Honda CR250R Owner'S Manual & Competition Handbook Download | Manualshive

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Servicing Your Honda

21

Servicing Your Honda

21

Maintenance Schedule

Perform the Pre-ride Inspection at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.

Frequency

Items

Throttle Operation

Air Cleaner

Spark Plug

Radiator Coolant

Cooling System

Cylinder Head Decarbonizing

Exhaust Valve and Linkage Decarbonizing

Piston and Piston Ring

Piston Pin and Connecting Rod Small End Bearing

Reed Valve Only

Transmission Oil

Drive Chain

Drive Chain Sliders

Drive Chain Rollers

Drive Sprocket

Driven Sprocket

Brake Fluid

Brake Pad Wear

Brake System

Clutch System

Control Cables

Expansion Chamber/Silencer

Suspension

Swingarm/Shock Linkage

Fork Oil

Fork Tube/Slider

Damper

Nuts, Bolts, Fasteners

Wheels/Tires

Steering Head Bearing

This maintenance schedule is based upon average riding condition. Machines subjected to severe use require more frequent servicing.
NOTE: 1. Clean after every moto for dusty riding conditions.

2. Replace every 2 years. Replacement requires mechanical skill.
3. Replace after the first break-in ride.

Ref. page

42

40

48

38

39

51

56

51

51, 52

58

36

72

72

73

74

74

66

68

65

44

76

75

60, 61

25, 61

62

86

77, 124

69, 70

76

Every 9 races

or about

22.5 hours

R

R

I

Every 3 races

or about

7.5 hours

R

C

C

R

R

R

R

L

R

Each race

or about

2.5 hours

I

C

I

I

I

I, L

I

I

I

I

I

I

I

I

I, L

I

I

I

I

Note

(Note 1)

(Note 2)

(Note 2)

(Note 3)

*CR250/00-23(31KSK630).qxd 6/2/06 9:54 AM Page 21

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Summary of Contents for CR250R

Page 1: ...is vehicle is sold as is with no vehicle and for use by experienced riders only The permit the carrying of a passenger NT NOTICES cycle and should remain with the motorcycle when it is resold nformation available at the time of approval for printing Honda Motor notice and without incurring any obligation rmission le ...

Page 2: ......

Page 3: ...vice e standard maintenance nual you will find the able reference ons or if you ever need a irs remember that your our CR best and is plete satisfaction ge of address or ownership so we will be able to g important production visit our website at California Proposition 65 Warning WARNING This product contains or emits chemicals known to the State of California to cause canser and birth defects or o...

Page 4: ...n devoted to Motorcycle Safety as well as a number of Safety Messages gnal words DANGER WARNING or CAUTION RT if you don t follow instructions T if you don t follow instructions tructions ted with operating or maintaining a motorcycle You must use your own good Safety Messages ...

Page 5: ...18 119 TECHNICAL INFORMATION 121 Vehicle Identification 122 Specifications 123 Torque Specifications 124 High Altitude Carburetor Adjustment 127 Oxygenated Fuels 128 Competition Logbook 129 Optional Parts List 131 Spare Parts Equipment 132 Wiring Diagram 133 CONSUMER INFORMATION 135 Authorized Manuals 136 Contacting Honda 137 Your Honda Dealer 138 The Honda Rider s Club USA only 139 TABLE OF CONTE...

Page 6: ...Motorcycle Safety 1 Motorcycle Safety mation 2 recautions 2 cations 3 4 ...

Page 7: ...x Even one drink y to respond to changing eaction time gets worse drink So don t drink and r friends drink and ride Safe Condition properly is critical to your r example can cause a ou can be seriously injured ...

Page 8: ...Accessories Modifications Motorcycle Safety 3 ...

Page 9: ...replacement ...

Page 10: ...Operating Controls 5 Operating Controls Locations 6 ...

Page 11: ...kickstarter rear brake pedal throttle grip front brake lever ...

Page 12: ...Before Riding 7 Before Riding e 8 ady to Ride 9 9 ...

Page 13: ...RNING met increases the injury or death in a ys wear a helmet eye er protective apparel ...

Page 14: ...nt and freeplay 44 ngs and related parts 76 operation 42 r improper inflation 70 ss 69 eness 69 ension for proper 60 61 es check operation 65 rect slack and adequate 72 sliders and guide rollers r 72 r springs for damage or 75 for looseness such as carburetor insulator bolts olts axle nuts handlebar riple clamp bolts drive e chain guide wire harness rter mounting bolt 124 ...

Page 15: ......

Page 16: ...Basic Operating Instructions 11 Basic Operating Instructions 11 Basic Operating Instructions ns 12 e Engine 13 13 13 13 ngine 14 15 ...

Page 17: ......

Page 18: ...ry warm to the touch glove Slowly increase the throttle Warming the to prevent cold seizures ON on into neutral b down 1 8 1 4 and operate the Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine 1 Push the choke knob down all the way to OFF 2 Open the throttle fully 3 While pushing the engine stop button crank the engine ...

Page 19: ......

Page 20: ...Basic Operating Instructions 15 Break in Guidelines ...

Page 21: ......

