Honda CR250R 2004 Owner'S Manual Download Page 8 | Manualshive

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HONDA O/M ’04 CR250R (E) 31KSK6000 00X31-KSK-6000

1

2

B

1

A

D

1

2

C

F

1

E

1

B

2

1

A

3. Loosen the lock nut and turn the integral cable

adjuster to adjust the clutch lever free play 3/8 – 3/4
in (10 – 20 mm) at the tip of lever. Tighten the lock nut.

(1) LOCK NUT
(2) INTEGRAL CABLE ADJUSTER
(3) INCREASE
(4) DECREASE

4. Adjust the clutch cable end adjuster for minor

adjustment.

(1) CABLE END ADJUSTER
(E) INCREASE
(F) DECREASE

CONTROL ADJUSTMENT

Clutch Lever Free Play

1. The normal clutch lever free play is 3/8—3/4 in

(10 — 20 mm) at the tip of the lever.

(1) CLUTCH LEVER

2. Minor adjustments can be made with the cable end

adjuster.
Turning the adjuster in direction A will increase free
play and turning in the direction B will decrease free
play.
If the adjuster is threaded out near its limit or the
correct free play cannot be reached, turn the ad-
juster all the way in and back out one turn and make
the adjustment with the integral cable adjuster.

(1) CABLE END ADJUSTER
(2) DUST COVER
(A) INCREASE
(B) DECREASE

Clutch Lever Position

CAUTION:

•

Make sure to adjust the clutch lever free play after
the clutch lever position adjustment or clutch cable
disconnected.

1. The clutch lever position can be adjusted by

loosening the lock nut and turning the adjuster.
Turning the adjuster counterclockwise moves the
clutch lever farther away from the grip; turning the
adjuster clockwise moves the clutch lever closer to
grip. Tighten the lock nut securely.

(1) ADJUSTER

(2) LOCK NUT

2. Turn the clutch cable adjuster in direction A until it

seats lightly and then turn it out 5 turns.

(1) CABLE END ADJUSTER
(A) INCREASE
(B) DECREASE

*CR250R (E) P001-010

12/10/03, 3:02 PM

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Summary of Contents for CR250R 2004

Page 1: ...OPERATION IS LEGAL OPERATOR ONLY NO PASSENGERS This motorcycle is designed and constructed as an operator only model The motorcycle load limit and seating configuration do not safely permit the carrying of a passenger READ THIS MANUAL CAREFULLY Pay special attention to statements preceded by the following words Indicates severe personal injury or death will result if instructions are not followed ...

Page 2: ...he latest product information available at the time of pproval for printing Honda Motor Co Ltd reserves the right to make changes at any time without otice and without incurring any obligation No part of this publication may be reproduced without written permission Honda Motor Co Ltd 2003 2004 E COVER HYO2 12 10 03 3 02 PM 2 ...

Page 3: ... The Service Manual for your CR is available from your authorized Honda dealer It is the same manual your dealer uses If you plan to do any service on your CR beyondthestandardmaintenanceproceduresincluded inthisOwner sManual youwillfindtheServiceManual aneffectiveandworthwhiletool Ifyourdealerdoesnot have the Service Manual for your particular year and model in stock he can order it PROTECTIVE AP...

Page 4: ...aner 23 Clutch 24 RC Valve 25 Reed Valve 28 29 Cylinder Head Cylinder Piston 29 30 Nuts Bolts Fasteners 35 Handlebar And Steering Head Bearings 35 Throttle Grip 35 Fuel Line 35 Carburetor 36 Front And Rear Wheels And Tires 36 Front Suspension 37 Rear Suspension 38 Brakes 39 Drive Chain 41 Drive Chain Sliders 43 Drive Chain Rollers 43 Driven Sprocket 43 Expansion Chamber 44 Control Cables 44 Torque...

Page 5: ...ed 32 1 FUEL OIL MIXING CHART UEL our CR has a two stroke engine that requires a gaso ne oil mixture uel tank capacity 2 0 US gal 7 7 liter 1 7 Imp gal o open the fuel fill cap pull the breather tube out of the teering stem nut Then turn the fuel fill cap ounterclockwise Use automobile gasoline with a pump octane number of 92 or higher If knocking or pinging occurs try a different brand of gasolin...

Page 6: ... side of the cylinder is very warm to the touch through your riding glove Slowly increase rpm and don t blip the throttle Warming the engine is important to prevent cold seizures Break In Procedure Help assure your CR s future reliability and perform ance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rap...

