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Honda CRF1000 User Manual

Honda CRF1000
573 pages
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SHOP MANUAL
CRF1000/A/D
CRF1000/A/D
G

Table of Contents

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Honda CRF1000 Specifications

General IconGeneral
Displacement998cc
Max Power Output70kW @ 7, 500rpm
Fuel SystemPGM-FI electronic fuel injection
StarterElectric
Final DriveChain
Wheelbase1, 575mm
Ground Clearance250mm
Fuel Capacity18.8L
Bore x Stroke92.0mm x 75.1mm
Transmission6-speed
Frame TypeSteel semi-double cradle
Front SuspensionShowa 45mm inverted telescopic fork with cartridge damper, adjustable compression and rebound damping and preload, 230mm stroke.
Front Brake310mm dual wave floating hydraulic disc with aluminium hub and radial 4-piston calipers
Rear Brake256mm single wave hydraulic disc with single-piston caliper
Front Tire90/90-21
Rear Tire150/70-18
Seat Height870mm
Engine TypeLiquid-cooled 4-stroke 8-valve parallel twin

Summary

HOW TO USE THIS MANUAL

Service Information

Explains the purpose and scope of the service manual.

For Your Safety

Provides crucial safety precautions for performing service procedures.

Important Safety Precautions

Details essential safety measures to prevent injury and damage.

GENERAL INFORMATION

Service Rules

Outlines the fundamental rules and guidelines for servicing the motorcycle.

Specifications

Lists detailed technical specifications for various motorcycle components.

Torque Values

Provides essential torque specifications for fasteners used in engine and frame assembly.

Lubrication & Seal Points

Details the materials and locations for lubrication and sealing of motorcycle parts.

Special Tool List

Lists specialized tools required for specific service procedures.

Emission Control Systems

Explains the systems designed to control motorcycle emissions and their components.

Technical Features

Highlights key technical features of the motorcycle, such as ABS and G Ride systems.

FRAME/BODY PANELS/EXHAUST SYSTEM

Service Information

Covers general service aspects for body panels, exhaust, and sidestand.

Troubleshooting

Addresses common issues like excessive exhaust noise and poor performance.

Body Panel Locations

Identifies the location and removal order of various body panels on the motorcycle.

Muffler/Exhaust Pipe Removal/Installation

Covers the removal and installation procedures for the muffler and exhaust pipe.

Sidestand Removal/Installation

Details the steps for removing and installing the motorcycle sidestand.

MAINTENANCE

Maintenance Schedule

Outlines the recommended schedule for periodic maintenance tasks.

Valve Clearance

Details the procedure for inspecting and adjusting valve clearance.

Engine Oil

Covers engine oil level inspection and the recommended oil specifications.

Drive Chain

Details the inspection and adjustment procedures for the drive chain slack.

Brake Fluid

Covers inspection of brake fluid levels, pads, and system for leaks.

Suspension

Covers inspection and adjustment of front and rear suspension systems.

Steering Head Bearings

Details the inspection and service procedures for steering head bearings.

PGM-FI SYSTEM

PGM-FI Troubleshooting Information

Offers general troubleshooting advice, including intermittent failures and DTC identification.

DTC Index

Lists Diagnostic Trouble Codes (DTCs) with their corresponding function failure and symptoms.

DTC Troubleshooting

Provides detailed step-by-step procedures for diagnosing and resolving specific DTCs.

MAP Sensor

Covers the removal, installation, and inspection of the MAP sensor.

ECT Sensor

Details the removal, installation, and inspection procedures for the ECT sensor.

IAT Sensor

Explains the removal, installation, and inspection process for the IAT sensor.

VS Sensor

Covers the removal, installation, and inspection of the VS sensor.

O2 Sensor

Details the removal, installation, and inspection procedures for the O2 sensor.

Bank Angle Sensor

Explains the removal, installation, and inspection of the bank angle sensor.

IGNITION SYSTEM

Troubleshooting

Addresses common ignition system issues such as no spark at the plug.

