Honda 2007 CR125R Owner'S Manual Download Page 32

Page: 32 / 144

Servicing Your Honda

Maintenance Component Locations

clutch lever

kickstarter

rear brake pedal

front brake lever

clutch cable
adjuster

integral clutch
cable adjuster

front brake fluid
reservoir

air cleaner

chain slider

drive chain

transmission oil drain bolt

rear brake
caliper

fuel tank

front brake
caliper

rear brake
fluid reservoir

transmission
oil filler cap

rear suspension spring
pre-load adjuster

seat

spark plug

transmission oil
check bolt

fuel fill cap

front suspension
rebound damping
adjuster

front suspension compression
damping adjuster

rear suspension rebound
damping adjuster

radiator cap

throttle grip

rear suspension high speed compression damping adjuster
rear suspension low speed compression damping adjuster

*CR125R/24-48(31KSR620) 5/6/05 1:12 PM Page 28

Summary of Contents for 2007 CR125R

Page 1: ...2006 Honda CR125R OWNER S MANUAL COMPETITION HANDBOOK CR125 00 23 31KSR620 qxd 5 6 05 1 10 PM Page c...

Page 2: ...to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that i...

Page 3: ...ed 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 S...

Page 4: ...t 38 Air Cleaner 40 Engine Throttle 42 Clutch System 44 Spark Plug 48 Cylinder System 49 RC Valve 55 Reed Valve 58 Chassis Suspension 60 Brakes 65 Wheels 69 Tires Tubes 70 Drive Chain 72 Expansion Cha...

Page 5: ...s to help you ride your CR safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CR Important Safety Information 2 Imp...

Page 6: ...Your CR Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Lear...

Page 7: ...tion could seriously impair your CR s handling stability and braking making it unsafe to ride Motorcycle Safety 3 WARNING Improper accessories or modifications can cause a crash in which you can be se...

Page 8: ...rcycle Safety 4 Motorcycle Safety Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement CR125 00 23 31KSR620 qxd 5...

Page 9: ...Controls 5 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CR Operation Component Locations 6 CR125 00 23 31KSR620 qxd 5 6 05 1 10...

Page 10: ...ating Controls Operation Component Locations clutch lever kickstarter engine stop button fuel valve rear brake pedal throttle grip front brake lever choke knob CR125 00 23 31KSR620 qxd 5 6 05 1 10 PM...

Page 11: ...is section discusses how to evaluate your riding readiness and what items you should check on your CR For information about suspension carburetor and other adjustments see page 81 Before Riding Are Yo...

Page 12: ...e 81 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and oth...

Page 13: ...r inflation pressure 70 Spokes for looseness 69 Rim locks for looseness 69 Front and rear suspension for proper operation 60 61 Front and rear brakes check operation 65 Drive chain for correct slack a...

Page 14: ...10 Before Riding CR125 00 23 31KSR620 qxd 5 6 05 1 10 PM Page 10...

Page 15: ...n gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 12 Starting Stopping the Engine 13 Preparation 13 Starting Procedure 13 Flooded En...

Page 16: ...Safety Precautions beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CR s exhaust cont...

Page 17: ...knob should be pushed down as soon as possible to prevent spark plug fouling 6 Allow the engine to warm up for at least 2 minutes before riding off preferably until the side of the cylinder is very wa...

Page 18: ...rottle grip 1 2 3 times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow fill the cr...

Page 19: ...how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is repla...

Page 20: ...16 Basic Operating Instructions CR125 00 23 31KSR620 qxd 5 6 05 1 11 PM Page 16...

Page 21: ...to check the ignition timing refer to the Honda Service Manual page 132 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance...

Page 22: ...l The Importance of Maintenance Keeping your CR well maintained is absolutely essential to your safety It s also a good way to get maximum performance during each moto Careful pre ride inspections and...

Page 23: ...rts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the t...

Page 24: ...the maintenance schedule are expressed in terms of races and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you...

Page 25: ...tem Clutch System Control Cables Expansion Chamber Silencer Suspension Swingarm Shock Linkage Fork Oil Nuts Bolts Fasteners Wheels Tires Steering Head Bearing This maintenance schedule is based upon a...

Page 26: ...quivalent when servicing your CR Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling...

Page 27: ...mance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Hon...

Page 28: ...eel makes the ignition control module compensate to maintain the ignition curve Cleaning dirt from the ignition side main seal helps to prevent premature seal wear Close inspection of this seal can re...

Page 29: ...ttempt to weld or otherwise repair a damaged swingarm Welding will weaken the swingarm Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file...

Page 30: ...d allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad wear 1 chain adjuster index marks Suspend the front wheel above the ground and use th...