Page 22: ...cautions 19 20 Maintenance 22 etition Maintenance 26 Practice Maintenance 26 Maintenance 27 ent Locations 28 29 30 32 34 36 38 40 42 44 48 49 55 58 Chassis Suspension 60 Brakes 65 Wheels 69 Tires Tubes 70 Drive Chain 72 Expansion Chamber 75 Additional Maintenance Procedures 76 Appearance Care 78 ...

Page 23: ......

Page 24: ...adequate ventilation ate the engine otorcycle parts Let the system cool before ng parts Do not run the ucted to do so ns before you begin and e the tools and skills motorcycle from falling rm level surface using the d or a maintenance stand to bility of a fire or ul when working around a non flammable high such as kerosene not parts Keep cigarettes away from all fuel related ...

Page 25: ...nspection page 9 at each e period nce Schedule Notes and moto for dusty riding ars Replacement requires rst break in ride es adjust lubricate or replace ...

Page 26: ...e require more frequent servicing Ref page 42 40 48 38 39 51 56 51 51 52 58 36 72 72 73 74 74 66 68 65 44 76 75 60 61 25 61 62 86 77 124 69 70 76 Every 9 races or about 22 5 hours R R I Every 3 races or about 7 5 hours R C C R R R R L R Each race or about 2 5 hours I C I I I I L I I I I I I I I I L I I I I ...

Page 27: ......

Page 28: ... noticeable off idle and in low rpm performance 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 Pro Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 40 Use the Honda g...

Page 29: ...in the fuel from the tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 Fuel Contamination Periodically drain the float chamber and inspect the carburetor for contamination from dirt page 35 Inlet Tract Sealing Air leaks around the carburetor insulator and reed valve assembly should be cured by disassembling cleaning ...

Page 30: ...to the tiny metal particles produced from the normal action of the fork as well as normal oil breakdown will deteriorate the performance of the suspension Refer to the Honda Service Manual Use only Pro Honda HP Fork Oil 5W U S A only or equivalent which contains special additives to assure maximum performance of your CR s front suspension Frame Because your CR is a high performance machine the fra...

Page 31: ... the fork tubes used by normal fork action ou are riding at higher that fork pressure of 0 at ase as elevation increases ews Be sure the fuel and oil is mixed well by agitating it thoroughly before pouring pre mix into the fuel tank 1 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Hand...

Page 32: ...eaning brushes ety drug food and e of these brushes are moving dirt from the many metal pieces of your abrasive brushes on the ed to sea air or salt water sible after the event dry it icant to all metal parts your CR or use cleaners are page 78 Servicing Your Honda 27 Before After Competition Maintenance ...

Page 33: ...ter rear brake fluid reservoir transmission oil filler cap ear suspension spring re load adjuster transmission oil check bolt fuel fill cap rear suspension high speed compression damping adjuster rear suspension low speed compression damping adjuster front suspension rebound damping adjuster front suspension compression damping adjuster ...

Page 34: ...prong 4 onto the seat seat rear prong 6 onto hing down and forward on hese areas nd tighten the seat bolts to e 2 8 kgf m Servicing Your Honda 29 Seat Removal 4 6 ...

Page 35: ... line 9 from the fuel valve 1 10 Remove the fuel tank 1 fuel valve 9 fuel line WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 5 7 1 9 6 ...

Page 36: ...Servicing Your Honda 31 7 and shroud B bolts A bolts collars 9 s e 29 Fuel Tank Removal 9 8 ...

Page 37: ...g it straight nting bolts nting bolt Installation 1 Loosely attach the upper and lower ends of the subframe to the mainframe while connecting the air cleaner connecting tube to the carburetor 2 Tighten the screw 1 on the connecting tube clamp 2 1 screw 2 connecting tube clamp 6 5 9 7 2 1 ...

Page 38: ...Servicing Your Honda 33 Subframe Removal r 6 to the expansion ealing rubber he bolt washer 7 7 bolt washer e cover 8 and bolt collar 9 bolt collar ge 29 9 ...

Page 39: ...re expected ture is left standing in a eriod of time lubricity will mixture within 24 hours or mended by the oil is opened the oil must be h since oxidation may 32 1 FUEL OIL MIXING CHART Fuel Oil 32 1 Gallons Liters Ounces cm3 0 5 1 89 2 0 59 1 0 3 79 4 0 118 1 5 5 68 6 0 177 2 0 7 57 8 0 237 2 5 9 46 10 0 296 3 0 11 36 12 0 355 3 5 13 24 14 0 414 4 0 15 14 16 0 473 4 5 17 03 18 0 532 5 0 18 92 2...

Page 40: ...tor To service the fuel filter 1 Drain the fuel from the fuel tank into an approved gasoline container Disconnect the fuel line 2 Remove the fuel valve 1 by removing the bolts 2 Wash the fuel filter 3 in high flash point cleaning solvent 1 fuel valve 3 fuel filter 2 bolt 4 O ring 3 Reassemble the fuel valve in the reverse order of removal Make sure the O ring 4 is in place Install the fuel valve i...

