Manual de Taller HONDA AFRICA TWIN CRF1000 ADVENTURE MANUAL TALLER 2017

SHOP MANUAL

CRF1000A/A2/AL/AL2/

D/D2/DL/DL2

CRF1000A/A2/AL/AL2/D/D2/DL/DL2

26-1

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26. CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

A Few Words About Safety ·······················26-2

INTRODUCTION··········································26-3

SERVICE RULES ········································26-4

MODEL IDENTIFICATION ··························26-5

SPECIFICATIONS ·······································26-7

TORQUE VALUES ····································26-13

LUBRICATION & SEAL POINTS··············26-16

CABLE & HARNESS ROUTING ···············26-17

TECHNICAL FEATURE ····························26-38

BODY PANEL LOCATIONS ·····················26-39

WINDSCREEN···········································26-41

MIDDLE COWL ·········································26-42

FRONT COVER ·········································26-44

INNER PANEL COVER ·····························26-45

SKID PLATE··············································26-46

FRONT SIDE PIPE ····································26-47

SEAT CATCH STAY ·································26-48

ETC TRAY ·················································26-49

SIDE COVER ·············································26-49

REAR SIDE INNER BODY ························26-51

REAR CARRIER········································26-52

CARRIER BRACKET ································26-53

REAR CENTER COWL ·····························26-54

REAR FENDER A······································26-54

REAR FENDER B······································26-56

MUFFLER/EXHAUST PIPE·······················26-58

SIDESTAND ··············································26-60

FRONT NUMBER STAY

(IN model only) ·········································26-60

MAINTENANCE SCHEDULE····················26-61

THROTTLE OPERATION··························26-63

SPARK PLUG············································26-63

PGM-FI SYSTEM LOCATION ···················26-64

PGM-FI SYSTEM DIAGRAM·····················26-65

PGM-FI DTC INDEX ··································26-67

PGM-FI DTC TROUBLESHOOTING·········26-70

MIL CIRCUIT TROUBLESHOOTING······26-115

ECM (CRF1000A/A2/AL/AL2)/

PCM (CRF1000D/D2/DL/DL2)

(PGM-FI SYSTEM) ··································26-115

GRIP APS/

RIGHT HANDLEBAR SWITCH ···············26-116

TBW RELAY············································26-122

IGNITION SYSTEM

SYSTEM DIAGRAM ································26-123

IGNITION SYSTEM INSPECTION ··········26-124

IGNITION COIL········································26-124

ELECTRIC STARTER SYSTEM

DIAGRAM················································26-127

FUEL TANK ············································ 26-128

AIR CLEANER HOUSING ······················26-128

THROTTLE BODY ··································26-128

EVAP CANISTER

(ED/KO/TH/FO/MA models) ···················26-131

RADIATOR·············································· 26-132

RIGHT CRANKCASE COVER

(CRF1000A2/AL2)···································26-133

DCT SYSTEM DIAGRAM ······················· 26-134

DCT DTC INDEX ····································· 26-135

DCT DTC TROUBLESHOOTING ··········· 26-140

A/M SWITCH TROUBLESHOOTING ····· 26-177

RIGHT CRANKCASE COVER

(CRF1000D2/DL2)···································26-178

ENGINE REMOVAL ································ 26-178

ENGINE INSTALLATION························ 26-180

SWINGARM ············································26-181

FRONT BRAKE CALIPER······················ 26-182

ABS SYSTEM DIAGRAM ······················· 26-183

ABS DTC INDEX·····································26-184

ABS DTC TROUBLESHOOTING ··········· 26-186

ABS MODULATOR································· 26-195

BATTERY/CHARGING SYSTEM SERVICE

INFORMATION ······································· 26-197

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING ···························· 26-198

BATTERY················································ 26-199

CHARGING SYSTEM INSPECTION ······ 26-200

TURN SIGNAL LIGHT/RELAY ··············· 26-201

COMBINATION METER ·························26-204

GEAR POSITION SENSOR

(CRF1000A/A2/AL/AL2) ························· 26-205

NEUTRAL SWITCH

(CRF1000A/AL/A2/AL2) ························· 26-206

SHIFT SPINDLE SWITCH

(CRF1000A/AL/A2/AL2) ························· 26-206

GRIP HEATER

(CRF1000A2/AL2/D2/DL2) ····················· 26-207

IMMOBILIZER SYSTEM (HISS) SYSTEM

DIAGRAM················································26-218

IMMOBILIZER SYSTEM (HISS)