Page 31: ...e Take care to prevent catching your fingers between the chain and sprockets Routine Cleaning If your CR is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon br...

Page 32: ...nk front brake caliper rear brake fluid reservoir transmission oil filler cap rear suspension spring pre load adjuster seat spark plug transmission oil check bolt fuel fill cap front suspension reboun...

Page 33: ...onto the seat bracket 5 and the seat rear prong 6 onto the tabs 7 by pushing down and forward on the seat in each of these areas 2 Install the collars and tighten the seat bolts to the specified torq...

Page 34: ...Unhook the air cleaner case cover 6 7 Unhook and remove the fuel tank band 7 8 Remove the fuel tank bolt 8 5 breather tube 6 air cleaner case cover 7 fuel tank band 8 fuel tank bolt 9 Disconnect the f...

Page 35: ...e air cleaner case cover 5 6 Put the breather tube 6 in the steering stem nut 3 fuel tank bolt 4 fuel tank band 5 air cleaner case cover 6 breather tube 7 Install the shrouds 7 and shroud B bolts coll...

Page 36: ...tube clamp 5 Remove the lower subframe mounting bolts 7 and upper subframe mounting bolt 8 6 Remove the subframe 9 by pulling it straight backward 7 lower subframe mounting bolts 8 upper subframe moun...

Page 37: ...n the lower subframe mounting bolts to the specified torque 22 lbf ft 30 N m 3 1 kgf m 3 subframe 4 upper subframe mounting bolt 5 lower subframe mounting bolts 6 Connect the silencer 6 to the expansi...

Page 38: ...fuel mixture in a clean container and shake until thoroughly mixed before filling the fuel tank USE PRO HONDA HP2 2 STROKE OIL 32 1 OR AN EQUIVALENT Too much oil will cause excessive smoking and spar...

Page 39: ...uel Filter The fuel filter is included in the fuel valve mounted on the bottom left side of the fuel tank Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor To service...

Page 40: ...um additives They may adversely affect clutch operation Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubr...

Page 41: ...filler hole until oil starts to flow out of the check bolt hole Install the oil check bolt and filler cap 6 Repeat steps 1 4 7 After inspecting the oil level or adding oil tighten the oil check bolt...

Page 42: ...rrosion protection Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to pro...

Page 43: ...sult your Honda dealer for replacing the water pump seal or the transmission oil seal Both seals should be replaced at the same time 1 water hoses 3 water pump cover 2 overflow tube 4 water leakage ch...

Page 44: ...as mileage and spark plug fouling Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear Cleaning 1 Remove the seat page 29 2 Loosen the air cleaner re...

Page 45: ...rence mark 10 on the air cleaner housing Tighten the retaining bolt securely Carefully position the sealing flange of the element to prevent dirt intrusion Improper installation of the air cleaner ass...

Page 46: ...he correct freeplay cannot be reached turn the adjuster all the way in and back out one turn Tighten the lock nut install the dust cover and make the adjustment with the lower adjuster Lower Adjustmen...

Page 47: ...ll steering positions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cable from the throttle grip down to the carburetor If the cable is kinked or chafed have it r...

Page 48: ...the lock nut 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns Cable end adjuster 3 cable end adjuster increase freeplay decrease freeplay 5 Loosen the l...

Page 49: ...ster 4 to obtain the specified freeplay 3 8 3 4 in 10 20 mm 4 Tighten the lock nut Check the adjustment 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not st...

Page 50: ...r bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing plate does not turn smoothly 7 clutch lifter 9...

Page 51: ...s pattern in 2 or 3 steps to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 clutch pressure plate 6 clutch spring bolts 9 Install a new O ring 7 in the groove of the clutch cover 8 10 Install the co...

Page 52: ...ngage the clutch by pulling the lever in If you re using a new plug ride for at least ten minutes before taking a plug reading a brand new plug will not color initially 4 Coast to a stop then remove a...

Page 53: ...he spark plug 1 water hose 2 spark plug cap 6 Remove the upper engine hanger plate bolts and nuts 3 then remove the clamp 4 and hanger plates 5 3 hanger plate bolts and nuts 5 hanger plates 4 clamp 7...

Page 54: ...ver 12 and gasket 10 bolts 12 left RC cover 11 clamp 7 Loosen the radiator hose clamp screw 13 and disconnect the radiator hose 14 8 Remove the radiator shrouds 15 on both sides 9 Loosen the upper mou...

Page 55: ...piston ring 3 piston 4 Spread each piston ring 4 and remove by lifting it up at a point just opposite the gap The piston ring may be damaged if the ends are spread too far Cylinder Head Cylinder Decar...