Page 41: ...gy conserving service label on the container They may affect lubrication and clutch performance NOT RECOMMENDED OK Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 30 transmission oil or 4 stroke engine oil SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 30 MA wi...

Page 42: ...tes then shut it off 2 Support the CR in an upright position on a level surface 3 Remove the oil filler cap from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the drain bolt 1 5 Pour the drained oil into a suitable container and dispose of it in an approved manner page 118 Improper disposal of drained fluids is harmful to the environment 6 After t...

Page 43: ...f 0 7 2 0 US oz 20 60 cm3 through the over flow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 16 US qt 1 10R at disassembly 1 02 US qt 0 97R at coolant change 3 Install the radiator cap securely If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage NOTICE WARNING Removing the radia...

Page 44: ...ally qualified Refer to the official Honda Service Manual page 136 To properly dispose of drained coolant refer to You the Environment page 118 Improper disposal of drained fluids is harmful to the environment NOTICE Coolant WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removin...

Page 45: ... cleaner is made in two pieces inner and outer which can t be separated 6 Clean the inside of the air cleaner housing 7 Allow the air cleaner to dry thoroughly After drying soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil Apply air cleaner oil to the entire surface inner and outer and rub it with both hands to saturate the air cleaner with oil Squeeze out ex...

Page 46: ...ing Tighten the rely the sealing flange of the dirt intrusion of the air cleaner assembly st to enter the engine and e piston rings and cylinder 8 air cleaner housing 9 tab 10 reference mark ole 11 Reinstall the seat page 29 making sure it is securely attached Servicing Your Honda 41 Air Cleaner 9 3 8 3 4 ...

Page 47: ...stment such as after replacing the throttle cables or removing the carburetor It is also used if you cannot get the proper adjustment with the upper adjuster 5 rubber cap increase 6 lock nut decrease 7 adjuster 1 Pull up the rubber cap 5 on the carburetor cap and loosen the lock nut 6 2 Turn the adjuster 7 in direction to decrease freeplay and in direction to increase freeplay 3 Tighten the lock n...

Page 48: ...Servicing Your Honda 43 Throttle ...

Page 49: ...ip e lock nut r r d adjuster for minor Clutch Lever Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 3 4 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear Make sure to adjust the clutch lever 1 freeplay after the clutch cable is disconnected 1 ...

Page 50: ...e clutch y the cable may be kinked discs may be worn See refer to the official Honda 134 Other Inspections Lubrication Check that the clutch lever assembly is positioned properly and the securing bolts are tight Check the clutch cable for kinks or signs of wear If necessary have it replaced Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corro...

Page 51: ...show signs of scoring or discoloration Measure the thickness of each clutch disc Service Limit 0 112 in 2 85 mm Replace the clutch discs and clutch plates as an assembly 1 clutch disc Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 008 in 0 20 mm Replace the cl...

Page 52: ...ng the six cover bolts to the specified torque 9 lbf ft 12 N m 1 2 kgf m 8 O ring 9 clutch cover 11 Lubricate the rear brake pedal pivot 10 and pivot bolt 11 with Pro Honda White Lithium Grease or an equivalent and install the pivot bolt and washer 12 Tighten the bolt to the specified torque 27 lbf ft 36 N m 3 7 kgf m Connect the brake pedal return spring 13 if it was removed 10 brake pedal pivot ...

Page 53: ...insulator around e should appear tan or pear burnt or the insulator ay lean or the electrodes ack or fouled rich there here page 109 Check the rburetor and fuel system 5 Tighten the spark plug 4 If the old plug is good 1 8 turn after is seats If installing a new plug tighten it twice to prevent loosening a First tighten the plug NGK 3 4 turn after it seats b Then loosen the plug c Next tighten the...

Page 54: ...lamp 4 and d nuts 5 hanger plates er head nuts A 6 and B washers 7 using the d below and remove the cylinder head use a osen each nut about 1 4 8 cylinder head washers 7 Remove the cylinder head gasket 9 and dowel pins 10 9 gasket 10 dowel pins Cylinder System 9 10 3 5 ...

Page 55: ... both sides mounting bolts 12 on mounting bolts 13 then s 14 forward on both 12 upper mounting bolt 13 lower mounting bolt 14 radiator 9 Remove the cylinder 15 by removing the four flange nuts 16 15 cylinder 16 flange nuts 10 Remove the gasket 17 and dowel pins 18 17 gasket 18 dowel pins 8 0 15 16 17 18 14 12 11 13 6 ...

Page 56: ... dome scratching the cylinder or the head gasket surface its from the exhaust port 2 Cylinder Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your Honda dealer for correct Service Limit measurements Servicing Your Honda 51 1 ...

Page 57: ...of the crankcase being careful not to let any material fall into the crankcase Be careful not to remove any metal from the gasket surface 2 Remove the shop towel Do not let any gasket debris fall into the crankcase 3 Place the new cylinder base gasket 1 and dowel pins 2 on the crankcase 1 cylinder base gasket 2 dowel pin 4 Lubricate the piston and ring with 2 stroke oil Align the ring end gap with...

