check the condition of the final driven sprocket
teeth.
Replace the sprocket if it is worn or damaged.
• If the final driven sprocket requ ires replacement, GOOD REPLACE
inspect the drive chain and drive sprocket.
• Never install a new drive chain on a worn
sprocket or a worn chain on new sprockets. Both
0 X
~~
chain and sprocket must be in good condition or
the replacement chain or sprocket wi ll wear rap-
idly.
DISASSEMBLY
Remove the driven sprocket nuts, bolts and driven
sprocket.
Wheel bearing removal

Install the bearing remover head into the bearing .
From the opposite side, instal l the bearing remover
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
13-8
ASSEMBLY
RIGHT WHEEL BEARING
LEFT WHEEL BEARING ~ --...urnt1

Wheel bearing installation
Pack the new bearing cavities with grease.
DRIVER
Replace the wheel Drive in a new right wheel bearing squarely with its
bearings in pa,rs. sealed side facing out.
Do not reuse old
TOOLS:
bearings.
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
Install the distance collar, then drive in the left

COLLAR
wheel bearing with its sealed side facing out.
I
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
13-9
Wheel center Wheel center adjustment
adjustment is nee· Place the rim on the work bench .
essary when new 11.0 ± 1.0 mm
spokes are Place the hub with the left side down and begin lac- (0.43 ± 0.039 in)
ing with new spokes.
installed.
!
Adjust the hub position so the distance from the
hub right end surface to the side of the rim is 11 .0 ±
1.0 mm (0.43 ± 0.039 in) as shown.
Tighten the spokes in 2 or 3 progressive steps to the
specified torque.
TOOL:
Spoke w rench, 4 .5 x 5.1 mm 07701-0020200 or
equivalent com-
merci ally avail-
able in U.S.A .
TORQUE: 3 N ·m (0.3 kgf· m, 2 lbf·ft)

Check the wheel rim runout (page 13-7).
Instal l the driven sprocket, bolts and nuts.
Tighten the nuts to the specified torque while hold-
ing the bolts.
INSTALLATION
Apply grease to the dust seal lips, then install it into
the left wheel hub.
Install the left side col lar into the left wheel hub.
Instal l the brake panel assembly into the right wheel

hub.
13-10
REAR WHEEL/ BRAKE/SUSPENSION
Place the rear wheel into the swingarm by aligning
the brake panel groove with the swingarm boss.
Install the drive chain over the driven sprocket.

Apply a thin layer of grease to the axle surface.
Install the rear axle with the right drive chain
adjuster from the right side.
Install the left drive chain adjuster and rear axle nut.
Adjust the drive chain slack (page 3-17).
Tighten the axle nut to the specified torque.
Install the spring onto the brake rod.

Connect the brake rod to the brake arm with the
joint pin.
Install the brake adjusting nut loosely.
Adjust the rear brake pedal free play {page 3-21 ).
13-11
REAR BRAKE
BRAKE PANEL REMOVAL
Remove the rear wheel and then remove the brake
panel (page 13-6).
INSPECTION
Measure the rear brake drum I.D.
Check the brake shoe springs for fatigue or damage

and check the brake cam for wear or damage.
Measure the brake lining thickness.
BRAKE PANEL DISASSEMBLY

Mark the side of Pull the brake shoes apart and remove them from
the brake shoes to the brake panel.
indicate their origi-
Rem ove the springs from the brake shoes.
nal position, before
removing them.
Remove the brake arm cover.

Remove the nut, bolt and brake arm.
13-12
Remove the indicator plate.
Remove the brake cam and dust seal.
13-13
BRAKE PANEL ASSEMBLY
BRAKE SHOES
-fiiii,w
BRAKE CAM
SHOE SPRINGS
INDICATOR PLATE BRAKE PANEL
Apply grease to the new dust seal lips.

Install a dust seal with the flat surface facing out
until they are seated.
~
o.r---fiimll DUST SEAL
Apply grease to the brake cam and brake shoe
anchor pin. _---fiiii.w
Install the brake cam into the brake panel.
13-14
Install the wear indicator plate onto the brake cam
by aligning its wide tooth with the wide groove in
the brake cam.
Install the brake arm by aligning the punch marks

on the brake arm and brake cam.
Install the brake arm pinch bolt and nut, then
tighten the nut to the specified torque.
TORQUE: 10 N ·m (1.0 kgf •m, 7 lbf·ft )
Install the brake arm cover.
INSTALLATION
Insta ll the brake shoes and springs onto the brake
panel as shown.
Install the rear wheel (page 13-10).
BRAKE PEDAL
REMOVAL/ DISASSEMBLY
Remove the brake pedal adjusting nut.
Push the brake pedal down and remove the brake
rod from the brake arm.
Remove the spring and joint pin.
13-15
Remove the brake pedal return spring .
Remove the two bolts and right foot peg and brake
pedal.
Remove the pivot collar.

COLLAR
Remove the split pin and joint pin.

SPLIT PIN
JOINT PIN
13-16
ASS EMBLY /INSTALLATION
Install the joint pin and new split pin.
......
~., SPLIT PIN
JOINT PIN
Apply grease to the pivot collar sliding surface then

install the pivot collar into the brake pedal. - ~ COLLAR
Install the brake pedal and right foot peg.