Page 7: ...31KSK6000 00X31 KSK 6000 ONTROLS OPERATING INSTRUCTIONS CLUTCH LEVER FRONT BRAKE LEVER ENGINE STOP BUTTON THROTTLE GRIP CHOKE KNOB FUEL VALVE SHIFT LEVER KICKSTARTER REAR BRAKE PEDAL FUEL FILL CAP E P001 010 12 10 03 3 02 PM 4 ...

Page 8: ...ill decrease free play If the adjuster is threaded out near its limit or the correct free play cannot be reached turn the ad juster all the way in and back out one turn and make the adjustment with the integral cable adjuster 1 CABLE END ADJUSTER 2 DUST COVER A INCREASE B DECREASE lutch Lever Position CAUTION Make sure to adjust the clutch lever free play after theclutchleverpositionadjustmentorcl...

Page 9: ...justment If the adjuster is threaded out near its limit or the correct free play 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 carburetor top adjuster 1 DUST COVER 2 LOCK NUT 3 UPPERADJUSTER A DECREASE B INCREASE 1 3 2 B A A Major adjustments can be made at the integral cable adjuster Loosen the...

Page 10: ... level with the right footpeg To adjust the rear brake pedal height 1 Loosen the lock nut and turn the adjusting bolt in direction A to raise the pedal or in direction B to lower it 2 Tighten the lock nut at the desired pedal height 1 REAR BRAKE PEDAL 2 LOCK NUT 3 ADJUSTING BOLT A RAISE THE PEDAL HEIGHT B LOWER THE PEDAL HEIGHT 2 1 3 ront Brake Lever he front brake lever position can be adjusted b...

Page 11: ...ike the optional seats and springs these sprockets are listed in the optional parts section of this manual andlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls are comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first Using optional handlebar lower holders the han dlebar position m...

Page 12: ...5 lmp oz 700 cm3 Piston valve TMX11A 420 6CHY12 82 2nd groove 32 5 1 1 2 turns out Item Engine Type Cylinder arrangement Bore and stroke Displacement Compression ratio Transmission oil capacity draining at disassembly Carburetor Type Identification number Main jet standard Jet needle standard Needle clip position standard Slow jet standard Air screw opening Float level Drive train Clutch type Tran...

Page 13: ...x groove with the top of the upper clamp 20 inch wheel assembly except brake disk tire tube tire flap rim lock bead stopper front tire 90 100 20 Fork height 0 in 0 mm align the top of the fork tube with the top of the upper clamp FRAME Shock spring Standard Optional Softer Stiffer Fork spring Standard Optional Softer Stiffer General flow characteristics Leaner Richer at1 16 to1 8 throttle 9 8 6CHY...

Page 14: ...AINTENANCE SCHEDULE Perform the Pre ride Inspection at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean R Replace L Lubricate FREQUENCY ITEM THROTTLE OPERATION AIR CLEANER SPARK PLUG RADIATOR COOLANT COOLING SYSTEM CYLINDER HEAD DECARBONIZING EXHAUST VALVE AND LINKAGE DECARBONIZING PISTON AND PISTON RINGS PISTON PIN AND CONNECTING ROD SMALL END...

Page 15: ...the fuel and oil is mixed well by agitating it thoroughly before pouring pre mix into the fuel tank Release the built up pressure in the fork tubes in excess of normal atmospheric pressure 0 psi caused by normal fork action while riding The front wheel should be suspended above ground for this operation 1 PRESSURE RELEASE SCREW BETWEEN MOTO BETWEEN PRACTICE AND MOTO MAINTENANCE Dirt wear and weigh...

Page 16: ...ges 14 16 there are some things you should do just after washing your CR to help prevent rust and corrosion Once your CR is clean and dry you should protect any bare steel from rusting 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 applying the chain lu...

Page 17: ...air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the serv icing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure togreasetheaircleanerflangewhereitcontactsthe air cleaner housing Honda White Lithium Grease or an equivalent is handy for this because any di...

Page 18: ...n sation evaporate Pull the flywheel rotor every few rides and clean it and its crankshaft mounting sur face the alternator stator the ignition pulse gen erator pickup and the entire ignition cavity thor oughly The presence of dirt between the ignition pulse generator and the flywheel makes the igni tion control module compensate to maintain the ignition curve Cleaning dirt from the ignition side ...