Page 58: ...hose ts 10 screw ve cables Adjust if 7 et 11 onto the RC valve ve cover and clamp 13 14 to the specified torque 0 5 kgf m 13 clamp 14 bolts 12 Install a new exhaust gasket 15 13 Install the expansion chamber and springs page 75 15 exhaust gasket Servicing Your Honda 53 Cylinder System 10 9 14 6 8 cont d 13 15 ...

Page 59: ...torque ft 54 N m 5 5 kgf m ft 34 N m 3 5 kgf m hose 11 to the cylinder ug and spark plug cap 12 11 water hose 12 spark plug cap nded coolant mixture into he correct level page 38 and seat page 29 30 d check for the following s noise ks 8 10 ...

Page 60: ...lve does not turn he exhaust valve and C valve 2 and valve shaft 3 valve shaft assembly Exhaust Valve Removal 1 Remove the cylinder page 50 2 Remove the socket bolt 1 and stopper plate 2 1 socket bolt 2 stopper plate 3 Remove the valve shaft assembly 3 from the cylinder 4 Remove the cylinder cover 4 by removing bolts A 5 and bolts B 6 Remove the RC valve 7 and O rings 8 3 valve shaft assembly 6 bo...

Page 61: ...installation place the cylinder upside down Set the RC valve 2 onto the cylinder cover 3 and O rings 4 to the cylinder 2 RC valve 4 O rings 3 cylinder cover 5 Install the cylinder cover carefully to the cylinder 6 Install the valve shaft assembly Make sure that the valve shaft and RC valve are aligned 7 Tighten the bolts A 5 and bolts B 6 to the specified torque 9 lbf ft 12 N m 1 2 kgf m 5 bolts A...

Page 62: ...nst the pin 2 2 Loosen the inner lock nut 3 until it reaches the end of the cable threads 3 Connect the front RC valve cable spring seat 4 to the RC valve pulley 4 Install the seat 5 to the cable guide 6 while compressing the spring 5 Tighten the adjuster 7 until the inner lock nut seats to the cylinder 8 6 Tighten the outer lock nut 9 securely 1 RC valve pulley 6 cable guide 2 pin 7 adjuster 3 in...

Page 63: ...d valves nstall them onto the cage screws 4 reed valve 5 spacer 6 cut out 3 Apply a locking agent to the reed valve mounting screw threads 4 Install and tighten the mounting screws to the specified torque 0 7 lbf ft 1 N m 0 1 kgf m 5 Make sure that the clearance between the reed valve and cage 7 is less than the 0 008 in 0 2 mm 4 reed valve 7 cage 2 1 1 6 3 7 4 5 4 0 008 in 0 2 mm ...

Page 64: ...Reed Valve ck for secondary air leaks nd insulator mounting bolts or page 107 Servicing Your Honda 59 4 5 ...

Page 65: ... still too stiff soft This p that will help you solve ms fork protectors 1 and dust and not packed with mud oil leakage Damaged or hould be replaced before 2 dust seal ngs 3 for wear or damage ng if it is 0 06 in 1 5 mm er tube 4 g with its end gap facing 3 wear ring 4 outer tube 3 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar severa...

Page 66: ...p and down h suspension action me page 32 or collapsed spring r a bent shaft or oil leaks l sideways to check for garm bearings There ment If there is have the y your Honda dealer Servicing Your Honda 61 Suspension 1 ...

Page 67: ...r tube when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube Amount of fork oil left in the fork within damper and spring unit cm3 minute C F 5 10 20 35 55 85 145 30 86 27 15 3 10 6 9 4 8 3 7 9 7 9 20 68 29 4 16 5 11 8 10 6 9 4 8 2 8 2 10 50 28 2 21 2 16 5 15 3 12 9 11 8 11 8 0 32 30 6 22 4 18 8 16 5 16 5 15 3 14 1 5 6 OOD NO GOOD 1 0 C 32 F 10 C 50 F 20 C 68 F 30 C 86 F 0 20 40 ...

Page 68: ...ression Slightly softer as it nears full compression scribe mark US oz cm3 US oz cm3 US oz cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression 2 scribe marks Standard oil capacity Maximum oil capacity Minimum oil capacity 13 2 US oz 389 cm3 14 4 US oz 425 cm3 11 0 US oz 326 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full...

Page 69: ......

Page 70: ...faces of the 3 ay exceeds 0 8 in 20 mm the brake system and it the Honda Service Manual ler for brake bleeding Brake Pedal Height The brake pedal height should be approximately level with the right footpeg 1 Loosen the lock nut 1 and turn the adjusting bolt 2 in direction to raise the pedal 3 or in direction to lower it 2 Tighten the lock nut at the desired pedal height 1 lock nut raise the pedal ...

Page 71: ...ght position check LOWER level mark 2 If the LOWER level mark or wear page 68 ld be replaced If the pads ur brake system inspected play exceeds 0 8 in ably air in the brake bled Refer to the Honda your Honda dealer for 2 ...

Page 72: ...removed or brake 6 upper level mark 4 reservoir cap 5 and ith DOT 4 brake fluid to k 6 Do not overfill agm and reservoir cap the specified torque 0 1 kgf m Other Inspection Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Servicing Your Honda 67 6 5 ...