Tighten the two bolts to the specified torque.
TORQUE: 55 N ·m (5.6 kgf,m , 41 lbf,ft)
Install the return spring to the swingarm.
13-17
Install the sprfng onto the brake rod.
Install the joint pin onto the brake arm.
Push down the brake pedal and insta ll the brake rod
into the joint pin.
Install the brake adjusting nut and adjust the brake
pedal free play (page 3-21 ).
SHOCK ABSORBER
REMOVAL
the engine.
Remove the shock absorber lower and connecting
rod (swingarm side) mounting bolts/nuts.
Remove the upper mounting bolt/nut, then remove

the shock absorber from the frame.
INSPECTION
Visually inspect the shock absorber for damage.
BUMP RUBBER
Check the:
- Damper rod for bend or damage.
- Damper unit for deformation or oil leaks.
- Bump rubber for wear or damage.
Check for smooth damper operation.
DAMPER UNIT
13-18
Check the upper bushing for wear or damage.
BUSHING
Inspect all the other parts for wear or damage.
If necessary, replace the shock absorber as an
assembly.
INSTALLATION
Install the shock absorber into the frame.
Install the upper and lower mounting bolts and
nuts.
Install the connecting rod (swing arm side) bolts
and nuts.
Tighten the upper mounting nut to the specified
torque.
Tighten the lower mounting and connecting rod - - - -- - - - - - - -

(swing arm side) bolts/nuts to the specified torque.
TORQUE:
Shock absorber lower mounting nut:
34 N·m (3.5 kgf·m , 25 lbf·ft)
Shock absorber connecting rod nut:
44 N·m (4.5 kgf·m, 33 lbf·ft)
SHOCK LINKAGE
REMOVAL
the engine.
Remove the two bolts and left foot peg.
13-19
REAR WHEEL/ BRAKE/SUSPENSION
Remove the bolt and lower chain slider.

- Shock absorber lower mounting bolt/nut
- Shock absorber connecting rod nuts/bolts
- Shock absorber arm bolt/nut
Remove the shock absorber connecting rod and
shock absorber arm.
INSPECTION
Remove the dust seals and pivot collars.
Check the dust seals and collars and bushing for
wear, damage or deterioration.
Check the shock absorber arm and shock absorber
connecting rod for cracks or damage.
Measure the bushing I.D.
SERVICE LIMIT: 18.25 mm (0.719in)
Measure the collar O.D.

ASSEMBLY
Apply molybdenum disulfide paste to each bushing
rolling area and dust seal lips surface.
~-~'~o
0
~ BUSH INGS
DUST SEALS
13-20
INSTALLATION
Install the shock absorber arm and shock absorber
connecting rod.
Insta ll the fol lowing:
- Shock absorber lower mounting bolt
- Shock absorber connecting rod bolts
- Shock absorber arm bolt
Tighten the each nuts to the specified torque as

shown.
TORQUE:
Shock absorber lower mounting nut:
34 N ·m (3.5 kgf.m, 25 lbf·ft)
Shock absorber connecting rod nuts:
44 N ·m (4.5 kgf·m, 33 lbf·ft)
Shock absorber arm nut:
44 N ·m (4.5 kgf·m, 33 lbf·ft)
Install the lower chain slider and tighten the bolt.
Install the left foot peg and tighten the two bolts to
13-21
SWINGARM
REMOVAL
- Rear wheel (page 13-6)
- Shock linkage (page 13-19)
Remove the return spring.
Remove the two bolts and drive chain case.
Remove the swingarm pivot nut.
Remove the swingarm pivot bolt, then remove the

swingarm from the frame.
13-22
DISASSEMBLY
Remove the drive chain guard.
~
DRIVE CHAIN GUIDE
Remove the two screws and drive chain sl ider.
Remove the dust seals and pivot collar.
COLLAR
INSPECTION
Measure each bushing 1.0. and the pivot collar 0 .0.
SERVICE LIMITS:
Bushing I.D.: 15.20 mm (0.598 in)
Pivot collar 0 .D.: 14.94 mm (0.588 in)
13-23
BUSHING REPLACEMENT
Drive the bushings out of the swing arm.
BUSHINGS
Drive a new bushing into the swingarm using the /
special tools. /
/
TOOLS:
/
Driver 07749-0010000
/
Attachment, 32 x 35 mm 07746-0010100
ASSEMBLY
Apply grease to the bushings, pivot collar and new
dust seal lips.
Install the pivot collar into the swingarm and instal l
the dust seals.
- ~ COLLAR
Install the drive chain slider and two screws.
SCREWS
Install the drive chain guard.
~- -
DRIVE CHAIN GUIDE
13-24
INSTALLATION
Apply a thin layer of grease to the swingarm pivot
bolt sliding surface.
Insta ll the swingarm and pivot bolt.
Install and tighten the swingarm pivot nut to the

specified torque.
Install the drive chain case and bolts.

