Manual de Taller HONDA AFRICA TIWN CRF 1000L MANUAL TALLER 2015

SHOP MANUAL

CRF1000/A/D

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HOW TO USE THIS MANUAL

A Few Words About Safety

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the

motorcycle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures

require the 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 risks to their personal safety and the safe operation of

the motorcycle.

If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of the motorcycle. Any error or oversight

while servicing a motorcycle can result in faulty operation, damage to the motorcycle, or injury to others.

For Your Safety

Because this manual is intended for the professional service technician, we 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 safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.

Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service or repair procedures. Only you can decide whether 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 safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills

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

pressurized air or liquids, and springs or other stored-energy components. If there is 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 motorcycle up in the air. Any time you lift the motorcycle, either with 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.

• Injury 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 gasoline 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.

Improper service or repairs can create an unsafe

condition that can cause your customer to be

seriously hurt or killed.

Follow the procedures and precautions in this

manual and other service materials carefully.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or

killed.

Follow the procedures and precautions in this

manual carefully.

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HOW TO USE THIS MANUAL

How To Use This Manual

This manual describes the service procedures for the CRF1000/A/D-G.

Sections 1,2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may

be required to perform service described in the following sections.

Section 4 through 24 describe parts of the motorcycle, grouped according to location.

Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition.

Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in

period.

Find the section you want on this page, then turn to the table of contents on the first page of the section.

Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent

pages give detailed procedure.

Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI

section troubleshooting first.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help

prevent damage to your vehicle, other property, or the environment.

SERVICE PUBLICATION OFFICE

Date of Issue: September, 2015

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety

messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the

hazards associated with servicing this vehicle.

You must use your own good judgement.

You will find important safety information in a variety of forms including:

• Safety Labels – on the vehicle

• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE

BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda

Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT

INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT

WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF

MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

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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.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise 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 (containing more than 3% molybdenum disulfide, NOGI #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, NOGI #2 or

equivalent).

Example:

• Molykote® G-n Paste manufactured by Dow Corning 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.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

CONTENTS

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GENERAL INFORMATION

FRAME/BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

PGM-FI SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER

FUEL SYSTEM

COOLING SYSTEM

LUBRICATION SYSTEM

CYLINDER HEAD/VALVE/CAMSHAFT

ALTERNATOR/STARTER CLUTCH

CLUTCH/GEARSHIFT LINKAGE (CRF1000/A)

DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D)

CRANKCASE/TRANSMISSION/BALANCER

CRANKSHAFT/PISTON/CYLINDER

ENGINE REMOVAL/INSTALLATION

FRONT WHEEL/SUSPENSION/STEERING

REAR WHEEL/SUSPENSION

HYDRAULIC BRAKE

ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D)

BATTERY/CHARGING SYSTEM

LIGHTS/METERS/SWITCHES

IMMOBILIZER SYSTEM (HISS)

WIRING DIAGRAM

INDEX

ENGINE/ELECTRICAL

CHASSIS

FRAME

ELECTRICAL

MEMO

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1. GENERAL INFORMATION

SERVICE RULES··································· 1-2

MODEL IDENTIFICATION ······················· 1-3

SPECIFICATIONS·································· 1-5

TORQUE VALUES ······························· 1-12

LUBRICATION & SEAL POINTS ············ 1-22

SPECIAL TOOL LIST ··························· 1-24

CABLE & HARNESS ROUTING ············· 1-26

EMISSION CONTROL SYSTEMS ··········· 1-47

TECHNICAL FEATURES ······················ 1-50

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GENERAL INFORMATION

SERVICE RULES

1. Use Honda Genuine 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, O-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 show in the Cable and Harness Routing (page 1-26).

9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

ABBREVIATION

Throughout this manual, the following abbreviations are used to identify the respective parts or systems.

DESTINATION CODE

Throughout this manual, the following codes are used to identify individual models for each region.