Page 56: ...n Install the piston with the IN mark 2 facing the intake side If the IN mark is not found on the piston install the piston with the hole 3 facing the intake side 6 Install new piston pin clips 4 Neve...

Page 57: ...ten the bolts 12 and screw 13 to the specified torque Right RC valve cover bolt 9 lbf ft 12 N m 1 2 kgf m Right RC valve cover screw 1 5 lbf ft 2 N m 0 2 kgf m 10 right RC valve cover 13 screw 12 bolt...

Page 58: ...ylinder head 5 and tighten the five cylinder head nuts 6 to the specified torque in a crisscross pattern in 2 or 3 steps 20 lbf ft 27 N m 2 8 kgf m 5 cylinder head 6 cylinder head nuts 4 Install the c...

Page 59: ...torque throughout the entire engine rpm range The valves should be fully closed at low rpm and fully open at high rpm The exhaust valve system is a precision assembly Before beginning inspection deca...

Page 60: ...assembly 7 RC valves 6 collar Exhaust Valve Decarbonizing 1 Remove the carbon deposits from the valve shaft assembly 1 and RC valves 2 Decarbonize the valve shaft assembly and RC valves each race 2 I...

Page 61: ...t the cut outs of the valve shaft 4 and collar 5 are aligned 4 cut out of the valve shaft 5 cut out of the collar 6 Install the washer 6 and nut 7 then tighten the nut to the specified torque 6 6 lbf...

Page 62: ...ked or damaged 1 reed valves Reed Valve Disassembly Assembly 1 Remove the reed valve mounting screws 1 stopper 2 sub reed valve 3 and reed valve 4 2 Align the cut outs 5 between the reed valves and st...

Page 63: ...valve assembly and insulator 4 to the crankcase 4 Install the six carburetor insulator mounting bolts 5 and tighten to the specified torque in a crisscross pattern 7 lbf ft 10 N m 1 0 kgf m After ins...

Page 64: ...als for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension adjustment Guidelines page 100 Make all rebound and compression damping adjustments in one click increme...

Page 65: ...ing two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compr...

Page 66: ...he spring guide and new O ring 4 as shown 6 Loosely install the lock nut 2 onto the damper rod 7 Install the distance collar 1 into the damper rod 1 distance collar 3 spring guide 2 lock nut 4 O ring...

Page 67: ...e 10 10 syringe Fork Oil Level Standard 0 44 kgf mm Fork Spring 7 8 9 10 5 7 No mark factory products Standard oil level capacity Maximum oil level capacity Minimum oil level capacity 2 8 in 71 mm 15...

Page 68: ...level is obtained measuring the level each time oil is added 13 Remove the lock nut and spring guide together Install the partition plate 6 6 partition plate 14 Install the spring guide 3 as shown Loo...

Page 69: ...he lock nut 1 2 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 Tighten...

Page 70: ...it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid...

Page 71: ...kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container or an equivalent When adding brake fluid be sure the reservoir is horizontal before the ca...

Page 72: ...the pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced 4 brake pads 6 brake disc 5 rear brake c...

Page 73: ...information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rim 3 spoke nipple 2 spoke 4 rim lock nut 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any...

Page 74: ...air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding condit...

Page 75: ...t The tires that came on your CR were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions Use a replacement tire equivalent to t...

Page 76: ...ack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm 1 drive chain slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several points along the chain The slac...

Page 77: ...the index marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm 1 rear axle nut 4 index mark 2 lock nut 5 axle plate 3 adjusting bolt 6 reference marks 3 Tighten t...

Page 78: ...pulled taut With the chain held taut and any kinked joints straightened measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replac...

Page 79: ...performance Expansion Chamber Removal 1 Remove the expansion chamber by removing the expansion chamber springs 1 and mounting bolts 2 2 Remove carbon deposits from the head pipe of the expansion chamb...

Page 80: ...o the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer Handlebar Inspection 1 Remove the handlebar pad 2 Check the handlebar 1 for bends or cracks 3 Check that th...

Page 81: ...SIDE 8 alternator cover bolt 9 left RC cover bolt Additional Maintenance Procedures Item ENGINE 1 Cylinder head nut 2 Cylinder mounting nut 3 Carburetor insulator bolt 4 Clutch cover bolt 5 Water pump...

Page 82: ...points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your CR You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove b...

Page 83: ...usting by applying a light coating of a rust inhibitor Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent Be sure the chain is wiped clean and is dry before...

Page 84: ...80 Servicing Your Honda CR125R 72 80 31KSR620 qxd 5 6 05 1 14 PM Page 80...