TROUBLESHOOTING ···························· 26-220

ECM (CRF1000A/A2/AL/AL2)/

PCM (CRF1000D/D2/DL/DL2) (HISS) ···· 26-222

IMMOBILIZER RECEIVER······················ 26-222

WIRING DIAGRAM

(CRF1000A/A2/AL/AL2) ························· 26-225

WIRING DIAGRAM

(CRF1000D/D2/DL/DL2) ························· 26-226

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

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

vehicle 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 vehicle.

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 vehicle. Any error or oversight while

servicing a vehicle can result in faulty operation, damage to the vehicle, 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 recommend 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 and 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 vehicle up in the air. Any time you lift the vehicle, 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 or others 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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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

INTRODUCTION

This addendum contains information for the CRF1000A/D/A2/D2/AL/DL/AL2/DL2-J.

Refer to CRF1000/A/D-G, H SHOP MANUAL (No. 62MJP00) and CRF1000/A/D-H, J SHOP MANUAL (No. 62MJP01Z) for service

procedures and data not included in this addendum.

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: November, 2017

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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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

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 shown in the Cable and Harness Routing (page 26-17).

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.

Abbrev. term Full term

ABS Anti-lock Brake System

APS Accelerator Position Sensor

CAN Controller Area Network

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

ESS Emergency Stop Signal

EVAP Evaporative Emission

GST Generic Scan Tool

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 short connector Service Check Signal short connector

TBW Throttle By Wire

TP sensor Throttle Position sensor

TR sensor Transmission Range Sensor

VS sensor Vehicle Speed sensor

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

DESTINATION CODE

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

MODEL IDENTIFICATION

SERIAL NUMBER

DESTINATION CODE REGION

BR, IIBR, IIIBR, IVBR Brazil

CH, IICH, IVCH China

ED, IIED, IIIED, IVED European direct sales

GS, IIGS, IIIGS, IVGS Gulf countries

II-IN, III-IN, IV-IN Indonesia

KO, IIKO, IIIKO, IVKO Korea

RU, IIRU, IIIRU Russia

TH, IITH, IIITH, IVTH Thailand

U, IIU, IIIU, IVU Australia, New Zealand

IIFO, IIIFO Taiwan

IIIMA, IVMA Malaysia

CRF1000D2 shown:

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

upper front left side of the throttle body as shown.

[1]

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

TYPES

TYPE CODE DESTINATION

CODE

Manual

Transmission

DCT ABS HSTC EVAP ACCESSORY

SOCKET

CRF1000A ED, IIED, IIIED – –

IIFO, IIIFO – –

GS, IIGS, IIIGS – – –

IIKO, IIIKO – –

U, IIU, IIIU – – –

CRF1000A2 IVED –

IVGS – –

IVU – –

CRF1000AL IIIMA – –

III-IN – – –

TH, IITH, IIITH – –

CRF1000AL2 IVMA –

IVTH –

CRF1000D ED, IIED, IIIED – –

GS, IIGS, IIIGS – – –

IIKO, IIIKO – –

U, IIU, IIIU – – –

CRF1000D2 IVED –

IVGS – –

IVKO –

IVU – –

CRF1000DL IIIMA – –

III-IN – – –

TH, IITH, IIITH – –

CRF1000DL2 IVMA –

IV-IN – –

IVTH –

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

SPECIFICATIONS

GENERAL SPECIFICATIONS

ITEM SPECIFICATIONS

DIMENSIONS Overall length CRF1000A//D 2,330 mm (91.7 in)

CRF1000A2//D2 2,340 mm (92.1 in)

CRF1000AL/AL2/DL/DL2 2,310 mm (90.9 in)

Overall width 930 mm (36.6 in)

Overall height CRF1000A/D 1,475 mm (58.1 in)

CRF1000A2/D2 1,570 mm (61.8 in)