Abbrev. term Full term

ABS Anti-lock Brake System

CKP sensor Crankshaft Position sensor

DCT Dual Clutch Transmission

DLC Data Link Connector

DTC Diagnostic Trouble Code

ECM Engine Control Module

ECT sensor Engine Coolant Temperature sensor

EEPROM Electrically Erasable Programmable Read Only Memory

EOP sensor Engine Oil Pressure sensor

EOT sensor Engine Oil Temperature sensor

EVAP Evaporative Emission

HSTC Honda Selectable Torque Control

IACV Idle Air Control Valve

IAT sensor Intake Air Temperature sensor

MAP sensor Manifold Absolute Pressure sensor

MCS Motorcycle Communication System

MIL Malfunction Indicator Lamp

PAIR Pulse Secondary Air Injection

PCM Powertrain Control Module

PGM-FI Programmed Fuel Injection

SCS Service Check Signal

TP sensor Throttle Position sensor

TR sensor Transmission Range Sensor

VS sensor Vehicle Speed sensor

DESTINATION CODE REGION

ED, IIED, IIIED European direct sales

RU, IIRU, IIIRU Russia

U, IIU, IIIU Australia, New Zealand

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GENERAL INFORMATION

MODEL IDENTIFICATION

SERIAL NUMBERS/LABELS

CRF1000/A:

CRF1000D:

The motorcycle Identification Number (V.I.N) [1] is stamped

on the right side of the steering head.

The engine serial number [1] is stamped on the lower back

side of the crankcase.

The throttle body identification number [1] is stamped on the

upper front left side of the throttle body as shown.

The color label [1] is attached on the up side of the ETC tray.

When ordering color-coded parts, always specify the

designated color code.

The registered number plate (ED, RU models) [1] is attached

on the right side of the rear frame.

The compliance label (U model only) [1] is attached on the

front side of the down tube.

[1]

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GENERAL INFORMATION

TYPES

TYPE

CODE

DESTINATION

CODE

Manual

Transmission

Dual Clutch

Transmission

Anti-lock

Brake System

HSTC

CRF1000 ED, IIED, IIIED – – –

U–––

CRF1000A ED, IIED, IIIED –

RU, IIRU, IIIRU –

U, IIU, IIIU –

CRF1000D ED, IIED, IIIED –

RU, IIRU, IIIRU –

U, IIU, IIIU –

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GENERAL INFORMATION

SPECIFICATIONS

GENERAL SPECIFICATIONS

ITEM SPECIFICATIONS

DIMENSIONS Overall length 2,335 mm (91.9 in)

Overall width CRF1000 875 mm (34.4 in)

CRF1000A/D 930 mm (36.6 in)

Overall height 1,475 mm (58.1 in)

Wheelbase 1,575 mm (62.0 in)

Seat height 870 mm (34.3 in)

Footpeg height 351 mm (13.8 in)

Ground clearance 250 mm (9.8 in)

Curb weight CRF1000 228 kg (503 lbs)

CRF1000A 232 kg (511 lbs)

CRF1000D 242 kg (534 lbs)

Maximum weight capacity 195 kg (430 lbs)

FRAME Frame type Semi double cradle

Front suspension Telescopic fork

Front axle travel 204 mm (8.0 in)

Rear suspension Swingarm

Rear axle travel 220 mm (8.7 in)

Front tire size 90/90-21M/C 54H

Rear tire size 150/70R18M/C 70H

Front tire brand D610F (DUNLOP)

Rear tire brand D610 (DUNLOP)

Front brake Hydraulic double disc

Rear brake Hydraulic single disc

Caster angle 27° 30’

Trail length 113 mm (4.4 in)

Fuel tank capacity 18.8 liters (4.97 US gal, 4.14 Imp gal)

ENGINE Cylinder arrangement 2 cylinders in-line, slant angle 22.5°

Bore and stroke 92.0 x 75.1 mm (3.62 x 2.96 in)

Displacement 998 cm

(60.9 cu-in)

Compression ratio 10.0 : 1

Valve train Chain driven, OHC with valve lifter and rocker arm

Intake

valve

opens at 1 mm (0.04 in) lift 5° 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 5° ATDC

Lubrication system Forced pressure and dry sump

Oil pump type Trochoid

Cooling system Liquid cooled

Air filtration Viscous paper element

Engine dry weight CRF1000/A 68.2 kg (150.4 lbs)

CRF1000D 76.4 kg (168.4 lbs)