Page 85: ...ustments to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or...

Page 86: ...R will get stiffer during a race For this reason release built up air pressure in the fork legs between motos Be sure the fork is fully extended with the front tire off the ground when you release the...

Page 87: ...on 2 Turn the adjuster counterclockwise 15 clicks This is the standard position 3 Make sure both fork legs are adjusted to the same position Fork Springs The fork springs in CR s are about right for r...

Page 88: ...uivalent support with the front wheel off the ground 2 Remove the number plate bolt 1 and number plate 2 1 number plate bolt 2 number plate 3 Remove the handlebar pad Remove the washers handlebar hold...

Page 89: ...will cause difficulty in fitting the brake disc between the brake pads 12 fork protector bolts 15 brake caliper bolts 13 brake hose clamp bolts 16 brake caliper 14 fork protectors 11 Loosen the fork...

Page 90: ...by holding the lock nut 25 16 Remove the spring seat 26 and fork spring 27 6 fork cap 26 spring seat 24 damper rod 27 fork spring 25 lock nut 17 Pour the recommended fork oil into the fork tube 20 unt...

Page 91: ...113 mm Slightly stiffer as it nears full compression Slightly softer as it nears full compression No mark factory products Optional Softer 0 42 kgf mm Fork Spring 1 scribe mark Standard oil level Maxi...

Page 92: ...ire up and hold the damper rod 24 Remove the mechanic s wire from the damper rod Screw the lock nut 25 by hand until stops 24 damper rod 25 lock nut 28 Place the spring seat 26 on the fork spring 27 w...

Page 93: ...bf ft 20 N m 2 0 kgf m 37 Tighten the fork upper pinch bolts 5 to the specified torque 16 lbf ft 22 N m 2 2 kgf m Tighten the bolts alternately in 2 or 3 steps Over tightening the pinch bolts can defo...

Page 94: ...y 45 Clean the threads of the caliper mounting bolts 15 and brake caliper thoroughly 46 Apply locking agent to the bolt threads 47 Install the brake caliper on the fork slider and tighten the caliper...

Page 95: ...ified torque 15 lbf ft 20 N m 2 0 kgf m 38 left fork pinch bolts 39 right fork pinch bolts To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg c...

Page 96: ...el off the ground 2 Loosen the connecting tube clamp screw and remove the rear subframe s three mounting bolts then remove the subframe See page 32 3 Check that the spring preload is adjusted to the s...

Page 97: ...Turn the adjuster counterclockwise 1 1 6 1 1 2 turns and the punch marks are aligned Low Speed Damping The low speed damping can be adjusted by turning the center screw of the compression adjuster The...

Page 98: ...far forward as possible on your CR s seat wearing your riding apparel Ask one helper to steady your CR perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple o...

Page 99: ...add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebou...

Page 100: ...front and rear may help especially if you are heavier than the average rider Your CR may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspens...

Page 101: ...ownhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in...

Page 102: ...oo stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained If initial travel isn t...

Page 103: ...ff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed co...

Page 104: ...w jet outlet Main Circuit Fuel is metered by the main jet 9 jet needle 10 and needle jet 11 It is then mixed with air coming from the air jet 12 and enters the venturi past the needle jet Baffle Plate...

Page 105: ...NC JN MJ AS SJ NC JN MJ AS SJ NC JN MJ AS SJ NC JN MJ 21 g 0 2 55 3 6DGY28 68 430 1 3 4 55 3 6DGY29 68 440 1 1 2 55 3 6DGY29 67 450 1 1 4 60 4 6DGY29 67 460 1 3 4 60 4 6DGY29 66 470 1 g 20 2 1 4 55 3...

Page 106: ...r than 113 degrees F After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CR If larger jett...

Page 107: ...ew The minimum to maximum range of air screw adjustments is 1 to 3 turns out from the lightly seated position If you exceed 3 turns out the next smaller slow jet is needed If you are under 1 turn out...

Page 108: ...maximum power with the correct spark plug reading It is always better to jet a little rich than a little lean It is advisable to record the settings course conditions lap times and climatic and barome...

Page 109: ...the float level 18 with the float tab just contacting the float valve and the carburetor intake 19 facing up The float level should be 0 30 in 7 5 mm Adjust the float level by bending the float tab c...

Page 110: ...and colorless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelai...

Page 111: ...the top of the upper clamp 3 Standard Position For Optional Front Wheel If you install the optional 20 inch wheel align the top of the fork tube 5 not the top of the fork cap with the top of the upper...

Page 112: ...then changes from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or s...

Page 113: ...n aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may trans...

Page 114: ...y on your CR Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead an...