Page 73: ...6 brake disc Other Inspections Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings 4 replace 0 04 in 1 mm minimum thickness indicator ...

Page 74: ... and rim specified torque m 0 4 kgf m 0 4 kgf m 2 kgf m unout If runout is Honda Service Manual for ons Axles Wheel Bearings See the Honda Service Manual for inspection information 1 Check the axle for runout 2 Check the condition of the wheel bearings Servicing Your Honda 69 4 1 ...

Page 75: ... your tires and wheels before you ride 1 tire tread depth Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before d...

Page 76: ...our CR were designed to nation of handling braking t across a broad range of tire equivalent to the ny time you replace a tire robably be stretched and if ire could fail Servicing Your Honda 71 21 51M 19 62M y tube ...

Page 77: ...t has pins or kinks that cannot e drive chain page 73 if it signs of rust Lubricate any s and work them free eeded 5 Check the chain slider 4 for wear If the wear is 3 16 in 5 mm or more replace it 4 chain slider 6 Check the chain guide slider 5 for wear Replace the chain guide slider if it is worn to the bottom of the wear limit groove 6 5 chain guide slider 6 wear limit groove 1 3 4 5 6 ...

Page 78: ...t counterclockwise hes the axle plate Then djusting bolt with a lock nut to the specified 2 8 kgf m Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda Chain Lube or an equivalent or SAE 80 or 90 gear oil is recommended Saturate each chain joint so that the lubricant penetrates the space between ...

Page 79: ...n 7 Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation 8 Recheck chain slack and adjust as necessary More About Drive Chain The mas...

Page 80: ...al sion chamber by removing mber springs 1 and st gasket 2 bolts posits from the head pipe hamber 3 on the head pipe for Expansion Chamber Installation Install the expansion chamber in the reverse order of removal Expansion Chamber 1 3 ...

Page 81: ... Control Cables Periodically disconnect the throttle and clutch cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant If the clutch lever and throttle operation is not smooth replace the cable Be sure the throttle returns freely from fully open to fully closed automatically in all steering positions 1 ...

Page 82: ...Servicing Your Honda 77 6 RC cover bolt olt t Additional Maintenance Procedures 1 3 2 5 ...

Page 83: ...a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damage or discolor the frame surface A muffler stain remover should only be used for removing stains on the non coated aluminum frame 4 After washing rinse your CR thoroughly with plenty of clean water to remove any residue 5 ...

Page 84: ...st mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame Do not use steel wool to clean the frame as i...

Page 85: ......

Page 86: ...Adjustments for Competition 81 ustments 82 stments 95 ts for Track Conditions 99 ts Guidelines 100 ts Tuning Tips 103 110 111 k Conditions 112 nts 113 Adjustments for Competition ...

Page 87: ...n good condition release screw to the 0 1 kgf m ews 2 O ring Front Suspension Damping Compression Damping Compression damping affects how quickly the fork compresses The compression damping adjuster has 16 positions or more Turning the adjuster screw one full turn advances the adjuster 4 positions Always start with the full hard position when adjusting damping 1 compression damping adjuster screw ...

Page 88: ...le igher the oil level the essure of any air in the Front Suspension Disassembly If your CR is brand new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in For optimum performance and extended fork life the fork should be completely disassembled and cleaned after the first three hours of riding See the Service Manual or your Honda dealer for thi...

Page 89: ...upport the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so 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 10 Loosen the fork leg lower pinch bolts 17 then pull the fork legs down and out 17 lower pinch bolts NO...

Page 90: ...wer end axle holder 25 of the slider in a vise with a piece of wood or soft jaws to avoid damage to it Over tightening the vise can damage the axle holder 18 Loosen the fork center bolt 26 25 axle holder 26 fork center bolt 19 Push out the fork center bolt from the axle holder of the slider by pushing the fork damper 20 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as ...

Page 91: ... 2 fork damper Check the lock nut installation If the lock nut is removed the piston rod will fall in the fork damper and you cannot reassemble the fork damper 1 Loosen the fork cap 1 by turning the fork damper 2 using the lock nut wrench 3 Make sure the compression damping adjuster is set the softest position NOTICE 25 28 29 30 32 1 3 2 ...

Page 92: ...e bushing and new O ring on the fork cap assembly 4 Extend the fork damper piston rod to maximum length and while holding it install the fork cap assembly to the fork damper 2 Be careful not to damage the fork cap bushing If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 2 fork damper 4 fork...

Page 93: ...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 14 Blow out the oil from the fork damper spring chamber 7 using compressed air to the oil hole 8 Wipe the oil completely off the fork damper 7 spring chamber 8 oil hole 15 If you can not use compressed air remove the pressure release screw 9 on the fork cap 10...

Page 94: ...ff the fork damper 2 lock nut 3 Wipe the oil completely off the fork spring 3 Install the fork spring to the fork damper Install the fork damper 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 fork spring cont d 2 3 4 1 0 43 0 51 in 11 13 mm 0 35 55 85 145 7 1 2 4 4 2 5 9 6 2 8 2 3 5 5 6 5 8 7 9 3 5 4 7 4 9 7 1 3 5 4 7 4 8 5 9 50 F 20 C 68 F 30 C 86 F minutes 80 100 120 1...