Page 19: ...ing them too sharp will reduce boot sole lifespan Sharpen only the points of the teeth Filing the grooves deeper will weaken the footpegs Be sure the pegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition SteeringHeadBearings Periodicallyclean inspect and regrease the steering head bearings espe cially if wet muddy or extremely dusty courses are encountere...

Page 20: ...BS MAINTENANCE PREPARATIONS EAT eat Removal Remove the seat bolts and collars Slide the seat back 1 SEAT BOLTS 2 SEAT FUEL TANK Fuel Tank Removal 1 Turn the fuel valve OFF 2 Remove the seat this page 3 Remove the shroud A bolts and collars 4 Remove the shroud B bolts collars and shrouds 1 SHROUD A BOLTS COLLARS 2 SHROUD B BOLTS COLLARS 3 SHROUD 5 Pull the breather tube out of the steering stem nut...

Page 21: ...e dis connected not the fuel line leading to the fuel tank Remove the fuel tank Gasoline is extremely flammable and is explosive under certain conditions Perform this operation in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refueled 1 FUEL LINE 2 FUEL VALVE 6 Install the shrouds col...

Page 22: ...ten the three subframe mounting bolts TORQUE Upper 22 lbf ft 30 N m 3 1 kgf m Lower 22 lbf ft 30 N m 3 1 kgf m 1 SUB FRAME MOUNTING BOLTS UBFRAME ubframe Removal Remove the seat page 17 Remove the side cover by removing the bolts collars 1 SEAT 3 SIDE COVER 2 BOLTS Loosen the screw on the air filter connecting tube clamp Remove the three rear subframe mounting bolts 1 SUBFRAME MOUNTING BOLTS Remov...

Page 23: ... hole add oil slowly through the oil filler hole until oil starts to flow out of the check bolt hole Install the oil check bolt and filler cap Repeat steps 1 4 After inspecting the oil level or adding oil tighten the oil check bolt and filler cap securely TORQUE 7 lbf ft 10 N m 1 0 kgf m 1 OIL FILLER CAP 2 OIL CHECK BOLT eplacing Transmission Oil Run the engine for three minutes then shut it off S...

Page 24: ...RADIATOR CAP 2 Add coolant up to the filler neck if the level is low NOTE Inspect the coolant level before each outing A coolant loss of 0 7 2 0 U S oz 20 60 cc 0 7 2 1 lmp oz through the over flow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 22 US qt 1 15 liter 1 01 lmp qt at disassembly 1 14 US qt 1 08 liter 0 95 lmp qt at coolant change 3 Install the ra...

Page 25: ...op buttonanddisengagetheclutchbypullingthelever in Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray NOTE 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 If the electrodes appear burnt or the insulator is white or light gray lean ...

Page 26: ...e resulting in rapid wear of the piston rings and cylinder 1 AIR CLEANER 2 PIN 3 AIR CLEANER HOUSING HOLE 4 TAB 5 REFERENCE MARK 6 AIR CLEANER HOUSING 7 AIR CLEANER HOLDER 1 2 1 2 3 5 Wash the air cleaner in clean non flammable clean ing solvent Then wash in hot soapy water rinse well and allow to dry thoroughly 6 Clean the inside of the air cleaner housing Never use gasoline or low flash point so...

Page 27: ...ter and clutch lifter rod Remove the eight clutch discs and seven clutch plates NOTE Turn the lifter 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 1 CLUTCH LIFTER 3 CLUTCH PLATES AND 2 CLUTCH LIFTER ROD DISCS Clutch Spring Measure each clutch spring s free length S...

Page 28: ...ING BOLTS 2 CLUTCH PRESSURE PLATE Install a new O ring in the groove in the clutch cover Install the cover by tightening the six cover bolts 1 CLUTCH COVER 2 O RING Lubricate the rear brake pedal pivot and pivot bolt and install the pivot bolt 1 PIVOT BOLT 2 BRAKE PEDAL RC VALVE The exhaust valves open and close according to engine speed to ensure sufficient torque throughout the entire engine rpm...

Page 29: ...engine thoroughly to keep dirt from entering the engine Warm up the engine to operating temperature top the engine and remove the RC valve cover onnect the tachometer tart the engine and check that the RC valve pulley is in he full close position ncrease the engine speed until about 8 000 min 1 rpm nd check that the RC valve pulley turns to the full open osition 1 PULLEY isconnect the cables from ...