- Return spring
- Shock linkage (page 13-21)
- Rear wheel (page 13-10)
After insta ll ing the swingarm, check and adjust the
following :
- Drive chain (page 3-17)
- Rear brake (page 3-20)
- Rear suspension (page 3-24)
13-25
14. ELECTRICAL SYSTEM
SYSTEM DIAGRAM .................................. 14-2 IGNITION COIL ......................................... 14-8
SERVICE INFORMATION ......................... 14-3 ICM (IGNITION CONTROL MODULE) ..... 14-9
TROUBLESHOOTING ............................... 14_4 ENGINE STOP BUTTON .......................... 14-9
IGNITION SYSTEM INSPECTION ............ 14-5 IGNITION SWITCH ................................. 14-10
IGNITION TIMING ..................................... 14-8
Ill
14-1
ELECTRICAL SYSTEM
SYSTEM DIAGRAM
IGN ITION COIL
IGNITION SWITCH
ALTERNATOR
/1
IGNITION PULSE GENERATOR
jJ
ENGINE STOP
~
81/W Bl
~
G
I I
~
Bu/Y
~ BVR
J
IGNmON
SWITCH CONTINUITY COIL
•
ENGINE
STOP IGNITION
BUTTON SWITCH
I~ IG E SPARK
PLUG
IGNITION
PULSE
RUN GENERATOR
OFF 0- k) Bl BLACK G GREEN

y YELLOW R RED
COLOR BIIW Bl COLOR BIIW G Bu BLUE w WHITE 0030Z•KN4•A600
14-2
ELECTRICAL SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
• The Ignition Control Module (ICM) may be damaged if dropped. Also, if the connector is disconnected when current is
flowing, the excessive voltage may damage the module. Always turn off the engine stop switch before servicing.
• Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• When servicing the ignition system, always fol low the steps in the troubleshooting sequence on page 14-4.
• The ignition timing does not normally need to be adjusted since the Ignition Control Modu le (ICM) is factory preset.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
SPECIFICATION
ITEM SPECIFICATION
Spark plug Standard NGK CR7HSA
DENSO U22FSR-U
For cold climate/below NGK CR6HSA
(5°C/41 °F) DENSO U20FSR-U
For extended high speed ,_ NGK CR8HSA
riding DENSO U24FSR-U
Spark plug gap 0.6 - 0. 7 (0.024 - 0.028)
Ignition coil primary peak voltage 100 V minimum
Alternator exciter coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F" mark) 15.5° BTDC / at 1,400 rpm
TOOLS
Peak voltage adaptor lgnitionMate Peak voltage tester

07HGJ-0020100 (not available in MTP07-0286 (U.S.A. only)
U.S.A.)
with commercially available digital

multimeter (impedance 10 MQ/min-
imum)
14-3
ELECTRICAL SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water in the spark plug cap (leaking ignition coil secondary voltage)
IGNITION SYSTEM
No spark at plug
Unusual condit ion Probable cause (check in numerical order)
Ignition coil Low peak voltage. 1. The multimeter impedance is too low; below 10 MQ/
primary DCV.
voltage 2. Cranking speed is too slow. (Operating force of the
kickstarter is weak.)
3. The sampling time of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Poorly connected connectors or an open circuit in igni-
tion system.
5. Faulty exciter coil. (Measure the peak voltage.)
6. Faulty ignition coil.
7. Faulty ICM (in case when above No. 1 - 6 are normal).
No peak voltage. 1. Incorrect peak voltage adapter connections.
2. Short circuit in the Black/white wire.
3. An open circuit or loose connection in Green wire.
4. Faulty ignition switch and/or engine stop switch.
5. Loose or poorly connected ICM connectors.
6. Open circuit or poor connection in ground wire of the
ICM.
7. Faulty peak voltage adaptor.
8. Faulty exciter coil. (Measure the peak voltage).
9. Faulty ignition pulse generator. (Measure the peak volt-
age.)
10. Faulty ICM (in case when above No.1 - 9 are normal).
Peak voltage is normal, but no spark 1. Faulty spark plug or leaking ignition coil secondary cur-
jumps at the plug. rent.
2. Faulty ignition coil.
Exciter coil Low peak voltage. 1. The mu ltimeter impedance is too low.
2. Cranking speed is too slow. (Operating force of the
4. Faulty exciter coil (in case when above No.1 - 3 are
normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Fau lty exciter coil.
Ignition pulse Low peak voltage. 1. The multimeter impedance is too low.
generator 2. Cranking speed is too slow. (Operating force of the
4. Faulty ignition pulse generator (in case when above
No.1 - 3 are normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty ignition pu lse generator.
14-4
ELECTRICAL SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark at the spark plug, check al l
connections for loose or poor contact before
measu ring each peak voltage.
• If using the peak voltage adaptor, use a commer-
cia Ily available digital multimeter wit h an imped-
ance of 10 Mn/OCV minimum.
• The display value differs depending upon t he
intern al im pedance of the multimeter.
• If using peak voltage tester (U.S.A. only), follow
the manufacturer's instructions.
Connect the peak vo ltage adaptor to the digital
multimeter, or use the pea k voltage tester (U.S.A. DIGITAL MULTl METER
only) .
If usmg the peak TOOLS:
voltage tester lgnitionMate Peak voltage tester
{U. S.A. onfy), fof- MTP-07-0286
low the manufac- (U.S.A. only) or
turer's instruction.
Peak voltage adaptor 07HGJ-0020100
(Not available in U.S.A.)
with commercially available digital multimeter
(impedance 10 M Q/DCV minimum)
PEAK VOLTAGE ADAPTOR
IGNITION COIL PRIMARY PEAK VOLTAGE