Page 95: ...er tool while applying pressure to the fork damper Install the center bolt to the axle holder and tighten it to the specified torque 51 lbf ft 69 N m 7 0 kgf m 9 fork center bolt 11 Measure the length between the axle holder and outer tube Standard 12 4 in 315 mm Compare the length 10 at assembly and at disassembly They should be the same length If the length at assembly is longer than at disassem...

Page 96: ... oz cm3 US oz cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression scribe mark US oz cm3 US oz cm3 US oz cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression 2 scribe marks Standard oil capacity Maximum oil capacity Minimum oil capacity 13 2 US oz 389 cm3 14 4 US oz 425 cm3 11 0 US oz 326 cm3 Slightly stiffer as it...

Page 97: ... will be tually applied to the fork ir pressure after the forks e lower pinch bolts and s so that the pressure ront of the rebound 17 Tighten the fork lower pinch bolts 13 to the specified torque 15 lbf ft 20 N m 2 0 kgf m 18 Tighten the fork upper pinch bolts 14 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 def...

Page 98: ...may rupture and cause a loss of braking efficiency Route the hose carefully 23 Clean the threads of the brake caliper mounting bolts 21 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the slider and tighten the brake caliper mounting bolts to the specified torque 22 lbf ft 30 N m 3 1 kgf m Fit the brake caliper over the disc taking care not to dama...

Page 99: ...be sure the axle is seated firmly onto the left fork leg clamp inner surface 29 Clean the threads of the disc cover bolts and axle holder thoroughly 30 Apply locking agent to the disc cover bolt threads 31 Install the disc cover 31 and tighten the disc cover bolts 32 to the specified torque 10 lbf ft 13 N m 1 3 kgf m 31 disc cover 32 disc cover bolts 32 Turn the compression and rebound damping adj...

Page 100: ...increase to more than er changes spring length One turn equals spring 7 2 lbs 7 8 kg Pin spanners should be used for turning the lock nut and adjusting nut See page 131 for optional pin spanners Spring preload length Standard spring Standard 10 2 in 258 1 mm Min 9 9 in 252 mm Spring preload length Optional spring Min Softer 5 0 kgf mm 9 7 in 246 mm Min Stiffer 5 4 kgf mm 9 7 in 247 mm Min Stiffer ...

Page 101: ...clicks ks are aligned Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 17 positions or more Turning the adjuster one full turn advances the adjuster 4 positions Rebound damping can be increased by turning the adjuster clockwise 3 rebound damping adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer t...

Page 102: ...he cost of slightly reduced straight line stability Increasing the race sag dimension example 4 3 in 110 mm may improve stability on faster terrain with less turns but will reduce turning performance slightly and may upset the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end o...

Page 103: ...ut kick sideways over lips ain It may even top out our CR bsorption quality of the it may be difficult for you R s suspension is rs may think the damping e ratio is too harsh In most likely insufficient ring that is too soft Either zing the full travel operly adjusted suspension ghtly every few minutes at the suspension to avoid this may cost more in overall ce than it is worth m for your weight w...

Page 104: ...arge jumps you ame spring as normal but th ways compression and ofter rebound damping the rough ground and small d you will hook up better damping the wheel returns t contact the ground ach bump The result is a wer lap times Adjustments for Competition 99 ...

Page 105: ...er compression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments If initial and middle travel are stiff Install the optional stiff spring If initial travel is stiff after installing the optional stiff spring Test soft compressi...

Page 106: ...duce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If final ...

Page 107: ...gh speed compression adjustments simultaneously d low speed compression adjustments and rebound adjustment simultaneously eplace the spring with a softer spring optional and begin with the standard settings to d low speed compression adjustments simultaneously eplace the spring with a stiffer spring optional and begin with the standard settings to d low speed compression adjustments and rebound ad...

Page 108: ...er a given portion of throttle valve opening These major circuits overlap as shown below Main Jet The main jet affects fuel air ratio from half 1 2 to full throttle 4 4 The size should be reduced at higher altitudes Your CR s carburetor jet sizes are numbered in increments of 10 When changing the main jet size increase or decrease it gradually until the desired jetting is obtained Because your CR ...

Page 109: ... 60 2 1 4 37 5 2 6DGY27 66 390 2 37 5 3 6DGY26 66 400 2 40 3 6DGY26 65 410 2 40 3 6DGY26 65 420 1 3 4 40 3 6DGY26 65 430 59 g 80 2 1 2 37 5 2 6DGY27 67 390 2 1 4 37 5 2 6DGY27 66 390 2 37 5 3 6DGY26 66 400 2 40 3 6DGY26 65 410 2 40 3 6DGY26 65 420 79 g 100 2 1 2 35 2 6DGY26 67 380 2 1 2 37 5 2 6DGY27 67 390 2 1 4 37 5 2 6DGY27 66 390 2 37 5 3 6DGY26 66 400 2 40 3 6DGY26 65 410 99 g 120 2 1 2 35 2 ...

