2004-2012 Honda CRF80F & CRF100F Motorcycle Service & Repair Manual

HOW TO USE THIS MANUAL ThlS aE!<YlCe maroJal describes the service procedures lor the CAFBOF and CRFH)OF FoIklw the Maintenance Schedule (Section 3) rerommeodatlons to ensure that the vet1lC1e IS In peak opemllng condition and the ermSSK)n levels are wlth,n the sklndaro sat by the US EnVirOnmel1tal Protection Ageocy (EPA) and California Air Resources Board (CARB). Pertorming !he first scheduled malmenan~e Is very Important II compensates tor the Initial wear lllat occurs dUring the break-in perIOd Sections I and 3 apply to tile whole motOrcyde SeclIOIl 2 Illustrates procedures tor removaVinstallation of components that may be reqUIred 10 perform sefvlCe described In the folloWing sections Section 4 through 14 describe paris of the moIorcycle. grouped according to locatlOfl Find the secllOI1 you want on this paga, then tum to the ta~e 01 contents on !he first page 01 the section Most sections start wlltl an assem~ Of system il lustralO(l(l, servICe IIllormallOrl and l.oubieshooUng lor tho sedlOrl. The subsequent pages gM! detailed procedures. II )'!:lu 000'\ know the source of the trouble. go to Secoon 16 Troubleshooting. Your saiety, and the safely 01 others, IS very IlTIpOftM1. To help you make <n'Oflned deciSIOnS we have provided safety messages and o1tler Inlo<ma!/Ofl throoghout tl\ls manual. Of wurst!. h is oot practICal Of possible to warn you about all the tlazards aSSOCIated WIth selVlCU>Q thIS vehICle You must use your own gOOd judgement. You Will find Important safely informatron in a vanely 01 forms irlcloong • Safety Labe!!! - on tile vehicle • Safety Messages - prec&ded by a :o.aTety alen sym~ 1 and one o! three sognal words, OANGER WARNING. or CAUTION These slQOiIl words mean You WILL be KILLED or SERIOUSLY ITlIW~[t1;;. HURT d you don·! follow rflS!ruCIIOnS. You CAN be KillED or SERIOUSLY HURT if you don't follow InStr1.lCtiQn$. You CAN be HURT W you don·t follow onstruCbOOS • Instructions - now to service this vahickl COflediy and safely AS you read this manual. you wil l lind rflformat<on that is preceded by a ..N01lCl. symbol The purpose of Ih,s message is to help prevent damage 10 your vehicle. other property, Or the environment. z ;; a: .... w > iX c c z " w z " z w CONTENTS MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR CRANKSHAFTITRANSMISSION/KICKSTARTER FRONT WHEEUBRAKEISUSPENSIONISTEERING REAR WHEEUBRAKEISUSPENSION ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used IhroughoUllhis manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically In the texl without the use of the symbols. ~ Replace the parl(s) with new one(s) before assembly. 'D Use recommended engine oil, unless otherwise specified. ~ Use molybdenum oil soluUon (mixture of the engine oil and molybdenum grease in a ratio all : 1). I .... -.. I 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 aquillalent). ~ Example: Molykot~ 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 Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) Roeol ASP manufactured by Roeol Limited, U.K. Roeol Paste manufactured by Sumico Lubricant, Japan ,Gi Use silicone grease. Cvm Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ",' &lID! Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. .. I Use Fork or Suspension Fluid .