CRF1000AL/DL 1,435 mm (56.5 in)

CRF1000AL2/DL2 1,510 mm (59.4 in)

Wheelbase CRF1000A/D Except FO models 1,575 mm (62.0 in)

FO model 1,570 mm (61.8 in)

CRF1000A2/D2 1,580 mm (62.2 in)

CRF1000AL/

AL2/DL/DL2

Except IN models 1,560 mm (61.4 in)

IN model 1,555 mm (61.2 in)

Seat height CRF1000A/D Standard position 870 mm (34.3 in)

Low position 850 mm (33.5 in)

CRF1000A2/

Standard position 920 mm (36.2 in)

Low position 900 mm (35.4 in)

CRF1000AL/DL 830 mm (32.7 in)

CRF1000AL2/DL2 860 mm (33.9 in)

Footpeg height CRF1000A/D 352 mm (13.9 in)

CRF1000A2/D2 372 mm (14.6 in)

CRF1000AL/AL2/DL/DL2 313 mm (12.3 in)

Ground clearance CRF1000A/D 250 mm (9.8 in)

CRF1000A2/D2 270 mm (10.6 in)

CRF1000AL/AL2/DL/DL2 210 mm (8.3 in)

Curb

weight

CRF1000A U/GS models 229 kg (505 lbs)

ED/KO/FO models 230 kg (507 lbs)

CRF1000A2 U/GS models 242 kg (534 lbs)

ED model 243 kg (536 lbs)

CRF1000AL 229 kg (505 lbs)

CRF1000AL2 242 kg (534 lbs)

CRF1000D U/GS/ models 239 kg (527 lbs)

ED/KO models 240 kg (529 lbs)

CRF1000D2 ED model 253 kg (558 lbs)

KO model 255 kg (562 lbs)

GS/U models 252 kg (556 lbs)

CRF1000DL IN model 240 kg (529 lbs)

MA/TH models 239 kg (527 lbs)

CRF1000DL2 252 kg (556 lbs)

Maximum weight capacity CRF1000A/AL/D/DL 213 kg (470 lbs)

CRF1000A2/D2/AL2/DL2 195 kg (430 lbs)

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

FRAME Frame type Semi double cradle

Front suspension Telescopic fork

Front axle travel CRF1000A/AL/D/DL 204 mm (8.0 in)

CRF1000A2/AL2/D2/DL2 224 mm (8.8 in)

Rear suspension Swingarm

Rear axle travel CRF1000A/AL/D/DL 220 mm (8.7 in)

CRF1000A2/AL2/D2/DL2 240 mm (9.4 in)

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

Rear tire size 150/70R18M/C 70H

Front tire brand D610FW (DUNLOP)

A41F G (BRIDGESTONE)

Rear tire brand D610W (DUNLOP)

A41R G (BRIDGESTONE)

Front brake Hydraulic double disc

Rear brake Hydraulic single disc

Caster angle 27° 30’

Trail length CRF1000A/AL/D/DL 113 mm (4.4 in)

CRF1000A2/AL2/D2/DL2 111 mm (4.4 in)

Fuel tank capacity CRF1000A/AL/D/DL 18.8 liters

(4.97 US gal, 4.14 Imp gal)

CRF1000A2/AL2/D2/DL2 24.2 liters

(6.39 US gal, 5.32 Imp gal)

ENGINE Cylinder arrangement 2 cylinders in-line, slant

angle 22.5°

Bore and stroke Except TH model 92.0 x 75.1 mm

(3.62 x 2.96 in)

TH models 92.000 x 75.148 mm

(3.6220 x 2.9586 in)

Displacement Except TH model 998 cm

(60.9 cu-in)

TH model 999.11 cm

(60.946 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 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

(CRF1000A/A2/

AL/AL2)

Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 6-speeds

Primary reduction 1.733 (78/45)

Final reduction Except FO/IN models 2.625 (42/16)

FO/IN models 2.470 (42/17)

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

ITEM SPECIFICATIONS

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

FUEL SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

DRIVE TRAIN

(CRF1000D/D2/

DL/DL2)

Clutch system 2 Multi-plate wet clutches

Clutch operation system Automatic

Transmission Constant mesh, 6-speeds

Primary reduction 1.883 (81/43)