Firing order 1 - 2

FUEL DELIVERY

SYSTEM

Type PGM-FI

Throttle bore 44 mm (1.73 in)

DRIVE TRAIN

(CRF1000/A)

Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 6-speeds

Primary reduction 1.733 (78/45)

Final reduction 2.625 (42/16)

Gear ratio 1st 2.866 (43/15)

2nd 1.888 (34/18)

3rd 1.480 (37/25)

4th 1.230 (32/26)

5th 1.100 (33/30)

6th 0.968 (31/32)

Gearshift pattern Left foot operated return system,

1 - N - 2 - 3 - 4 - 5 - 6

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GENERAL INFORMATION

PGM-FI SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

FUEL SYSTEM SPECIFICATIONS

DRIVE TRAIN

(CRF1000D)

Clutch system 2 Multi-plate wet clutches

Clutch operation system Automatic

Transmission Constant mesh, 6-speeds

Primary reduction 1.883 (81/43)

Final reduction 2.625 (42/16)

Gear ratio 1st 2.562 (41/16)

2nd 1.761 (37/21)

3rd 1.375 (33/24)

4th 1.133 (34/30)

5th 0.972 (36/37)

6th 0.882 (30/34)

Gearshift pattern Automatic and electric shift (left hand operated)

return system,

N - 1 - 2 - 3 - 4 - 5 - 6

ELECTRICAL Ignition system Full transistorized ignition

Starting system Electric starter motor

Charging system Triple phase output alternator

Regulator/rectifier FET shorted/triple phase full wave rectification

Lighting system Battery

ITEM SPECIFICATIONS

IAT sensor resistance (at 40°C/104°F) 1.0 – 1.3 k

Fuel injector resistance (at 20°C/68°F) 11 – 13 

2 sensor heater resistance (at 20°C/68°F) 6.7 – 10.5 

IACV resistance (at 25°C/77°F) 99 – 121 

ITEM SPECIFICATIONS

Spark plug SILMAR8A9S (NGK)

Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)

Ignition coil primary peak voltage 100 V minimum

CKP sensor peak voltage 0.7 V minimum

Ignition timing ("F"mark) 10° BTDC at idle

ITEM SPECIFICATIONS

Throttle body identification number GQA5A

Engine idle speed 1,200 ± 100 min

-1

(rpm)

Throttle grip freeplay 2 – 6 mm (0.08 – 0.24 in)

Fuel pressure at idle 324 – 367 kPa (3.3 – 3.7 kgf/cm

, 47 – 53 psi)

Fuel pump flow (at 12 V) 319 cm

(4.2 US oz, 4.4 Imp oz) minimum/10 seconds

PAIR control solenoid valve resistance (at 20°C/68°F) 24 – 28 

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GENERAL INFORMATION

COOLING SYSTEM SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS

Unit: mm (in)

ITEM SPECIFICATIONS

Coolant capacity Radiator and

engine

CRF1000/A 1.63 liters (1.72 US qt, 1.43 Imp qt)

CRF1000D 1.65 liters (1.74 US qt, 1.45 Imp qt)

Reserve tank 0.33 liter (0.35 US qt, 0.29 Imp qt)

Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm

, 16 – 20 psi)

Thermostat Begin to open 80 – 84°C (176 – 183°F)

Fully open 95°C (203°F)

Valve lift 8 mm (0.3 in) minimum

Recommended antifreeze High quality ethylene glycol antifreeze containing

silicate-free corrosion inhibitors

Standard coolant concentration 1:1 mixture with distilled water

ITEM STANDARD SERVICE LIMIT

Engine oil

capacity

CRF1000/A After draining 3.9 liter (4.1 US qt, 3.4 Imp qt) –

After draining/engine oil

filter change

4.1 liter (4.3 US qt, 3.6 Imp qt) –

After disassembly 4.9 liter (5.2 US qt, 4.3 Imp qt) –

CRF1000D After draining 4.0 liter (4.2 US qt, 3.5 Imp qt) –

After draining/engine oil

filter/clutch oil filter

change

4.2 liter (4.4 US qt, 3.7 Imp qt) –

After disassembly 5.2 liter (5.5 US qt, 4.6 Imp qt) –

Recommended engine oil Honda "4-stroke motorcycle oil" or an

equivalent motor oil.