Page 30: ...es each race Inspect the flap valve valve shaft assembly for wear or damage 1 VALVE SHAFT ASSEMBLY 2 FLAP VALVES Exhaust valve Installation Install the flap valve into the slot on the cylinder as shown Position the flap valves fully open Install the valve shaft assembly with its position as shown 1 VALVE SHAFT ASSEMBLY 2 FLAP VALVES Install the stopper plate and tighten the socket bolt TORQUE 7 lb...

Page 31: ...VER 2 GASKET Tighten the RC valve cover bolts and wire clamp TORQUE 7 lbf ft 10 N m 1 0 kgf m 1 BOLTS 2 WIRE CLAMP 3 ALTERNATOR WIRE Install the alternator wire to the wire clamp FRONT RC VALVE CABLE Turn the RC valve pulley clockwise fully until the RC valve pulley stops against the pin Loosen the inner lock nut until it reaches the end of the cable threads Connect the front RC valve cable spring...

Page 32: ...lace the reed valves with new ones if the seats are cracked or damaged 1 REED VALVE ASSEMBLY DISASSEMBLY ASSEMBLY Remove the screws stoppers and reed valves Align the cut outs between the reed valves and stop pers then install them onto the cage 1 REED VALVE STOPPER 2 REED VALVE 3 CUT OUTS Apply a locking agent to the reed valve mounting screw threads Install and tighten the mounting screws TORQUE...

Page 33: ...s pattern to loosen each nut about 1 4 turn at a time then remove the nuts Remove the cylinder head gasket 1 RADIATOR HOSE 2 HANGER PLATES 3 SPARK PLUG CAP 4 CYLINDER HEAD Cylinder Removal Remove the expansion chamber page 44 Remove the water hose and left radiator from the frame Disconnect the RC valve control cables page 28 Remove the exhaust manifold and gasket 1 EXHAUST MANIFOLD 2 GASKET eed V...

Page 34: ...tion We recommend you consult the Service Manual or your authorized Honda dealer for correct service limit measurements Piston Cylinder Head Decarbonizing Remove the carbon deposits from the cylinder head and piston dome CAUTION Use care not to scratch the cylinder head and piston dome or the head gasket surface 1 CYLINDER HEAD Cylinder Decarbonizing Clean carbon deposits from the exhaust port and...

Page 35: ...ng up Locate the piston ring end gaps on the pins in the ring grooves Lubricate the small end bearing and piston pin with clean 2 stroke oil Install the connecting rod small end bearing piston and piston pin NOTE Install the piston with the IN mark facing the intake side Install the piston pin clips CAUTION Use new pin clips Never reuse oil clips Do not let the clips fall into the crankcase 1 IN M...

Page 36: ...YLINDER Install the new gasket with pointed down Install the exhaust manifold and tighten the bolts 1 GASKET 2 EXHAUST MANIFOLD Connect the RC valve control cables page 28 Install the left radiator and water hose Install the expansion chamber page 44 Install the four mounting nuts and tighten to the speci fied torque TORQUE 29 lbf ft 39 N m 4 0 kgf m NOTE Tighten the nuts in a crisscross pattern i...

Page 37: ... CYLINDER HEAD 2 CYLINDER HEAD NUTS Install the spark plug and spark plug cap Install the hanger plate and tighten the bolts TORQUE Engine side 40 lbf ft 54 N m 5 5 kgf m Frame side 20 lbf ft 26 N m 2 7 kgf m Connect the radiator hose to the cylinder head Pour the recommended coolant mixture into the radia tor up to the correct level page 21 1 RADIATOR HOSE 2 HANGER PLATES 3 SPARK PLUG 4 CYLINDER ...

Page 38: ...Inspect the condition of the throttle cable from the throttle grip down to the carburetor If the cable is kinked chafed or improperly routed it should be replaced or rerouted Check the cable for tension or stress at both full left and full right steering positions 1 THROTTLE GRIP For safe operation and positive engine response the throttle cable must be properly adjusted FUEL LINE Fuel valve and h...

Page 39: ...warmenoughtorunwithoutthe choke push the choke knob down to its off position 3 Loosen the lock nut and turn the throttle stop screw to obtain the smoothest idle To increase idle speed turn the screw clock wise To decrease idle speed turn the screw counter clockwise 4 Tighten the lock nut while holding the throttle stop screw 5 Adjust the air screw to obtain the best off idle performance If the eng...