• Check all system connect ions before inspection.
If the system is disconnected, incorrect peak volt-
age might be measured.
• Check cylinder compression and make su re the
spark plug is installed correctly.
Shift the transmission into neut ral.
Disconnect the spark plug cap from the spark plug.
Connect a known good spa rk plug to the spark plug
cap and ground the spark plug to the cylinder as
done in a spark test .
14-5
ELECTRICAL SYSTEM
With the ignition coil primary wire connected, con-
nect the peak voltage adaptor or peak voltage tester IGNITION COIL
to the ignition coil.
TOOLS:
lgnitionMate Peak voltage tester
MTP-07-0286
(U.S.A. only) or
CONNECTION:
Black/yellow terminal (+) - Body ground (-)
Turn the ignition switch to "ON ".
Avoid touching che Crank the engine with kickstarter and read ignition
spark plug or tester coil primary peak voltage.
probes to prevent
electric shock.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnormal, check for an open
circuit or poor connection in Black/Yellow wire.
If not defects are found in the harness, refer to the
troubleshooting chart on page 14-4.
ALTERNATOR EXCITER COIL PEAK

VOLTAGE
• Check cylinder compression and make sure the
Disconnect the 2P and 4P connectors from the ICM.
Connect the peak voltage adaptor or peak voltage
tester probes to the 2P connector terminal of the
wire harness side and body ground.
TOOLS:
MTP-07-0286
(U.S.A. only) or
Peak voltage adaptor 07HGJ-0020100 2P CONNECTOR
(Not available in U .S.A.)
CONNECTION:
Black/red terminal (+) - Body ground (-)
Shift the transmission into neutral.
Avoid touching the Crank the engine with the kickstarter and read the
spark plug or tester peak voltage.
probes to prevent
electric shock.
PEAK VOLTAGE: 100 V minimum
14-6
ELECTRICAL SYSTEM
If the peak voltage measured at the ICM connector
is abnormal, measure the peak vo ltage at the alter-
nator exciter coil connector.
Remove t he fuel tank (page 2-4).
Disconnect the alternator exciter coil connector and
connect the tester probes to the Black/Red terminal
(exciter coif side) and body ground .
In the same manner as at the ICM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ICM connector.
• ff the peak voltage measured at the ICM is abnor-
mal and the one measured at the alternator
exciter coil is normal, the wire harness has an
open or short circuit, or loose connection.
• If both peak voltage measurements are abnor-
mal, check each item in the troubleshooting chart
(page 14-4). ff all items are normal, the alternator
exciter coi f is faulty (See page 10-5 for stator
repl acement).
IGNITION PULSE GENERATOR PEAK
VOLTAGE
• Check cyl inder compression and make sure the
Disconnect the 2P and 4P connectors from the ICM.
Connect the peak voltage adaptor or peak voltage
tester probes to the connector terminal of the wire
harness side and body ground.
TOOLS:
MTP-07-0286
(U.S.A. only) or
CONNECTION:
Blue/yellow terminal (+) - Body ground (-)
Crank the engine with the kickstarter and read the
peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ICM connector is
abnormal, measure the peak voltage at the pulse
generator connector.
Disconnect the ignition pulse generator connector
and connect the tester probes to the Blue/yellow ter-
minals of the ignition pulse generator side and body
ground.
14-7
ELECTRICAL SYSTEM
In the same manner as at the ICM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnor-
mal and the one measured at the ignition pu lse
generator is normal, the wire harness has an
open or short circuit, or loose connection.
• If both peak voltage measurements are abnor-
mal, check each item in the troubleshooting chart
(page 14-4). If all items are normal, t he ignition
pu lse generator is fau lty (See page 10-5 for igni-
tion pulse generator replacement).
IGNITION TIMING
• Read the manufacturer's instructions for timing
light operation.
Warm up the engine.
Stop the engine and remove the left crankcase
cover (page 10-4).
Connect a timing light to the spark plug w ire.
Start the engine and let it 1,400 rpm.
The ignition timing is correct if the "F" mark on the

flywheel aligns with the index notch on the left
crankcase.
Increase the engine speed by turning t he throttle
stop screw and make sure the "F" mark begins to
move clockwise.
Install the left crankcase cover (page 10-8).
IGNITION COIL
Disconnect the spark plug cap from the spark plug.
14-8
ELECTRICAL SYSTEM
Disconnect the primary wires from the ignition coil.
Remove the ignition coil.
Insta ll ation is in the reverse order of removal.
ICM (IGNITION CONTROL MODULE)

REMOVAL/I NSTALLATION
Disconnect the ignition control module (ICM) con-
nectors.
Remove the ICM from the frame.
ENGINE STOP BUTTON

INSPECTION
Disconnect the engine stop button connectors.
Check for continuity between the connector termi-

nals of the engine stop switch side.
There should be continuity when the button is
pressed and no continuity when released.
14-9
ELECTRICAL SYSTEM
IGNITION SWITCH
INSPECTION
IGNITION SWITCH CONNECTORS
Disconnect the ignition switch connectors.
Check for continuity between the connector termi-
nals of the ignition switch side.
There should be no continuity with the ignition
switch to "ON" and continuity with the ignition
switch to "OFF".
Disconnect the ignition switch connectors.
Release the tabs on the ignition switch body and

remove the ignition switch.
Dunng mstallatton, Instal lation is in the reverse order of removal.