Page 110: ... d or restricted exhaust or y air cleaner Pre Adjustment Checks Before adjusting carburetor settings check the following air cleaner air leaks float level clogged carburetor jets spark plug fouling improper heat range or other cause freshness of fuel and fuel oil ratio owner modifications such as exhaust system holes in the air box etc ignition timing compression If the above check out then adjust...

Page 111: ... consideration the and factors for temperature 104 ed that the main and slow ed you must remove the chamber plug will allow chamber to drain Do not the engine is hot 5 Turn the fuel valve OFF and disconnect the fuel line from the fuel valve 6 Loosen the connecting and insulator band screws Rotate the carburetor Remove the float chamber plug 4 4 float chamber plug 2 WARNING Gasoline is highly flamm...

Page 112: ...nd screw 1 ttle sensor connector 2 e band 3 and clamp 4 ctor 5 Loosen the screws 5 and remove the carburetor top 6 5 screws 6 carburetor top 6 Pull up the throttle position sensor arm 7 then pull out the throttle valve 8 from the carburetor body 7 throttle position sensor arm 8 throttle valve 6 cont d 4 5 7 8 ...

Page 113: ...loat 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 carefully 17 float level gauge 19 carburetor intake 18 float level 13 To assemble reverse the disassembly procedures To install the carburetor reverse the removal procedures RNING flammable and n be burned or when handling fuel e and keep heat sparks y y outdoo...

Page 114: ...gine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 1 insulator 3 side electrode 2 center electrode Spark Plug Coloring Guidelines Remember that in addition to improper jetting A lean condition can be caused by air leaks in the inlet tract in the center crankcase joint and leaking ignition side crank seal A rich condition may be caused by a leaking...

Page 115: ... shorten the wheelbase to improve turning However we suggest you do not lengthen the wheelbase of your CR unless you are racing on a track with more fast sections than normal As a general recommendation keep the wheelbase as short as possible This positions the wheels closer together improves turning response increases weighting traction on the rear wheel and lightens weighting on the front wheel ...

Page 116: ...the front end light so it can float from the peak of one sand whoop to the next Generally with higher gearing it is easier to maintain that perfect attitude maximum rear wheel traction and a light front end because you remain in the powerband longer in each gear The higher gearing allows you to steer more efficiently with throttle control and body English If you are riding a track with sections wh...

Page 117: ...ons for specific latively short knobs that rder to obtain the largest on the surface The rubber softer for hard ground in not so soft that the knobs ect holding a straight line ar more quickly than of the combination of soft n pattern to avoid clogging he relatively long knobs from a harder rubber ny tendency to bend back wear quickly ar in construction to those nd mud but with a few ...

Page 118: ...th and riding preference Think this through carefully and cut off just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide fur...

Page 119: ......

Page 120: ...Tips 115 torcycle 116 117 nt 118 119 Tips 115 Tips ...

Page 121: ...ch to the upper ends ndlebar one on the right eft close to the fork n straps do not contact any rical wiring til the front suspension is way Too much pressure uld damage the fork seals strap to keep the rear of the ng ou do not transport your an damage the motorcycle ould be a hazard ...

Page 122: ...t air flow and isture to accumulate Removal from Storage 1 Uncover and clean your CR Change the transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the silencer and remove the rag from the silencer outlet 3 Fill the fuel tank with pre mixed fuel page 34 4 Pour a fresh recommended coolant mixture page 38 slowly into the radiator filler hole up to the f...

Page 123: ...drained fluids is harmful to ...

Page 124: ...tor Lack of fuel in tank P 35 Clogged fuel line P 35 Clogged fuel fill cap breather tube P 35 Clogged fuel valve P 35 Clogged fuel filter P 35 Not cleaned frequently enough P 40 Contaminants in the fuel Jet size wrong rejet in the opposite direction P 106 Faulty RC valve cables Faulty RC valve ERFORMANCE AT HIGH SPEED RRECT ESTRICTED L FLOW CLEANER DIRTY CLOGGED RRECT INCORRECT FUEL FLOW RESTRICTE...

Page 125: ......

Page 126: ...Technical Information 121 Technical Information 122 123 124 tor Adjustment 127 128 129 131 ent 132 133 ...

Page 127: ... is stamped on the left 2 ...

Page 128: ...US qt 0 70R Piston valve TMX11A 420 40 2 turns out 0 30 in 7 5 mm Wet multi plate type 5 speed constant mesh 3 000 1 800 1 470 1 210 1 000 0 869 Item Drive train Final reduction Gear shift pattern Electrical lgnition Starting system Spark plug Standard Spark plug gap English Metric 3 769 Left foot operated return system 1 N 2 3 4 5 CDI Kickstarter NGK BR9EG N 8 0 027 0 031 in 0 7 0 8 mm ...

Page 129: ...ylinder head nut 2 Cylinder mounting nut 3 Carburetor insulator bolt 4 Clutch cover bolt 5 Water pump cover bolt 6 RC cover bolt kgf m 2 8 4 0 1 2 1 2 1 2 0 5 N m 27 39 12 12 12 5 lbf ft 20 29 9 9 9 3 7 Torque Remarks ...