Final reduction Except IN models 2.625 (42/16)

IN model 2.470 (42/17)

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

Throttle body identification

number

Except GS/U/IN

models

GNH3A

GS/U/IN models GNH3B

Engine idle speed 1,250 ± 100 min

-1

(rpm)

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

, 47 – 53 psi)

Fuel pump flow (at 12 V) 319 cm

(10.8 US oz, 11.2 Imp oz) minimum/10 seconds

ITEM SPECIFICATIONS

Coolant

capacity

Radiator and engine 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

Except IN/TH/MA models High quality ethylene glycol antifreeze containing

silicate-free corrosion inhibitors

IN/TH/MA models Honda PRE-MIX coolant

Standard coolant

concentration

Except IN/TH/MA models

1:1 mixture with distilled water

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cold tire

pressure

Driver only CRF1000A/AL/D/DL 200 kPa (2.00 kgf/cm

, 29 psi) –

CRF1000A2/AL2/D2/

DL2

225 kPa (2.25 kgf/cm

, 33 psi) –

Driver and passenger 225 kPa (2.25 kgf/cm

, 33 psi) –

Axle runout – 0.2 (0.01)

Wheel rim

runout

Radial – 1.0 (0.04)

Axial – 1.0 (0.04)

Wheel hub-to-rim distance 28.5 – 30.5 (1.12 – 1.20) –

Wheel balance weight – 60 g (2.1 oz) max.

Fork Spring free

length

CRF1000A/D 433.7 (17.07) 425.0 (16.73)

CRF1000A2/D2 465.7 (18.33) 456.4 (17.97)

CRF1000AL/AL2/DL/

DL2

394.2 (15.52) 386.3 (15.21)

Recommended fork fluid Honda Ultra Cushion Oil 10W –

Fluid level CRF1000A/D 95.0 (3.74) –

CRF1000A2/D2 110.0 (4.33) –

CRF1000AL/AL2/DL/

DL2

104.0 (4.09) –

Fluid

capacity

CRF1000A/D 721 ± 2.5 cm

(24.4 ± 0.1 US oz,

25.4 ± 0.1 Imp oz)

–

CRF1000A2/D2 695 ± 2.5 cm

(23.5 ± 0.1 US oz,

24.5 ± 0.1 Imp oz)

–

CRF1000AL/AL2/DL/

DL2

710 ± 2.5 cm

(24.0 ± 0.1 US oz,

25.0 ± 0.1 Imp oz)

–

Pre-load

adjuster

standard

position

CRF1000A/A2/AL/DL 5 turns from the full soft position –

CRF1000D/D2 8.5 turns from the full soft position –

CRF1000AL2/DL2 10.5 turns from the full soft position –

Rebound

adjuster

standard

position

CRF1000A/A2/D/D2 2 1/4 turns from maximum position –

CRF1000AL/AL2/DL/

DL2

2 1/2 turns from maximum position –

Compression

adjuster

standard

position

CRF1000A/D 8 clicks from maximum position –

CRF1000A2/D2 4 clicks from maximum position –

CRF1000AL/AL2/DL/

DL2

10 clicks from maximum position –

Steering head bearing pre-load 9.8 – 14.7 N (1.0 – 1.5 kgf, 2.2 – 3.3 lbf) –

26-11

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Cold tire

pressure

Driver only CRF1000A/AL/D/DL 250 kPa (2.50 kgf/cm

, 36 psi) –

CRF1000A2/AL2/D2/DL2 280 kPa (2.80 kgf/cm

, 41 psi) –

Driver and passenger 280 kPa (2.80 kgf/cm

, 41 psi) –

Axle runout – 0.2 (0.01)

Wheel rim runout Radial – 1.0 (0.04)

Axial – 1.0 (0.04)

Wheel hub-to-rim distance 5.2 – 7.2 (0.205 – 0.283) –

Wheel balance weight – 60 g (2.1 oz) max.