ai,gn the guide on
tile ignition switch
with rhe groove on
the bracket.
14-10
15. WIRING DIAGRAM
WIRING DIAGRAM ......... ···· ...................... 15-2
15-1
--
u,
I
N
ENGINE STOP
BUTTON
~
81/W Bl
~
81/W G
00
81/W G
....__.~~·~~ n
81/W G 81/Y BI/Y G G Bu/Y BVR
~
81/R Bu/Y
IGNITION
Bu/Y
0
BVR
IGNITION COIL
SWITCH CONTINUITY CONTROL
MODULE
ENGINE
STOP IGNITION
BUTTON SWITCH
~
ALTERNATOR
IG E SPARK IGNITION
PLUG PULSE
GENERATOR
RUN
OFF 0- f-0 Bl BLACK G GREEN

V YELLOW R RED
COLOR BI/W Bl COLOR 81/W G Bu BLUE w WHITE 0030Z-KN4-A600
16. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE AT

START ....................................................... 16-2 HIGH SPEED ........ ..................................... 16-5
ENGINE LACKS POWER .......................... 16-3 POOR HANDLING .................................... 16-6
POOR PERFORMANCE AT LOW AND IDLE

SPEED ............ ··· ..................... ·.......... ······ ... 16-5
16-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Carburetor Inspection
Check the fuel flow to carburetor.
Is fuel reaching the carburetor?
NO - • Clogged fuel hose or fuel strainer screen
• Sticking float valve
• Clogged fuel tank breather hose
YES - GO TO STEP 2.
2. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug burning condition wet?
NO - GO TO STEP 4.
YES - GO TO STEP 3.
3. Fuel system Inspection
Inspect the fuel system.
Is the fuel system in good condition?
NO - • Flooded carburetor
• Throttle valve open
• Air cleaner dirty
• Improper carburetor settings
YES - GO TO STEP 4.
4. Spark Test
Perform a spark test.
Is there a good spark?
NO - • Incorrect spark plug gap
• Incorrect spark plug heat range
• Faulty spark plug
• Broken or shorted spark plug wire
• Faulty ignition control module
• Broken or shorted ignition coil
• Faulty ignition pulse generator
• Faulty exciter coil
• Faulty ignition switch
• Faulty engine stop button
• Loose or disconnected ignition system wires
YES - GO TO STEP 5.
5. Cylinder Compression Inspection
Test the cylinder compression .
Is the compression normal?
NO - • Valve stuck open
• Valve clearance too small
• Worn cylinder and piston rings
• Leaking/damaged cylinder head gasket
• Seized valve
• Improper valve timing
YES - GO TO STEP 6.
6. Engine Start Condition
Start by following the normal procedure.
Does the engine start but then stop?
YES - • Improper choke operation
• Carburetor incorrectly adjusted
• Intake pipe leaking
• Improper ignition timing (faulty ICM or ignition coi l or ignition pulse generator)
• Fuel contaminated
16-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise wheel off the ground and spin by hand.
Does the wheel spin freely?
NO - • Brake dragging
• Worn or damaged wheel bearings
• Bent axle
• Improper drive chain slack adjustment
YES - GO TO STEP 2.
2. Tire Pressure Inspection
Check the tire pressure.
Is the tire pressure correct?
NO - • Faulty tire valve
• Punctured tire
YES - GO TO STEP 3.
3. Clutch Inspection
Accelerate rapidly from low to second .
Does the engine speed change accordingly when clutch is released?
NO - • Clutch slipping
• Worn clutch discs/plates
• Warped clutch discs/plates
• Weak clutch spring
• Additive in engine oil
YES - GO TO STEP 4.
4. Engine Performance Inspection
Accelerate lightly.
Does the engine speed increase?
NO - • Choke valve closed
• Clogged air cleaner
• Restricted fuel flow
• Clogged muffler
YES - GO TO STEP 5.
5. Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing normal?
NO - • Fau lty ignition control module
YES - GO TO STEP 6.
6. Cylinder compression Inspection
Test the cylinder compression.
ls the compression normal?
NO - • Valve stuck open
• Worn cylinder and piston rings
• Leaking/damaged head gasket
• Improper valve timing
YES - GO TO STEP 7.
16-3
TROUBLESHOOTING
Check the carburetor for clogs.
Is t he carburetor clogged ?
YES - Carburetor not serviced frequently enough
NO - GO TO STEP 8.
8. Spark Plug Inspection
Remove and inspect the spark plug.
Is th e spark plug in good condition 7
NO - • Plug not serviced frequently enough
• Incorrect spark plug heat range
• Incorrect spark plug gap
YES - GO TO STEP 9.
9. Engine Oil Inspection
Check the oil level and condition.
Is the engine oil in good condition?
NO - • Oil level too high
• Oil level too low
• Contaminated oil
YES - GO TO STEP 10.
10. Lubrication Inspection
Remove cylinder head cover and inspect lubrication .
Is the valve train lubricated prop erly?
NO - • Clogged oil passage
• Faulty oil
YES - GO TO STEP 11.
11. Over Heating Inspection
Check for engine over heating.
Is the engine over heating?
YES - • Excessive carbon build-up in combustion chamber
• Use of poor quality fuel
• Clutch sl ipping
• Lean fuel mixture
• Wrong type of fuel
NO - GO TO STEP 12.
12. Engine Knocking Inspection
Accelerate or run at high speed.
Does the engine knock?
YES - • Worn piston and cylinder
• Wrong type of fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advanced (faulty ignition control module)
• Lean fuel mixture
NO - • Engine does not knock
16-4
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Carburetor Pilot Screw Inspection
Check the carburetor pilot screw adjustment.
Is the pilot screw correct?
NO - (page 5-18)
YES - GO TO STEP 2.
2. Intake Pipe Leaking Inspection
Check for leaks in the intake pipe.
Is there leaking?
YES - • Loose carburetor mounting nut
• Damaged insulator
NO - GO TO STEP 3.
3. Spark Test
Perform a spark test.
Is there a good spark?
NO • Faulty carbon or wet fou led spark plug
• Faulty ignition control module
• Faulty ignition coil
• Broken or shorted spark plug wire
• Faulty engine stop button
• Faulty exciter coi l
• Faulty ignition switch
• Loose or disconnected ignition system wires
YES - GO TO STEP 4.
Check the ignition timing .
NO - Improper ignition timing (Faulty ignition control module)
POOR PERFORMANCE AT HIGH SPEED