1. GENERAL INFORMATION SERVICE RULES ......................................... ' ·2 MODEL IDENTIFiCATION ........................ · .. '·2 GENERAL SPECiFiCATIONS· .............. · ...... ' ·5 LUBRICATION SYSTEM SPECiFiCATIONS .... ·· .. ·· ........ · .. ·· .. · ...... ·· .. · .. · ' -7 FUEL SYSTEM SPECIFICATIONS (CRF'00F) .. · .. ·· .. ·· .... ··· .. · .. · .. ·· .. · .. ·...... ·· ........ ·· ' -7 FUEL SYSTEM SPECIFICATIONS (CRFBOF) · .. · .. ··· .. ·· .... ·· ........ · .... · .. · ...... · .. · ...... ·· ' -7 CYLINDER HEADIVALVES SPECIFICATIONS .... .. .................................. '-8 CYLINDER/ PISTON SPECIFICATIONS (CRF'OOF) .... ·· · .. ·· .... ·· .. · .. · .. ·· ........ ··· .. · .. · .... .. ·· ' -9 CYLINDER/ PISTON SPECIFICATIONS (CRFBOF) · .. · .. ·.... · .. · ...... · .... ·· · ...... .. .... · .. · .. ·· .. ··· ' -9 CLUTCH/ GEARSHIFT LINKAGE SPECiFiCATIONS · ...... · .. ·· .. · .. ·· .... ·· .... .. · .... .. '- '0 CRANKSHAFT/TRANSMISSION/ KICKSTARTER SPECIFICATIONS (CRF'OOF) · .. · .. ·...... ·.... · .... · .... · .... ·.... · .... · .. · .. · ' - '0 CRANKSHAFT/TRANSMISSION/ KICKSTARTER SPECIFICATIONS (CRFBOF) .. ·.... · .. · .... ··· .. ··· .. ·.... ··· .... · .. · ·· .. ·.... ·· , -" FRONT WHEEL/BRAKE/SUSPENSION/ STEERING SPECIFICATIONS .................. , -" REAR WHEEL/ BRAKE/ SUSPENSION SPECIFICATIONS ............................... .. ... . ' - '2 ELECTRICAL SYSTEM SPECIFICATIONS ..................................... '- '2 STANDARD TOROUE VALUES ............... '- '3 ENGINE & FRAME TOROUE VALUES .... '- '3 LUBRICATION & SEAL POINTS · ........ ·.... '-'5 CABLE & HARNESS ROUTING ............... ' -17 EMISSION CONTROL SYSTEMS .......... .. '-2' 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 100ls when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotler 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

II The Vehicle Identification Number is stamped on the left side of the steering head. T he engine serial number is stamped on the l ower left side of the lower crankcase. The Model Identification label (U.S.A.) or Safety Certification label (Ca nada) is located on right side of the steering head. The ca rburetor identification number is stamped on the right side of the carburetor body as shown. GENERAL INFORMATION 1-3

GENERAL INFORMATION The Emission Control Information Label is attached as shown. The color label is attached as shown. When ordering color-coded parts, always specify the designated color code. 1-4 '04 - '07 After '07 U.S.A. TYPE ~ EMISSION CONTROL , It:JFORMATION LABEL INFORMATI ON LABEL

GENERAL INFORMATION GENERAL SPECIFICATIONS CRF80F ITEM SPE CIFI CAnON DIMENSIONS Overall length 1,749 mm (68 .9 in) Overall width 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 we ig ht 75 kg (16,,5 :c ' .. bs.,I '-_ ________ -i FRAME Frame t~y~ pe ;::---------------+'Back bone FrOn! 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 oil damper Fr ont tire sile 2.50-164PR Rea r tire size 3.60- 14 4PA Tire brand IRC Fron t brake Internal expanding shoe Rear brake Internal expanding shoe Caster angle 28°02' Trail 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 lite r (0.18 US gal, 0.15 Imp gal) hE "N " G"""Nil'E-- -j- B"o ;C , ;;;eC;a nd strok"e C-----==--=-"---- 47.5 x 45.0 mm (1.87 x 1.77 in) Displacement 79.7 cm' (4.86 cu-in) Compression ratio 9.7: 1 Valve train Chain drive and OHC with rocker arm Intake valve Exhaustvalve opens closes opens closes l ubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dry weight r-"""'",,""mi,~-iCyli nder arrangement CARBURETOR Carburetor type Thronle bore I-D "R n' ;cVw E'T~R~A~'N~-t-;. Clutch system Clut ch operation system Transmission Primary reduction Final reduct ion Gear ratio Gearshift panern at 1 mm (0.04 inllift at 1 mm (0. 04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift 8 0 BTDC 40 0 ABDC 40" BBDC 8 0 ATOC Forced pressure and wet sump Trochoid Air cooled Oiled polyurethane f oam Assembled type 18.9 kg (41.7 Ibs) Single cylinder inclined 15" from vertical Piston valve type 18 mm (0.7 1 in) -------i~ Multi-plate, wet 1S1 2nd 3,d 4'h 5.h Mechanical type 5 speeds 4.437 (71/16) 3.285 (46/14) 2.692 (35/13) 1.823 (31/17) 1.400 (28/20) 1.130 (26123) 0.960 (24/25) left fo ot operated return system, 1-N -2-3- 4 -5 r-"E" lE~C PTnR~'~C~A" l ---t"g ;;;n ~;".;~ o~ n~ s~ y~ SI~e;;;m;;---------------1- Capacitive Discharged Ignition Starting system Kickstarter 1-5