Ignition System Inspection

Details the procedures for inspecting the ignition system, including spark plug and primary voltage checks.

Ignition Coil Primary Peak Voltage

Explains how to measure the ignition coil's primary peak voltage.

CKP Sensor Peak Voltage

Covers the procedure for measuring the CKP sensor's peak voltage.

Ignition Timing

Details how to check and adjust the ignition timing.

ELECTRIC STARTER

Troubleshooting

Addresses common issues like the starter motor not turning or turning slowly.

Starter Motor Removal/Installation

Covers the procedure for removing and installing the starter motor.

Starter Relay Switch Removal/Installation

Details the steps for removing and installing the starter relay switch.

FUEL SYSTEM

Troubleshooting

Addresses common issues like the engine not starting or stalling.

Fuel Line Inspection

Covers procedures for relieving fuel pressure and inspecting the fuel line.

Fuel Pressure Normalization

Details the process for normalizing and testing fuel pressure.

Fuel Tank Removal/Installation

Details the steps for removing and installing the fuel tank.

Fuel Pump Unit Removal/Installation

Covers the removal, installation, and inspection of the fuel pump unit.

Throttle Body Removal

Covers the procedure for removing the throttle body assembly.

IACV Removal/Inspection

Details the removal and inspection process for the Idle Air Control Valve (IACV).

Fuel Injector Removal/Disassembly

Covers the removal and disassembly of the fuel injector assembly.

COOLING SYSTEM

Troubleshooting

Addresses common cooling system issues like engine temperature too high or too low, and coolant leaks.

Coolant Replacement/Air Bleeding

Details the process for replacing coolant and bleeding air from the system.

Thermostat Removal/Installation

Covers the removal and installation procedures for the thermostat.

Radiator Removal/Installation

Details the steps for removing and installing the left and right radiators.

Water Pump Removal/Installation

Covers the removal and installation process for the water pump.

LUBRICATION SYSTEM

Troubleshooting

Addresses common issues related to oil level, pressure, contamination, and emulsification.

Oil Pressure Inspection

Covers the procedure for measuring engine oil pressure using a gauge.

Oil Pump (CRF1000/A) Removal/Installation

Details the steps for removing and installing the oil pump on CRF1000/A models.

Oil Pump (CRF1000D) Removal/Installation

Covers the procedure for removing and installing the oil pump on CRF1000D models.

Oil Strainer Removal/Installation

Explains the process for removing and installing the oil strainer.

CYLINDER HEAD/VALVE/CAMSHAFT

Troubleshooting

Addresses common engine top-end issues like low compression and excessive noise.

Cylinder Compression

Details the procedure for measuring cylinder compression pressure.

Rocker Arm Removal/Installation

Details the procedure for removing and installing the rocker arm assembly.

Camshaft Removal/Installation

Covers the procedure for removing and installing the camshaft.

Cylinder Head Removal/Installation

Details the steps for removing and installing the cylinder head.

Valve Clearance

Details the procedure for inspecting and adjusting valve clearance.

ENGINE REMOVAL/INSTALLATION

Service Information

Provides general information and warnings regarding engine removal and installation.

Component Location

Identifies the location of engine mounting points and related components.

Engine Removal

Details the step-by-step procedure for removing the engine from the motorcycle.

Engine Installation

Covers the procedure for installing the engine back into the motorcycle frame.

FRONT WHEEL/SUSPENSION/STEERING

Troubleshooting

Addresses common issues related to steering, wheel wobble, suspension, and front suspension noise.

Handlebar Removal/Installation

Covers the removal and installation of the handlebar and related controls.

Front Wheel Removal/Installation

Covers the procedure for removing and installing the front wheel.

Wheel Bearing Replacement

Details the process of replacing the wheel bearings for both front and rear wheels.

Fork Disassembly

Explains the steps for disassembling the front fork components.

Steering Stem Removal/Installation

Covers the removal and installation of the steering stem assembly.