1. Fuel Line Inspection
Disconnect the fuel hose at the carburetor.
Does the fuel flow freely?
NO - • Clogged fuel line
• Clogged fuel strainer screen
YES - GO TO STEP 2.
Remove the carburetor and check for clogged jets.
Are the jets clogged?
YES - Clean
NO - GO TO STEP 3.
3. Valve Timing Inspection
Check the va lve timing.
Is the valve timing correct?
NO - Cam sprocket not installed properly
YES - GO TO STEP 4.
16-5
TROUBLESHOOTING
Check the ignition timing.
NO - • Fau lty ignition control module
• Fau lty ignition pulse generator
YES - GO TO STEP 5.
5. Valve Spring Inspection
Check for the va lve springs.
Is the valve spring free length normal?
NO - Fau lty valve spring
YES - Not weak
POOR HANDLING
Steering is heavy
• Steering bearing adj usting nut too tight
• Damaged steering head bearings
Either wheel is wobbling
• Excessive w heel bearing play
• Bent rim
• Improperly installed wheel hub
• Swingarm pivot bearing excessively worn
• Bent frame
The motorcycle pulls to one side
• Front and rear wheel not aligned
• Faulty shock absorber
• Bent fork
• Bent swingarm
• Bent axle
• Bent frame
16-6
17. INDEX
AIR CLEANER ............................................................... 3-10 FRONT FENDER ............................................................ 2-5
AIR CLEANER HOUSING ··············································5-6 FRONT WHEEL .......................................................... 12-10
AIR SCREW ADJUSTMENT (CRF80f) ..······················ 5-19 FRONT WHEEUBRAKE/SUSPENSION/STEERING
BODY PANEL LOCATIONS ··· ....................................... 2-2 SPECIFICATIONS ······································· ................ 1-11
BRAKE PEDAL··· .. ·········•············· .............................. 13-15 FUEL LINE···························· ............ ······························ 3-9
BRAKE SHOE WEAR ·· ...... ··· ········· ............................... 3-20 FUEL SYSTEM SPECIFICATIONS (CRF100F) .............. 1-7
BRAKE SYSTEM ........................... ............................... 3-20 FUEL SYSTEM SPECIFICATIONS (CAFBOF) ................ 1-7
CABLE & HARNESS ROUTING·· ................................. 1-11 FUEL TANK·· ···················· .. ··········································· 2-4
CAM CHAIN TENSION ················································ 3-15 GEARSHIFT LINKAGE .. ··············································· 9-12
CAMSHAFT INSTALLATION·· ··································· 7-18 GENERAL SPECIFICATIONS ........................................ 1-5
CAMSHAFT REMOVAL .................................................7_5 HANDLEBAR·····························································..· 12·6
CARBURETOR ASSEMBLy ......................................... 5-12 HIGH ALTITUDE ADJUSTMENT ··················· ............. 5-20
CARBURETOR DISASSEMBLY···· ························ .. ·······5-8 ICM (IGNITION CONTROL MODULE)······ .. ················ 14-9
CARBURETOR INSTALLATION ··································5-15 IGNITION COIL ............................................................ 14-8
CARBURETOR REMOVAL ·························· ·················5-6 IGNITION SWITCH ··· .. ·········································.. ···· 14-10
CLUTCH····································· .. ········· ·························· 9-7 IGNITION SYSTEM INSPECTION······························· 14-5
CLUTCH SYSTEM ····················· .. ································· 3-22 IGNITION TIMING ······················································· 14-8
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS ···1 -10 KICKSTARTER ····· ·····"··············································· 11-18
COMPONENT LOCATION LEFT CRANKCASE COVER INSTALLATION· .. ········· .. 10-8
ALTERNATOR ........................................................ 10-2 LEFT CRANKCASE COVER REMOVAL······················ 10-4
CLUTCH/GEARSHIFT LINKAGE ·······························9-2 LUBRICATION & SEAL POINTS ································· 1-15
CRANKSHAFT/TRANSMISSION/ LUBRICATION SYSTEM DIAGRAM ........................... .. 4-2
KICKSTARTER ......................................................... 11 -2 LUBRICATION SYSTEM SPECIFICATIONS ················· 1-7
CYLINDER HEADNALVEs ........................................ 7-2 MAINTENANCE SCHEDULE··········· ······························ 3-5
CYLINDER/PISTON ................................................... 8-2 MODEL IDENTIFICATION ............................................. 1-2
ENGINE REMOVAUINSTALLATION ........................ 6-2 MUD GUARD································.. ·· ····························· 2-6
FRONT WHEEUBRAKE/SUSPENSION/ MUFFLER/EXHAUST PIPE ........................................•... 2-7
STEERING································································ 12-2 NUMBER PLATE· ······ .................................................... 2-5
FUEL SYSTEM··· ························································5-2 NUTS, BOLTS, FASTENER$ ....................................... 3-25
REAR WHEEUBRAKE/SUSPENSION ····················· 13-2 OIL PUMP············································ ·························· 4-5
CRANKCASE ASSEMBLY ·········································11-19 PILOT SCREW ADJUSTMENT (CRF100F) ················· 5-18
CRANKCASE BEARING REPLACEMENT ................. 11-12 PISTON INSTALLATION ............................................... 8-9
CRANKCASE PROTECTOR ........................................... 2-6 PISTON REMOVAL·· .. ·· ·············· ·································· 8-6
CRANKCASE SEPARATIQN ........................................ 11 -7 PISTON/PISTON RING INSPECTION··························· 8-7
CRAN KCASEITRAN SM ISS 10 N/KICKSTARTER POOR HANDLING ····················· ·································· 16-6
SPECIFICATIONS (CRF100F) ....................................... 1-10 POOR PERFORMANCE AT HIGH SPEED ................... 16-5
CRANKCASE/TRANSMISSION/KICKSTARTER POOR PERFORMANCE AT LOW AND
SPECIFICATIONS (CRFBOF) ................................ ········ 1-11 IDLE SPEED ........... · ················ ······························· 16-5