GENERAL INFORMATION CRF100F I DIMENSIONS ITEM Overall length Overall width Overall height Wheelbase Seat height footpeg height Ground clearance Curb weight SPECIFICATION 1,853 mm (73.0 in) 786 mm (30.9 in) 1,046 mm (4.12 in) 1,249 mm (49.2 in) 786 mm (30.9 in) 319 mm (12.6 in) 252 mm (9.9 in) ('04 - '07) 79 kg (174Ibs) FRAME frame type _ _ __ -"IA"h"'e,,'_·O~7'_'1 ____ ri 77 kg (170 Ibs) Back bone Telescopic fork 132 mm (5.2 in) Swingarm ENGINE front suspension front wheet travel Rear suspension Rear wheel travel Rear damper front tire size Rear tire size Tire brand front brake Rear brake Caster angle Trait length fuel tank capacity fuel tank reserve capacity Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Crankshaft type ('04 - '07) (After '07) ('04 - '07) (After '07) at 1 mm (0.04 in) lift at 1 mm (0.04 in ) lift at 1 mm (0.04 in ) lift at 1 mm (0.04 in) lift 148.0 mm (5.83 in) Conventional type oil damper 70/100· '9 M/C 42M 90/100, '6 M/C 51M Cheng shin Internal expanding shoe Internal expanding shoe 28~50' 99 mm (3.9 in) 5.51iter (1,45 US gal, 1.21 Imp gal) 5.0 liter (1.32 US gal. 1.10 Imp gal) 1. 1 liter (0.29 US gal, 0.24 Imp gal) 0.7 liter (0.18 US gal, 0.15 Imp gal) 53.0)( 45.0 mm (2.09)( 1.77 in) 99.2 cm J (6.' cu-in) 9.4 : 1 Silent, multi-link chain drive and OHC with rocker arm 10° BTDC 35 ° ABDC 40 ° BBDC 5° AToC Forced pressure and weI sump Trochoid Air cooled Oiled polyurethane foam Assembled type 21.4 kg (47.18Ibs) ± Engine dry weight Cylinder arrangement CARBURETOR Carburetor type ;;=c="----- - __ ri Single cylinder inclined 15 0 from vertical Piston valve type Thronle bore DRIVE TRAIN Clutch system --- ----- - ELECTRICAL Clutch opera tion system Transmission Primary reduction final reduction Gear ratio Gearshift panern Ignition system ,,, 2nd 3,d 4,h 5th ----+-- 20 mm (0.8 in) Multi -plate, wet Mechanical type 5 speeds 4.437 (71116) 3. 571 (50114) 3.083 (37112) 1.882 (32117) 1.400 (28120) 1.130 (26123) D o.923 (24126) Left foot operated return system, 1- N-2 - 3-4-5 Condenser Discharged Ignitio ~n ;;--------l __ --'--' 5 ,, ''''' '-" rti ng sy"s ""."m "-___ _ _______ ~Kickstarter ____ _ 1-6 I J

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2004-2012 Honda CRF80F & CRF100F Motorcycle Service & Repair Manual

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