Drive

chain

Slack CRF1000A/AL/D/DL 35 – 45 (1.4 – 1.8) –

CRF1000A2/AL2/D2/DL2 45 – 55 (1.8 – 2.2) –

Size/link DID525HV3-124LE –

Shock

absorber

Pre-load adjuster standard position 7 clicks from minimum position

(first click is "0" position)

–

Rebound

adjuster

standard

setting

CRF1000A/D 9 clicks from maximum position –

CRF1000A2/D2 13 clicks from maximum position –

CRF1000AL/DL/AL2/DL2 17 clicks from maximum position

–

Compress

ion

adjuster

standard

position

CRF1000A/D 14 clicks from maximum position –

CRF1000A2/D2 19 clicks from maximum position –

CRF1000AL/DL/AL2/DL2 13 clicks from maximum position –

ITEM SPECIFICATIONS

Battery Type HY110

Capacity 12 V – 6.0 Ah (20 HR)

Current leakage 0.66 mA max.

Voltage

(20°C/68°F)

Fully charged 13.5 – 14.0 V

Needs charging Below 10.8 V

Alternator Capacity 0.49 kW/5,000 min

-1

(rpm)

Charging coil resistance (20°C/68°F) 0.1 – 1.0 

26-12

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

LIGHTS/METERS/SWITCHES SPECIFICATIONS

ITEM SPECIFICATIONS

Bulbs Headlight Hi LED

Lo LED

Brake/taillight LED

Position light LED

Front turn signal light LED

Rear turn signal light LED

License light 12 V – 5 W

Instrument light LED

Turn signal indicator LED

High beam indicator LED

Neutral indicator LED

Low oil pressure indicator LED

Fuel reserve indicator LED

MIL LED

High coolant temperature indicator LED

HISS indicator LED

ABS indicator LED

Rear ABS indicator LED

Parking brake indicator

(CRF1000D/D2/DL/DL2)

LED

Torque control indicator LED

Torque control off indicator LED

Fuse Main fuse 30 A

FI fuse 15 A

ABS M fuse 30 A

ABS FSR fuse 30 A

DCT M fuse (CRF1000D/D2/DL/DL2) 30 A

Sub

fuse

CRF1000A/A2/AL/AL2 20 A x 2, 10 A x 6

CRF1000D/D2/DL/DL2 20 A x 2, 10 A x 7

ECT sensor resistance 40°C (104°F) 1.0 – 1.3 k

100°C (212°F) 0.14 – 0.18 k

Open air temperature sensor resistance 25°C (77°F) 4.9 – 5.1 k

Fuel level sensor resistance Full 6.4 – 10.4 

Empty 204.8 – 210.8 

26-13

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

TORQUE VALUES

ENGINE & FRAME TORQUE VALUES

FRAME BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm)

N·m (kgf·m,

lbf·ft)

Windscreen mounting screw 4 5 0.42 (0.04, 0.3)

Skid plate mounting bolt 3 8 26 (2.7, 19)

Front side cover mounting screw

(CRF1000A2/D2/AL2/DL2)

6 5 0.42 (0.04, 0.3)

Left rear cover mounting bolt 2 6 12 (1.2, 9)

Pillion step bracket mounting bolt 4 8 32 (3.3, 24)

Brake hose oil bolt 2 10 34 (3.5, 25)

Brake pipe joint 2 10 14 (1.4, 10) Apply brake fluid to the threads.

Exhaust pipe cover C pan screw 3 6 9.0 (0.9, 6.6)

Exhaust outer cover screw 1 6 9.0 (0.9, 6.6)

Exhaust pipe joint nut 4 8 20 (2.0, 15)

Exhaust pipe cover A pan screw 1 6 9.0 (0.9, 6.6)

Exhaust pipe cover B front band

screw

1 – 1.2 (0.1, 0.9)

Exhaust pipe cover B rear band

screw

1 – 3.5 (0.4, 2.6)

Muffler band bolt 2 8 17 (1.7, 13)

Muffler cover pan screw 2 6 9.0 (0.9, 6.6)

Tail cap cover bolt 2 6 9.0 (0.9, 6.6)

Exhaust pipe stud bolt 4 8 – See page 2-18

Sidestand pivot nut 1 10 42 (4.3, 31) See page 26-60

Self-lock nut

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm)

N·m (kgf·m,

lbf·ft)

Air cleaner element mounting screw 4 5 1.1 (0.1, 0.8) Tapping screw

Air cleaner cover screw 8 5 1.1 (0.1, 0.8) Tapping screw

Spark plug 4 10 22 (2.2, 16)

Valve adjusting screw lock nut 4 5 10 (1.0, 7) Apply engine oil to the threads and

seating surface.

Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads.

Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply grease to the threads.

Engine oil drain bolt 2 12 30 (3.1, 22)

Oil filter boss (crankcase side) 1 20 – Apply locking agent to the threads.

See page 3-12

Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads.

Clutch oil filter cover bolt

(CRF1000D/D2/DL/DL2)

2 6 12 (1.2, 9)

Rear axle nut 1 18 100 (10.2, 74) Self-lock nut

Drive chain adjuster lock nut 2 8 27 (2.8, 20) UBS-nut

Drive sprocket bolt 1 10 54 (5.5, 40)

Driven sprocket nut 5 12 100 (10.2, 74) Apply engine oil to the threads and

seating surface.

Self-lock nut

Parking brake adjuster lock nut

(CRF1000D/D2/DL/DL2)

1 8 17.2 (1.8, 13)

Front spoke 36 BC 3.5 3.7 (0.4, 2.7)

Rear spoke 32 BC 3.5 3.7 (0.4, 2.7)

26-14

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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM

ENGINE REMOVAL/INSTALLATION

LIGHTS/METERS/SWITCHES

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Right lower frame bolt 4 10 44 (4.5, 32)

Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and

seating surface.

Self-lock nut

Rear lower nut (10 mm) 1 10 44 (4.5, 32)

Front lower nut (10 mm) 1 10 44 (4.5, 32)

Front middle nut (8 mm) 2 8 32 (3.3, 24)

Front middle nut (10 mm) 1 10 44 (4.5, 32)

Front upper bolt 3 8 32 (3.3, 24)

Rear upper bolt (8 x 25 mm) 2 8 32 (3.3, 24)

Rear upper nut (8 mm) 1 8 32 (3.3, 24)

Drive sprocket bolt 1 10 54 (5.5, 40)

EOT sensor

(CRF1000D/D2/DL/DL2)

1 10 15 (1.5, 11)

Clutch EOP sensor wire stay bolt

(CRF1000D/D2/DL/DL2)

1 6 12 (1.2, 9)

Clutch EOP sensor cover bolt

(CRF1000D/D2/DL/DL2)

2 6 10 (1.0, 7)

Shift spindle switch terminal nut

(CRF1000A/A2/AL/AL2)

1 4 1.7 (0.2, 1.3)

Neutral switch terminal nut

(CRF1000A/A2/AL/AL2)

1 4 1.7 (0.2, 1.3)

Neutral switch terminal nut

(CRF1000D/D/DL/DL2)

1 4 1.7 (0.2, 1.3)

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

License light cover screw 2 5 3.8 (0.4, 2.8)

Combination meter mounting screw/

washer

4 5 1.0 (0.1, 0.7) Tapping screw

EOP switch

(CRF1000A/A2/AL/AL2)

1 PT 1/8 12 (1.2, 9) Apply sealant to the threads.

See page 22-19

EOP switch terminal bolt/washer

(CRF1000A/A2/AL/AL2)

1 4 2.0 (0.2, 1.5)

EOP sensor

(CRF1000D/D2/DL/DL2)

1 10 22 (2.2, 16)

Ignition switch mounting bolt 2 8 26 (2.7, 19) Replace with a new one.

Sidestand switch mounting bolt 1 6 10 (1.0, 7) Replace with a new one.

Gear position sensor mounting bolt

(CRF1000A/A2/AL/AL2)

1 6 12 (1.2, 9)

Neutral switch

(CRF1000A/A2/AL/AL2)

1 10 12 (1.2, 9)

Neutral switch terminal nut

(CRF1000A/A2/AL/AL2)

1 4 1.7 (0.2, 1.3)

Shift spindle switch

(CRF1000A/A2/AL/AL2)

1 10 12 (1.2, 9)

Shift spindle switch terminal nut

(CRF1000A/A2/AL/AL2)

1 4 1.7 (0.2, 1.3)

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