2008-2009 Honda CRF230L CRF230M Service & Repair Manual
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HOW TO USE THIS MANUAL
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
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Replace the partes) with new one{s) before assembly .
....
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Use the recommend engine oil, unless othelWise specified.
-,
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
~-~
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (conlalnlng more than 3% molybdenum disulfide, NOG! #2 or
equivalent).
~
Example:
• Molykote® BR-2 plus manufactured by Dow Coming U.SA
• Multi-purpose M·2 manufactured by Mitsubishl Oil, Japan
Usa molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
~ ·
Molykote® G·n Paste manufactured by Dow Coming U .S.A.
·
Honda Moly 60 (U.S.A. only)
·
Rocel ASP manufactured by RocolUmi ted. U.K.
·
Rocel Paste manufactured by Sumice Lubricant, Japan
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Use silicone grease .
em
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
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Apply sealant.
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Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
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Use fof'1( or suspension fluid .
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CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
ENGINE REMOVAUINSTALLATION
CYLINDER HEADNALVES
CYLINDER/PISTON
CLUTCH/GEARSHIFT LINKAGE
ALTERNATOR/STARTER CLUTCH
CRANKCASEITRANSMISSION/CRANKSHAFT
III FRONT WHEEUSUSPENSION/STEERING
~ F=========================================
~ REAR WHEEUSUSPENSION
~ P=====================================
U HYDRAULIC DISC BRAKE
..J
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U
ii:
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W
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
LIGHTS/METER/SWITCHES
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
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MEMO
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SERVICE RULES ·· .. ·· ··· ··· ········ ····· ·· ···· ·· · ··· ····· 1-2
MODEL IDENTIFICATION ····························1-3
GENERAL SPECIFICATIONS ·· ····· ·· · ·· ······ ·· ··1-6
LUBRICATION SYSTEM
SPECIFICATIONS ···· ·· ···· ·······························1-8
FUEL SYSTEM SPECIFICATIONS········ ·· ·· ···1-8
CYLINDER HEADNALVES
SPECIFICATIONS · ··· ·· ········ ·· · ·· · ·· ····· ·· ·· ··········1-8
CYLINDER/PISTON SPECIFICATIONS ······· 1-9
CLUTCH/GEARSHIFT LINKAGE
SPECIFICATIONS ·········································1-9
ALTERNATOR/STARTER CLUTCH
SPECIFICATION ······························· ············ 1-9
CRANKCASEITRANSMISSION/
CRANKSHAFT SPECIFICATIONS · ··· ······ ··· 1-1 0
1. GENERAL INFORMATION
FRONT WHEEUSUSPENSION/STEERING
SPECIFICATIONS"" " " "" "" """""""" """, 1 -1 0
REAR WHEEUSUSPENSION
SPECIFICATIONS"""" """" "" "" " " """"" , 1 -11
HYDRAULIC DISC BRAKE
SPECIFICATIONS ················· ·· ······· ············· 1-11
BATTERY/CHARGING SYSTEM
SPECIFICATIONS" " " "" " """""""""" " " " , 1 -11
IGNITION SYSTEM SPECIFICATIONS·· ··· · 1-12
ELECTRIC STARTER SPECIFICATION ···· 1-12
LIGHTS/METERS/SWITCHES
SPECIFICATIONS """""""""""""""" "" ", 1 -12
TORQUE VALUES ····················· ·· ··· ··· · ·· ···· .. 1-13
LUBRICATION & SEAL POINTS ·· ···· ··· ······1-17
CABLE & HARNESS ROUTING ················· 1-19
EMISSION CONTROL SYSTEMS ······ ···· ·· ·· 1-27
1·1
GENERAL INFORMATION
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lUbricants or their equivalents. Parts that do not 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 fasten-
e<s .
4. Install new gaskets. O-rings. cotter pins, and lock plates when reassembling.
5. When lightening 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 1·19).
ABBREVIATION
Throughout this manual. the following abbreviation are used to identify the respective parts or systems.
1-2
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GENERAL INFORMATION
MODEL IDENTIFICATION
NOTE:
The illustrations and phot ographs in this manual are main ly of the CRF2301.
CRF230l; U.S.A. type shown:
CRF230M; U.S.A. type shown:
1·3
GENERAL INFORMATION
SERIAL NUMBERS
The Vehicle Identification Number (YIN) Is stamped on the right side of the
steering head .
The engine serial number is stamped on Ihe lower left side of the crank- ~:~~~~~~~~~~~~~
case.
The carburetor identifICation number is stamped on the left side of the car· ~~IIIIIIIIIIIIII~IIIIIII~~~""""""':"'~==~~
burator body. U.S.A. type shown:
LABELS
The safety certification label is attached on the front side of the steering
head.
1-4
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What's Included?
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Print one or all pages of your manual
$33.99
2008-2009 Honda CRF230L, CRF230M OEM Service & Repair Manual
Models covered:
- Honda CRF230L
- Honda CRF230M
Tackling maintenance on your dual-sport or supermoto? The 2008-2009 Honda CRF230L, CRF230M OEM Service & Repair Manual provides the complete technical blueprint for these versatile single-cylinder machines. This factory resource contains detailed specifications and procedures for both the trail-oriented CRF230L and the street-focused CRF230M variants, covering every system from the air-cooled powerplant to the specialized suspension components.
Valve adjustment giving you headaches or carburetor running too rich? This manual breaks down each component with detailed illustrations, precise specifications, and systematic service procedures. You'll find exact valve clearances, ignition timing parameters, suspension setup specifications, and critical torque values for the entire motorcycle—from engine internals to chassis components.
These little 230s might seem simple, but there's a world of difference between "close enough" and factory specs. Whether you're rebuilding the top end, dialing in the suspension, or just performing routine maintenance, this manual eliminates the guesswork that leads to compromised performance. Skip the forum debates and maintain your CRF with the exact specifications Honda engineers established for these bulletproof machines.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