API classification: SG or higher

JASO T903 standard: MA

Viscosity: SAE 10W-30

–

Oil pressure (at oil filter cartridge) 499 – 637 kPa (5.1 – 6.5 kgf/cm

72 – 92 psi) at 5,000 min

-1

(rpm)/

(80°C/176°F)

–

Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)

ITEM STANDARD SERVICE LIMIT

Cylinder compression at 500 rpm 1,245 kPa (12.7 kgf/cm

, 181 psi) –

Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) –

0.23 ± 0.02 (0.009 ± 0.001)

(between roller and cam lobe)

–

Valve, valve guide Valve stem O.D. IN 5.475 – 5.490 (0.2352 – 0.2358) 5.465 (0.215)

EX 5.465 – 5.480 (0.2152 – 0.2157) 5.465 (0.214)

Valve guide I.D. IN/EX 5.500 – 5.512 (0.2165 – 0.2170) 5.542 (0.219)

Valve guide projection

above cylinder head

IN 17.7 – 18.0 (0.70 – 0.71) –

EX 17.8 – 18.1 (0.70 – 0.71) –

Valve seat width IN 1.1 – 1.3 (0.04 – 0.05) 1.5 (0.06)

EX 1.3 – 1.5 (0.05 – 0.06) 1.9 (0.07)

Valve spring Free length 43.20 (1.701) 42.2 (1.97)

Valve lifter Valve lifter O.D. IN 28.978 – 28.993 (1.1409 – 1.1415) 28.97 (1.141)

Valve lifter bore I.D. IN 29.010 – 29.026 (1.1421 – 1.1428) 29.04 (1.143)

Rocker arm Arm I.D. EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)

Shaft O.D. EX 11.977 – 11.990 (0.4715 – 0.4720) –

Camshaft Cam lobe height IN 41.240 – 41.480 (1.6236 – 1.6331) 41.21 (1.622)

EX 41.531 – 41.771 (1.6351 – 1.6445) 41.50 (1.634)

Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)

Cylinder head warpage – 0.10 (0.004)

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GENERAL INFORMATION

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (CRF1000/A)

Unit: mm (in)

DUAL CLUTCH TRANSMISSION SPECIFICATIONS (CRF1000D)

CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS (CRF1000/A)

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Starter driven gear boss O.D. 57.749 – 57.768 (2.2736 – 2.2743) –

I.D. 44.000 – 44.016 (1.7323 – 1.7329) –

ITEM STANDARD SERVICE LIMIT

Clutch lever freeplay 10 – 20 (0.4 – 0.8) –

Clutch Spring free length 52.48 (2.066) 51.48 (2.02)

Disc thickness 3.22 – 3.38 (0.127 – 0.133) 3.0 (0.12)

Plate warpage – 0.20 (0.008)

Primary driven gear I.D. 41.958 – 41.983 (1.6519 – 1.6529) –

Clutch outer guide O.D. 34.975 – 34.991 (1.3770 – 1.3776) –

I.D. 28.000 – 28.021 (1.1024 – 1.1032) –

Mainshaft O.D. at clutch outer guide 27.967 – 27.980 (1.1011 – 1.1016) –

ITEM STANDARD SERVICE LIMIT

Shift clutch Clutch clearance 0.9 – 1.1 (0.035 – 0.043) –

Disc thickness 1.88 – 2.00 (0.074 – 0.079) worn out lining

Plate thickness 1.95 – 2.05 (0.077 – 0.081) discoloration

EOT sensor resistance (20°C/68°F) 2.5 – 2.8 k –

ITEM STANDARD SERVICE LIMIT

Transmission Gear I.D. M5, M6 31.000 – 31.025 (1.2205 – 1.2215) –

C1 25.000 – 25.021 (1.3780 – 1.3789) –

C2, C3, C4 33.000 – 33.025 (1.2992 – 1.3002) –

Gear bushing

O.D.