CRANKSHAFT .............................................................. 11 -8 PRIMARY DRIVE GEAR ··············································· 9-10
CYLINDER COMPRESSION TEST································· 7-6 REAR BRAKE ............................................................. 13-12 a!llil
CYLINDER HEAD ASSEMBL y ..................................... 7-16 REAR FENDER··············································· .. ·············· 2-5 - -
CYLINDER HEAD DISASSEMBLY·························"· .. · 7-10 REAR WHEEL······························································· 13-6
CYLINDER HEAD INSPECTION ........................ ··········7-11 REAR WHEEUBRAKE/SUSPENSION
CYLINDER HEAD INSTALLATION ··· ........................... 7-17 SPECIFICATIONS ··················· ····································· 1-12
CYLINDER HEAD OIL CHECK BOLT ............................. 4_5 RIGHT CRANKCASE COVER INSTALLATION··········· 9-14
CYLINDER HEAD REMOVAL ..................................... .. 7-10 RIGHT CRANKCASE COVER REMOVAL······················ 9-5
CYLINDER HEADNALVES SPECIFICATIONS ·············· 1-8 SEAT ................................................................ .............. 2-3
CYLINDER INSPECTION············································· 8-5 SERVICE INFORMATION
CYLINDER INSTALLATION ......................................... 8- 10 AL TERNA TOR············· ············································ 10-3
CYLINDER REMOVAL···································· .. ··············8-5 CLUTCH/GEARSHIFT LINKAGE ······························· 9-3
CYLINDER/PISTON SPECIFICATIONS (CRF100F) ·······1-9 CRANKSHAFT/TRANSMISSION/
CYLINDER/PISTON SPECIFICATIONS (CRF80F) ......... , _9 KICKSTARTER····························· ···························· 11-3
DRIVE CHAIN ······ ·· ...................................................... 3-17 CYLINDER HEADNALVES ······································· 7-3
DRIVE CHAIN SLIDER·········· ············· ···························3-19 CYLINDER/PISTON ··················································· 8-3
ELECTRICAL SYSTEM SPECIFICATIONS .................. 1-12 ELECTRICAL SYSTEM·······································..··· 14-3
EMISSION CONTROL SYSTEMS ······························· 1-21 ENGINE REMOVAUINSTALLATION ······················· 6-3
ENGINE & FRAME TORQUE VALUES······················· 1-13 FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 2-2
ENGINE DOES NOT START OR IS FRONT WHEEUBRAKE/SUSPENSION/
HARD TO START ········ ...............................................,.16-2 STEERING······························································· 12-3
ENGINE IDLE SPEED··················································· 3-16 FUEL SYSTEM .......................................................... 5-3
ENGINE INSTALLATION ............................................... 6-7 LUBRICATION SYSTEM···· ....................................... 4-3
ENGINE LACKS POWER ............................................. 16-3 MAINTENANCE ........................................................ 3-2
ENGINE OIL·····················································............. 3.13 REAR WHEEUBRAKE/SUSPENSION ···················· 13-3
ENGINE OIL STAINER SCREEN .................................. 3-15 SERVICE RULES ···························································· 1-2
ENGINE REMOVAL, ....................................................... 5_4 SHOCK ABSORBER··················· .. ······························ 13-18
ENGINE STOP BUTTON ··· ........................................... 14-9 SHOCK LINKAGE ...................................................... 13-19
FLYWHEEL ................................................................... 10-4 SIDE COVER .................................................................. 2-3
FORK··········································································· 12-18 SIDE STAND·····"························································· 3-23
FRONT BRAKE ........................................................... 12-15 SPARK ARRESTER··························· ··········· ................ 3-24
17-1
INDEX
SPARK PLUG ............................................................... 3-11 CRANKSHAFT/TRANSMISSION/
STANDARD TORQUE VALUES .................................. 1-13 KICKSTARTER ...................................... ................... 11 -6
STATOR···.................................................................... 10-5 CYLINDER HEADN ALVEs ........................................ 7-5
STATOR BASE ............................................................ 10-7 CYLINDER/PISTON ................................................... g-4
STEERING HEAD BEARINGS ..................................... 3-26 ELECTRICAL SYSTEM ............................................ 14-4
STEERING STEM ...................................................... 12-26 FRAME/BODY PANELS/EXHAUST SYSTEM .......... 2-2
SUSPENSION .............................................................. 3-23 FRONT WHEEUBRAKE/SUSPENSION/
SWINGARM······ ......................................................... 13-22 STEERING ............................................................... 12-5
SYSTEM DIAGRAM FUEL SYSTEM .......................................................... 5-5
ELECTRICAL SYSTEM,., ......................................... 14-2 LUBRICATION SYSTEM ........................................... 4-4
TANK SHROUD ·· ............ ................... ............................ 2-3 REAR WHEEUBRAKE/SUSPENSION ..................... 13-5
THROTTLE OPERATION ............................................... 3-9 VALVE CLEARANCE .................................................... 3.12
TRANSMISSION ASSEMBLY/INSTALLATION ....... 11-15 VALVE GUIDE REPLACEMENT .................................. 7-13
TRANSMISSION REMOVAUDISASSEMBLY········.... 11 -9 VALVE SEAT INSPECTION/REFACING ...................... 7-13
TROUBLESHOOTING WHEELS/TIRES ····· ....................................................... 3-25
CLUTCH/GEARSHIFT LINKAGE, .............................. 9-4 WIRING DIAGRAM ...................................................... 15-2
17-2