Page 40: ... we recommend that you disassemble and clean the fork after riding your CR for three hours See page 62 for fork disassembly Replace the fork oil every three races or 7 5 hours of running See Section 6 for oil capacity adjust ment after changing the fork oil Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maxi mum performance of your CR s front suspension Pe...

Page 41: ...k it in for approximately one hour with the standard suspension settings before attempting to adjust the rear suspension Make all compression and rebound damping ad justmentsinspecifiedincrementsorturnsdescribed in page 53 Adjusting 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 adjus...

Page 42: ...fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 1 SCREWS 2 LOWER LEVEL MARK Rear Brake Fluid Whenever the fluid level is near the lower mark on the reservoir fill it with DOT 4 BRAKE FLUID from a sealed container Remove the bolts reservoir cap and diaphragm Add the brake fluid to the upper level mark if necessary do not overfill Reinstall the diaphr...

Page 43: ...y 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 1 REAR BRAKE CALIPER 2 BRAKE PADS 3 BRAKE DISC 1 2 3 REPLACE MINIMUM THICKNESS INDICATOR 0 04 in 1 mm REPLACE WEAR INDICATOR GROOVES REPLACE MINIMUM THICKNESS INDICATOR 0 04 in 1 mm 2 2 0 04 in 1 mm Other Checks Make sure there are no fluid leaks Ch...

Page 44: ...INK 3 Inspect the sprocket teeth for possible wear or damage Replace if necessary NOTE Never install a new drive chain on badly worn sprockets or use new sprockets with a badly worn drive chain Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is da...

Page 45: ... inserting the master link In stall the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation The master link is the most critical part affecting the security of the drive chain Master links are reusable if they remain in excellent condi tion but it is recommended that a new master link retaining clip be installed whenever the drive chain i...

Page 46: ...lers to avoid the wrong installation If the lower drive chain roller was removed install it with its mark side facing out 1 UPPER ROLLER 3 MARK 2 LOWER ROLLER RIVE CHAIN SLIDERS Check the chain slider for wear If the wear is 3 16 in 5 mm or more replace it 1 CHAIN SLIDER Check the chain guide slider for wear Replacetheguidesliderifthechainisvisiblethrough the wear inspection window 1 CHAIN GUIDE S...

Page 47: ...nsion chamber springs 2 pcs and mounting bolts Remove carbon deposits from the head pipe of the expansion chamber 1 SPRINGS 2 BOLTS nstallation Note Install the expansion chamber in the reverse order of removal CONTROL CABLES Lubrication Periodically disconnect the throttle and clutch cables at their upper ends Thoroughly lubricate the cable pivot points and the inside of clutch cable end adjuster...

Page 48: ...ivot bolt Spokes Rim locks Subframe bolts upper lower Fork center bolt Fork center bolt lock nut Disc cover bolts Fork protector bolts Sprocket nuts Seat bracket screw Shroud mounting bolts Seat bolts Footpeg bracket bolts upper lower Drive chain roller bolt 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 11 0 2 2 2 0 2 2 9 0 2 0 13 0 2 8 5 5 2 7 ...

Page 49: ...y rich mixture must be delivered to the cylinder when the engine is being started When the choke knob s pulled up fuel is metered by the starter jet and is mixed with air from the air passage to provide a rich mixture for starting The mixture discharges through he orifice into the cylinder 1 CHOKE KNOB 2 STARTER JET 3 AIR PASSAGE 4 ORIFICE Main Circuit Fuel is metered by the main jet jet needle an...

Page 50: ...4 CABLE HOLDER 5 THROTTLE VALVE SPRING 6 JET NEEDLE 11 Remove the carburetor NOTE Be careful not to damage around the throttle sensor Do not assemble or move the carburetor with holding the throttle sensor lead 12 Remove the float bowl plug float bowl screws and float bowl Gasoline is extremely flammable and is explosive under certain conditions Perform this operation in a well ventilated area wit...

Page 51: ...ks in the area where gasoline is drained or stored and where the fuel tank is refueled 5 Turn the fuel valve OFF and disconnect the fuel line from the fuel valve 6 Remove the drive sprocket cover 7 Loosen the connecting and intake tube bands Ro tate the carburetor Remove the float bowl plug 1 FLOAT BOWL PLUG 2 OVERFLOW HOSE 3 FLOAT BOWL SCREW Pre adjustment Checks Before adjusting carburetor setti...