M5 30.955 – 30.980 (1.2187 – 1.2197) –

M6 30.950 – 30.975 (1.2185 – 1.2195) –

C1 24.959 – 24.980 (0.9826 – 0.9835) –

C2 32.955 – 32.980 (1.2974 – 1.2984) –

C3, C4 32.950 – 32.975 (1.2972 – 1.2682) –

Gear bushing I.D. M5 27.985 – 28.006 (1.1018 – 1.1026) –

C1 21.985 – 22.006 (0.8655 – 0.8664) –

C2 29.985 – 30.006 (1.1805 – 1.1813) –

Mainshaft O.D. at M5 27.967 – 27.980 (1.1011 – 1.1016) –

Countershaft

O.D.

at C1 21.987 – 22.000 (0.8656 – 0.8661) –

at C2 29.967 – 29.980 (1.1798 – 1.1803) –

Shift fork,

fork shaft

Fork I.D. 12.000 – 12.018 (0.4724 – 0.4731) –

Claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.83 (0.230)

Shift fork shaft O.D. 11.957 – 11.968 (0.4707 – 0.4712) –

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GENERAL INFORMATION

CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS (CRF1000D)

Unit: mm (in)

CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Transmission Gear I.D. M5 35.000 – 35.025 (1.3780 – 1.3789) –

M6 43.000 – 43.025 (1.6929 – 1.6939) –

C1 35.000 – 35.025 (1.3780 – 1.3789) –

C2 25.000 – 25.021 (0.9843 – 0.9851) –

C3, C4 33.000 – 33.025 (1.2992 – 1.3002) –

Gear bushing O.D. M5 34.950 – 34.975 (1.3760 – 1.3770) –

M6 42.950 – 42.975 (1.6909 – 1.6919) –

C1 34.950 – 34.975 (1.3760 – 1.3770) –

C2 24.959 – 24.980 (0.9826 – 0.9835) –

C3, C4 32.950 – 32.975 (1.2972 – 1.2982) –

Gear bushing I.D. M5 32.000 – 32.025 (1.2598 – 1.2608) –

M6 40.007 – 40.028 (1.5751 – 1.5759) –

C1 30.000 – 30.021 (1.1811 – 1.2067) –

C2 21.985 – 22.006 (0.8655 – 0.8664) –

Inner mainshaft O.D. M5 31.957 – 31.970 (1.2581 – 1.2587) –

Outer mainshaft O.D. M6 39.975 – 39.991 (1.5738 – 1.5744) –

Countershaft O.D. C1 29.967 – 29.980 (1.1798 – 1.1803) –

C2 21.987 – 22.000 (0.8656 – 0.8661) –

Shift fork I.D. 12.000 – 12.018 (0.4724– 0.4731) –

Claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.83 (0.230)

Shaft O.D. 11.957 – 11.968 (0.4707 – 0.4712) –

ITEM STANDARD SERVICE LIMIT

Crankshaft Connecting rod side clearance 0.10 – 0.20 (0.004 – 0.008) 0.35 (0.014)

Runout – 0.05 (0.002)

Main journal bearing oil clearance 0.019 – 0.038 (0.0007 – 0.0015) 0.05 (0.002)

Crankpin bearing oil clearance 0.027 – 0.045 (0.0011 – 0.0018) 0.065 (0.0026)

Cylinder I.D. 92.000 – 92.015 (3.6220 – 3.6226) 92.10 (3.626)

Piston,

pis-ton pin,

piston ring

Piston O.D. at 12 mm (0.5 in) from

bottom

91.981 – 91.996 (3.6213 – 3.6218) 91.89 (3.618)

Piston pin hole I.D. 22.002 – 22.008 (0.8662 – 0.8665) 22.02 (0.867)

Piston pin O.D. 21.994 – 22.000 (0.8659 – 0.8661) 21.98 (0.865)

Piston ring end gap Top 0.15 – 0.30 (0.006 – 0.012) 0.40 (0.016)

Second 0.45 – 0.60 (0.018 – 0.024) 0.70 (0.028)

Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.90 (0.035)

Piston ring-to-ring

groove clearance

Top 0.030 – 0.060 (0.0012 – 0.0024) –

Second 0.030 – 0.060 (0.0012 – 0.0024) –

Connecting rod small end I.D. 22.030 – 22.044 (0.8673 – 0.8679) 22.054 (0.8683)

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