Page 130: ...r 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 13 14 15 16 17 18 19 20 21 Item NOTES 2 Apply oil to the threads and flange surface 3 Stake 4 U nut 5 UBS nut 6 SH bolt 11 0 2 2 2 0 2 2 4 5 2 0 13 1 2 8 5 5 5 5 4 5 4 5 9 0 3 5 3 1 5 4 5 4 5 4 4 5 3 9 1 0 3 5...

Page 131: ...lts Front brake reservoir cap screw Rear brake reservoir cap bolt Fork air plug Upper chain roller Lower chain roller 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Item NOTES 2 Apply oil to the threads and flange surface 3 Stake 4 U nut 5 UBS nut 6 SH bolt 3 1 1 6 1 6 3 7 0 4 0 4 1 2 3 1 3 1 7 0 2 2 1 3 0 7 3 3 2 8 0 1 0 1 0 1 1 2 1 2 22 12 12 27 2 7 2 7 9 22 22 51 16 10 5 2 24 20 0 7 0 7 ...

Page 132: ...Technical Information 127 High Altitude Carburetor Adjustment ...

Page 133: ...g service station or switch soline r performance problems of an oxygenated fuel he percentages of above are not covered can damage paint and to spill fuel when filling p any spills immediately damage paint and plastic ...

Page 134: ...ng portions of the course as the day progressed that may prove helpful in future events any places on the course where you chose the wrong line and were passed too easily notes on strategy used by your competition or by riders in another event that are worth remembering Maintenance Records Regular maintenance items you ll want to record in your logbook should include dates and results of cylinder ...

Page 135: ...ng Suspension Settings Gearing Chassis Adjustments Maintenance ...

Page 136: ...arts 280 0 lbf in 5 0 kgf mm White paint 302 4 lbf in 5 4 kgf mm Green paint 313 6 lbf in 5 6 kgf mm Pink paint 24 64 lbf in 0 44 kgf mm No mark factory products or 3 scribe marks aftermarket parts 23 52 lbf in 0 42 kgf mm 1 scribe mark 25 76 lbf in 0 46 kgf mm 2 scribe marks FRAME Shock spring Standard Optional Softer Stiffer Fork spring Standard Optional Softer Stiffer Remarks adjust shock sprin...

Page 137: ...da HP Coolant Pro Honda DOT 4 Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda brite Cleaner Honda Contact Cleaner Honda Dielectric Compound Pro Honda Handgrip Cement Pro Honda Hondalock Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Pro Honda White Lithium Grease Wheel Bearing Grease Silicone Sealer high temperatu...

Page 138: ...Technical Information 133 Wiring Diagram ...

Page 139: ......

Page 140: ...Consumer Information 135 136 137 138 ub USA only 139 Consumer Information ...

Page 141: ...de Daytime Telephone Number P A Y M E N T Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Master Card Account Number VISA VISA Discover Check here if your billing address is different from the shipping address shown above Expiration Date Mo Yr Customer Signature Date These Publications cannot be returned for credit without receiving advance authorization within 14...

Page 142: ...Contacting Honda Consumer Information 137 ...

Page 143: ...m you about competition ou ll also find that your nformation USA only the f America s pleased with the service ntinues to provide after the e quality and dependability ...

Page 144: ...Consumer Information 139 The Honda Rider s Club USA only ealer for more information on to ...

Page 145: ...nditions 112 Personal Fit Adjustments 113 TIPS 115 Transporting Your Motorcycle 116 Storing Your Honda 117 You the Environment 118 Troubleshooting 119 TECHNICAL INFORMATION 121 Vehicle Identification 122 Specifications 123 Torque Specifications 124 High Altitude Carburetor Adjustment 127 Oxygenated Fuels 128 Competition Logbook 129 Optional Parts List 131 Spare Parts Equipment 132 Wiring Diagram 1...

Page 146: ...rting 13 stop button 14 stopping 14 won t start 13 environment protecting 118 expansion chamber 75 filter air 40 flooded engine starting 13 fork front suspension adjustment 82 front suspension inspection 60 oil recommendation 62 front brake lever adjustment 65 front suspension maintenance 83 fuel line 35 filter 35 recommendation 34 refueling 35 system 34 oxygenated 128 tank capacity 35 valve 35 F ...

Page 147: ...7 important safety information 2 safety precautions 2 safety important information 2 important precautions 2 labels 4 maintenance 19 riding precautions 12 schedule maintenance 20 serial numbers 122 service customer 138 manuals 136 spare parts 132 spark knock 48 spark plug maintenance 48 reading 109 specifications 123 spring pre load rear suspension 95 starting engine 13 troubleshooting 119 steerin...

Page 148: ...Index 143 Index ...

Page 149: ...transmission oil fuel drive chain drive chain guide sliders guide rollers cables nuts bolts spark plug and cap throttle brakes clutch lever expansion chamber unleaded gasoline pump octane number of 91 or higher Premix Pro Honda HP2 2 stroke oil 32 1 Tank 2 0 US gal 7 7R Pro Honda HP Trans oil Pro Honda GN4 4 stroke oil or an equivalent Front 80 100 21 51M Rear 110 90 19 62M Type bias ply tube Fron...

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