Page 115: ...to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 112 Storing Your Honda 113 You the Environment 114 Troubleshooting 115 Tips 111 Tips CR125R 11...

Page 116: ...on your vehicle Attach to the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables...

Page 117: ...their recommended pressures 8 Place your CR on the optional workstand or equivalent to raise both tires off the ground 9 Stuff a rag into the silencer outlet Then tie a plastic bag over the end of the...

Page 118: ...ng guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons...

Page 119: ...cessive carbon build up on the RC valve Faulty RC valve POOR PERFORMANCE AT LOW AND IDLE SPEEDS CORRECT CORRECT NOT LEAKING GOOD SPARK CORRECT INCORRECT INCORRECT LEAKING WEAK OR INTERMITTENT SPARK IN...

Page 120: ...116 Tips CR125R 111 116 31KSR620 5 6 05 1 17 PM Page 116...

Page 121: ...other technical data Vehicle Identification 118 Specifications 119 Torque Specifications 120 High Altitude Carburetor Adjustment 123 Oxygenated Fuels 124 Competition Logbook 125 Optional Parts List 1...

Page 122: ...rs in the Quick Reference section at the rear of the manual The VIN vehicle identification number 1 appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 1 VIN T...

Page 123: ...Engine Type Cylinder arrangement Bore and stroke Displacement Compression ratio Transmission oil capacity After draining After disassembly Carburetor Type Identification number Main jet standard Slow...

Page 124: ...ENGINE 1 Cylinder head nut 2 Cylinder mounting nut 3 Carburetor insulator bolt 4 Clutch cover bolt 5 Water pump cover bolt 6 Right RC cover bolt 7 Right RC cover screw 8 Alternator cover bolt 9 Left...

Page 125: ...rk cap Rear shock arm swingarm side shock link side Rear shock link nuts Frame side Shock spring lock nut Kickstarter arm bolt Front brake master cylinder holder Brake hose bolts 1 2 3 4 5 7 8 9 10 11...

Page 126: ...nt brake reservoir cap screw Rear brake reservoir cap bolt Fork air plug Upper chain roller Lower chain roller 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Item NOTES 1 Apply Honda Thread...

Page 127: ...eased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See...

Page 128: ...utyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by vol...

Page 129: ...on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to sch...

Page 130: ...on Logbook Date Running Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use CR125R 117 1...

Page 131: ...he top of the fork tube with the top of the upper clamp FRAME Driven sprocket Higher gearing Standard Lower gearing Handlebar lower holder Standard Optional Front wheel Standard Optional Remarks 246 4...

Page 132: ...justable wrenches open end box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop...

Page 133: ...Technical Information 129 Wiring Diagram CR125R 117 140 31KSR620 5 6 05 1 51 PM Page 129...

Page 134: ...130 Technical Information CR125R 117 140 31KSR620 5 6 05 1 51 PM Page 130...

Page 135: ...ormation about contacting Honda and how to get an official Honda service manual Authorized Manuals 132 Contacting Honda 133 Your Honda Dealer 134 The Honda Rider s Club USA only 135 Consumer Informati...

Page 136: ...CR125R Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Publication Item Description Qty Price Total Item No Each Price Sub Total Purchaser s Sales Tax...

Page 137: ...e dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor C...

Page 138: ...s and products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from...

Page 139: ...rd or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exciusive HRCA website complete with access to the official Honda Common Service Manual contests insider in...

Page 140: ...System 34 Transmission Oil 36 Coolant 38 Air Cleaner 40 Engine Throttle 42 Clutch System 44 Spark Plug 48 Cylinder System 49 RC Valve 55 Reed Valve 58 Chassis Suspension 60 Brakes 65 Wheels 69 Tires T...

Page 141: ...4 minor adjustments 103 care appearance 78 chain drive 72 chassis adjustment for track conditions 96 choke knob 13 cleaner air 40 cleaning appearance care 78 clutch system adjustment 44 component loca...

Page 142: ...5 instructions 11 optional parts list 127 sprockets 127 oxygenated fuels 124 pads brake 68 parts optional 127 personal fit adjustments 110 pinging engine 34 plug spark 48 pre load rear suspension 92...

Page 143: ...rottle freeplay 42 inspection 43 tires air pressure 70 flat 70 selection 109 tools 128 torque specifications 120 transporting 112 troubleshooting 115 tubes replacing 70 valve fuel 35 valve RC 55 valve...

Page 144: ...on oil Tires Tire Pressure cold Spark Plug Drive Chain The maintenance schedule page 21 lists service frequencies for each race or about 2 5 hours every 3 races or about 7 5 hours and every 9 races or...

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