Honda CRF80F CRF100F (2004-2013) Service Manual

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A Few Words About Safety

For Your Customer's Safety

Important Safety Precautions

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

Follow the Maintenance Schedule (Section 3) recommendations to

You CAN be KILLED or SERIOUSLY HURT TROUBLESHOOTING

You CAN be HURT if you don't follow INDEX

• Instructions - how to service lhis vehicle correctly and safely.

~ Use recommended engine oil, unless otherwise specified.

~ Use silicone grease.

•tum Apply sealant.

.. Use Fork or Suspension Fluid.

SERVICE RULES ......................................... 1.2 CRANKSHAFT/ TRANSMISSION/

GENERAL SPECIFICATIONs ...................... 1.5 CRANKSHAFT/ TRANSMISSION/

CYLINDER/ PISTON SPECIFICATIONS

LUBRICATION & SEAL POINTS .............. 1-15

The Model Identification Label (U.S.A.) or Safety Certification Label

The carburetor identification number is stamped on the right side of

The color label is attached as shown. When ordering color-coded parts,

FUEL SYSTEM SPECIFICATIONS (CRF100F)

Throttle grip free play _ _ _ _ _2_-_ 6 _m_m 4 _m....:.)_ _ _ _ _ _ ~

FUEL SYSTEM SPECIFICATIONS (CRF80F)

CYLINDER/PISTON SPECIFICATIONS (CRF80F)

0.10 - 0.35 (0.0039 - 0.0138) 0.60 (0.024)

FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS

ELECTRICAL SYSTEM SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

CLUTCH/ GEARSHIFT LINKAGE

ENGINE REMOV AL/INSTALLATION

FRONT BRAKE CABLE

ENGINE STOP BUTION WIRE W IRE CLAMP ALTERNATOR/

CARBURETOR DRAIN HOSE

CRANKCASE WIRE BAND

CARBURETOR DRAIN HOSE

ENGINE STOP BUTION WIRE

IGNITION CONTROL ALTERNATOR/

After '07 CRANKCASE

CARBURETOR DRAIN HOSE

AIR VENT HOSE

CRANKCASE BREATHER SEPARATOR

SERVICE INFORMATION ........................... 2-2 NUMBER PLATE ····· .................................... 2-5

TROUBLESHOOTING ..... ·· .......................... 2-2 FRONT FENDER ......................................... 2-5

BODY PANEL LOCATIONS ........................ 2-2 REAR FENDER ............................................ 2-5

SIDE COVER, ............................................... 2-3 MUD GUARD .............................................. 2-6

SEAT, ........................................................... 2-3 CRANKCASE PROTECTOR ........................ 2-6

TANK SHROUD ........................................... 2-3 MUFFLER/EXHAUST PIPE ........................ 2-7

FUEL TANK ................................................. 2-4

BODY PANEL LOCATIONS

BREATHER HOSE SCREW

Remove the front engine hanger bolt/nut and crank- 1BOLT/

Inspect the stopper rubber for wear or damage,

Tighten the two crankcase protector bolts.

Remove the exhaust pipe/muffler mounting bolts

Install the exhaust pipe, temporari ly install the

TORQUE: 26 N ·m (2.7 kgf,m, 20 lbf·ft)

MAINTENANCE SCHEDULE ...................... 3-5 DRIVE CHAIN SLIDER .. ............................ 3-19

SPARK PLUG ............................................ 3-11 SIDE STAND ............................................. 3-23

ENGINE OIL ............................................... 3-13 SPARK ARRESTER ................................... 3-24

CAM CHAIN TENSION ............................. 3-15 WHEELS/TIRES ........................................ 3-25