Page 52: ...quired Reinstall the jet needle throt tle valve cable holder and carburetor top 1 Turn the carburetor upright and tighten its clamp screws 2 Install the drive sprocket cover 3 Adjust the air screw opening as required Recon nect the fuel line at the carburetor 4 Repeat steps 2 through 11 until the engine gives maximum power with the correct spark plug read ing It is always better to jet a little ri...

Page 53: ...e Main jet jet needle stage General changes due to temperature and altitude All jetting is based on Standard Jetting 32 1 Fuel Oil Ratio Unmodified Engine Including Porting Exhaust and Timing STANDARD JETTING CARBURETOR ADJUSTMENT 21 0 1 1 2 32 5 2nd 6CHY12 82 420 1 1 4 32 5 2nd 6CHY12 82 430 1 1 2 35 2nd 6CHY13 82 440 1 1 4 35 3rd 6CHY12 82 450 1 35 3rd 6CHY12 81 460 1 20 1 3 4 30 2nd 6CHY12 82 4...

Page 54: ...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 jetting changes are necessary check for worn crankshaft seals air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner SPARK PLUG COLORING INDICATIONS Remember that in addition to improper jetting A lean condition can be caus...

Page 55: ... are described elsewhere in this manual he first step toward determining proper suspension djustment is to set the rear spring preload so that the roper ride height or Race Sag dimension is achieved or this adjustment procedure the bike should be rought to normal racing weight correct fuel trans mission oil and coolant levels irst measure the Unloaded dimension when your CR s supported by a workst...

Page 56: ...g may require the installation of ptional rate fork springs as well in order to maintain roper front rear suspension balance These and other omponents are listed in the Optional Parts section of his manual eep in mind that a properly adjusted suspension ystem may bottom very slightly at least once per lap t full racing speed This knowledge combined with hese adjustment guidelines and those on damp...

Page 57: ...ed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 8 clicks NOTE Both the high and low speed compression damping can be increased by turning the appropriate ad juster clockwise Adjust the high speed compression adjuster each 1 12 turns CAUTION B...

Page 58: ... oil chambers to prevent aeration The design also isolates the oil in each fork tube slider which may contain air bubbles and or metal particles from the sealed cartridge to provide more consistent damping 1 COMPRESSION DAMPING ADJUSTER 2 REBOUND DAMPING ADJUSTER Fork Springs The fork springs in CR s are about right for riders weighingbetween150and160lbs lessridinggear So if you re a heavier rider...

Page 59: ...te bolt and number plate 1 NUMBER PLATE BOLT 2 NUMBER PLATE ebound Damping Adjustment he rebound damping adjuster has 16 positions or more Turning the adjuster screw one full turn clock wise advances the adjuster four positions To adjust he rebound damping to the standard setting proceed s follows urn the adjuster clockwise until it will no longer turn ightly seats This is the full hard position h...

Page 60: ...maging the fork caps 1 UPPER PINCH BOLTS 2 FORK DAMPER Remove the disc cover by removing the two bolts 1 DISC COVER 2 BOLTS Remove the axle nut and loosen the axle pinch bolts on both forks Pull the front axle out of the wheel hub and remove the front wheel 1 FRONT AXLE 2 AXLE PINCH BOLTS 3 AXLE NUT Remove the fork protector and brake caliper CAUTION Do not support the brake caliper by the brake h...

Page 61: ...he adjuster screw counterclockwise until it stops old the outer tube then remove the fork damper from he outer tube using a special tool Gently slide the uter tube down onto the lower end of the slider pipe 1 FORK DAMPER 2 OUTER TUBE 3 LOCK NUT WRENCH 4 SLIDER LOWER END Amount of fork oil left in the fork within damper and spring 0 C 32 F 10 C 50 F 20 C 68 F 30 C 86 F 0 20 40 60 80 100 120 140 160...

Page 62: ... cm3 11 0 US oz 324 cm3 Optional Softer 0 42 kgf mm Fork Spring 1 scribe mark Optional Stiffer 0 46 kgf mm Fork Spring 2 scribe marks Standard oil capacity Maximum oil capacity Minimum oil capacity Slightly stiffer as it nears full compression Slightly softer as it nears full compression 12 9 US oz 382 cm3 14 0 US oz 415 cm3 10 8 US oz 319 cm3 Standard oil capacity Maximum oil capacity Minimum oil...

Page 63: ...hen tighten the fork damper to the specified torque using a special tool TORQUE 40 lbf ft 54 N m 5 5 kgf m Torque wrench scale reading 36 lbf ft 49 N m 5 0 kgf m using a 20 in 50 cm long torque wrench For ease of releasing air pressure after the forks are installed loosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adju...