REAR WHEEL/SUSPENSION

Troubleshooting

Addresses common issues like steering alignment, wheel wobbling, and suspension stiffness.

Rear Wheel Removal/Installation

Covers the procedure for removing and installing the rear wheel.

Wheel Bearing Replacement

Details the process of replacing the wheel bearings using special tools.

Cushion Linkage Disassembly/Inspection

Explains the disassembly and inspection of the cushion arm and connecting rod.

Pivot Bearing Replacement

Covers the procedure for replacing pivot bearings using special tools and a hydraulic press.

Swingarm Removal/Installation

Details the steps for removing and installing the swingarm assembly.

HYDRAULIC BRAKE

Troubleshooting

Addresses common brake issues like soft or spongy levers and brake drag.

Brake Fluid Replacement/Air Bleeding

Details the procedure for draining, replacing, and bleeding brake fluid.

Front Brake Caliper Removal/Installation

Details the steps for removing and installing the front brake caliper.

Rear Brake Caliper Removal/Installation

Covers the procedure for removing and installing the rear brake caliper.

Parking Brake Pad/Pin Replacement (CRF1000D) Removal

Explains the removal of parking brake pads and pins for CRF1000D models.

Front Master Cylinder Removal/Installation

Details the steps for removing and installing the front brake master cylinder.

Rear Master Cylinder Removal/Installation

Covers the procedure for removing and installing the rear brake master cylinder.

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

ABS Troubleshooting Information

Covers ABS pre-start self-diagnosis and general troubleshooting procedures.

DTC Index

Lists Diagnostic Trouble Codes (DTCs) for the ABS system with their failures and symptoms.

DTC Troubleshooting

Provides step-by-step procedures for diagnosing DTCs related to ABS indicator and wheel speed sensors.

ABS Modulator Removal/Installation

Details the procedure for removing and installing the ABS modulator assembly.

BATTERY/CHARGING SYSTEM

Troubleshooting

Addresses common issues like weak battery, current leakage, and charging voltage problems.

Battery Removal/Installation

Covers the procedure for removing and installing the motorcycle battery.

Charging System Inspection

Covers current leakage and charging voltage tests.

Regulator/Rectifier Removal/Installation

Details the procedure for removing and installing the regulator/rectifier.

Alternator Charging Coil Inspection

Explains how to measure the resistance of the alternator charging coil.

LIGHTS/METERS/SWITCHES

System Location

Identifies the location of various lights, meters, and switches on the motorcycle.

Headlight Removal/Installation

Covers the procedure for removing and installing the headlight assembly.

Turn Signal Light/Relay (CRF1000A/D) Removal/Installation

Explains the steps for removing and installing turn signal lights and relays on CRF1000A/D.

Combination Meter Removal/Installation

Covers the procedure for removing and installing the combination meter.

TXD Line Inspection

Provides procedures for checking the TXD line for open or short circuits.

Ignition Switch Inspection/Removal/Installation

Covers inspection, removal, and installation of the ignition switch.

Handlebar Switches Inspection

Details the process of checking continuity for handlebar switch connectors.

HSTC System Inspection

Covers the pre-start self-diagnosis and inspection of the HSTC system.

IMMOBILIZER SYSTEM (HISS)

System Location

Identifies the location of HISS system components like ECM/PCM and immobilizer receiver.

Key Registration Procedures

Details the procedure for registering new transponder keys.

Troubleshooting

Addresses issues when the HISS indicator does not come on or stays on.

ECM (CRF1000/A)/PCM (CRF1000D) CKP Sensor Line Inspection

Covers checking the CKP sensor line connected to the ECM/PCM.

WIRING DIAGRAM

Wiring Diagram (CRF1000)

Provides the complete wiring diagram for the CRF1000 model.

Wiring Diagram (CRF1000/A)

Illustrates the wiring diagram for the CRF1000/A model.

Wiring Diagram (CRF1000D)

Shows the wiring diagram specific to the CRF1000D model.

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