Page 64: ...ft fork leg clamp inner surface Tighten the axle nut TORQUE 65 lbf ft 88 N m 9 0 kgf m 1 AXLE NUT Align the brake caliper and hose with the left fork leg making sure that the brake hose is not twisted Clean the threads of the caliper mounting bolts and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the fork slider and tighten the caliper mounting bolt...

Page 65: ...disc cover and tighten the bolts TORQUE 9 lbf ft 13 N m 1 3 kgf m 1 BOLTS 2 DISC COVER Turn the rebound damping adjuster screws back to their original settings With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation Tighten the left fork pinch bolts alternately first While keeping the forks parallel alternately tighten the right fork pi...

Page 66: ...OLE Temporarily install the fork damper to the outer tube Set the lower end axle holder of the slider in a vise with a piece of wood or soft jaws to avoid to damage CAUTION Do not overtighten the axle holder Loosen the center bolt 1 CENTER BOLT 2 AXLE HOLDER Push out the fork center bolt from the axle holder of the slider by pushing the fork damper Apply pressure to the fork damper and insert a sp...

Page 67: ...FORK ASSEMBLY Damper Oil Change CAUTION Check the lock nut installation If lock nut is re moved piston rod falls in the fork damper and you can not reassemble the fork damper Set a special tool to the cut outs of the fork damper 1 FORK CAP 2 FORK DAMPER 3 LOCK NUT WRENCH Loosen the fork cap by turning the fork damper using the special tool Remove the fork cap from the fork damper NOTE Be careful n...

Page 68: ...rk cap assembly Apply a locking agent to the fork cap threads Extend the fork damper piston rod to maximum hold ing it install the fork cap assembly to the fork damper NOTE Be careful not to damage the fork cap bushing If it is difficult to install the fork cap assembly fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 1 FORK CAP 2 FORK DAMPER Se...

Page 69: ...damper piston rod to full troke 1 FORK DAMPER 2 SOFT JAWS 3 SPRING CHAMBER Drain the extra oil from the fork damper spring cham ber oil hole NOTE By doing this procedure about 17 cm3 of fork fluid will be drained from the damper spring chamber through the oil hole and cause 178 cm3 of fork fluid to be left in the chamber 1 SPRING CHAMBER 2 OIL HOLE Blow out the oil from the fork damper spring cham...

Page 70: ...fork damper 1 LOCK NUT Wipe the oil completely off the fork spring Install the fork spring Install the fork damper to the outer tube slider 1 SPRING 2 FORK DAMPER ASSEMBLY 3 OUTER TUBE SLIDER Amount of fork oil left in the fork without damper and spring C F minute 5 10 20 35 55 85 145 30 86 20 68 10 50 0 32 7 1 10 6 11 8 12 9 5 9 8 2 8 3 10 6 4 7 7 1 7 2 9 4 4 2 5 9 6 2 8 2 3 5 5 6 5 8 7 9 3 5 4 7...

Page 71: ...ly by hand 1 CENTER BOLT 2 PUSH ROD 4 STOPPER TOOL 3 LOCK NUT 5 ADJUSTING ROD Measure the length of the lock nut and center bolt clearance STANDARD 0 06 0 08 in 1 5 2 0 mm Iftheclearanceisoutofspecification checkthelocknut and center bolt installation 1 LOCK NUT 2 CENTER BOLT Tighten the lock nut to the center bolt closely by hand Tighten the lock nut to the specified torque TORQUE 16 lbf ft 22 N ...

Page 72: ...apacity Slightly stiffer as it nears full compression Slightly softer as it nears full compression 12 9 US oz 382 cm3 14 0 US oz 415 cm3 10 8 US oz 319 cm3 NOTE Be sure the oil capacity is the same in both fork legs Install the fork damper as described in Fork oil change page 60 62 Standard oil capacity Maximum oil capacity Minimum oil capacity Slightly stiffer as it nears full compression Slightl...

Page 73: ...n the sand The spring force requirements probably won t change much between a hard track and a sand track You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy race you want a stiffer spring front and rear because your CR becomes much heavier with the accumulation of mud If you don t compensate for the additi...

Page 74: ...al travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring If initial and middle travel are not stiff Test stiffer compression damping adjustments in one click increments If initial and middle travel are stiff Instal...

Page 75: ...e smooth fork action from initial to middle travel If final travel is still stiff after the above adjustment or If initial and middle travel become stiff Install the optional soft spring Test softer compression damping adjustments in one click increments If the entire travel feels stiff after the above adjustment Test softer compression damping adjustments in one click increments until the desired...

Page 76: ... 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 compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment 2 If it still feels stiff fur...

Page 77: ...rs more weight to the rear to help the bike hook up better and wheelie easier You can use these wheelbase adjustments for more or less trail as mentioned eariler You must realize that these chassis adjustments offer subtle changes in overall handling yet a noticeable improvement will be realized in the areas specified If you change your wheelbase be sure to recheck race sag and adjust if necessary...

Page 78: ...itions can be harder to pre vent the relatively long knobs from bending back under acceleration or wearing quickly Loose and Sandy Soil conditions are best handled with a tire that is similar in construction to those needed for tacky soil and mud but with a few more knobs Don t stray from the factory recommended sizes since this may affect handling and even acceleration CAUTION Unless you have the...

Page 79: ...ents or compo ent selections were successful A logbook can remind ou to change suspension gearing tires and jetting to he settings that worked well in the past at any given ace track It can even remind you where on the course our competition was nearly able to pass you on the nal lap so you II be forewarned imekeeping his Manual lists maintenance intervals for every so many races or every so many ...

Page 80: ...0 MAINTENANCE TUNING RACING LOGBOOK 20 CR Make several photocopies of this page for future use Date Running Time Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc E P070 079 12 10 03 3 13 PM 77 ...

Page 81: ...es eat gnition Components GENERAL TOOLS Sockets 3 8 inch drive Screwdrivers Blade Phillips No 1 2 3 Wrench Large Adjustable Wrenches Open end and Box Wrenches Hex Allen Wrench Spoke Torque Wrench metric scale click stop style Pliers Standard Needle Nose Channel Lock Type Hammer Plastic Head Syringe With Adjustable Stop Tire Pressure Gauge Tire Irons Tire Pump or Air Tank BASIC TOOLS Drop Light Fee...

Page 82: ... alternator 2 Faulty ignition control module 3 Faulty ignition pulse generator 1 Lack of fuel in tank 2 Clogged fuel line P 35 3 Clogged fuel fill cap breather tube P 2 4 Clogged fuel valve P 36 5 Clogged fuel filter P 37 1 Not cleaned frequently enough P 23 1 Contaminants in the fuel 1 Jet size wrong reject in the opposite direction P 50 1 Control cables faulty 2 Damaged exhaust valves CHECK 1 Ch...

Page 83: ... before riding your CR Several applications may be necessary to restore normal braking performance Remove the alternator cover wipe out any visible moisture and allow the cavity to air dry for at least a couple of hours page 13 Braking performance may be impaired immedi ately after washing your CR 3 CLEANING Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and ro...

Page 84: ...ubricate the drive chain 5 Remove the spark plug and pour a tablespoon 15 20 cc of clean engine oil into the cylinder With the spark plug grounded or the Engine Stop Botton pressed in crank the engine several times to distribute the oil then reinstall the spark plug 6 Inflate the tires to their recommended pressures 7 Place your CR on the optional Honda work stand or equivalent to raise both tires...

Page 85: ...82 HONDA O M 04 CR250R E 31KSK6000 00X31 KSK 6001 5 WIRING DIAGRAM E P080 086 12 10 03 3 12 PM 82 ...

Page 86: ... maintenance 14 eneral service information 12 Handlebar and steering head bearings 35 Handlebar position width shape 7 Ignition 22 Index 83 Maintenance preparations 17 Maintenance procedures 20 Maintenance schedule 11 Maintenance tuning racing logbook 76 Nuts bolts fasteners 35 Operating instructions 2 Optional parts list 10 Poor performance at high speed 79 Poor performance at low and idle speeds...

Page 87: ...e for delivery NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation S H I P T O Customer Name Attention Street Address No P O Box Number Apt City State Zip Code Daytime Telephone Number P A Y M E N T Check or money order encl...

Page 88: ...85 HONDA O M 04 CR250R E 31KSK6000 00X31 KSK 6001 MEMO E P080 086 12 10 03 3 12 PM 85 ...

Page 89: ...86 HONDA O M 04 CR250R E 31KSK6000 00X31 KSK 6001 MEMO E P080 086 12 10 03 3 12 PM 86 ...

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