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1. am X ip bL A Le f 2 fuel line 2 A 1 NN E i 178 i N a 1 E a i i m 4 T i k h Tua f A C zy mo 1 1 Y J 1 fuel valve Check the fuel valve 1 and fuel filter for contamination 2 Check for leaks 3 Check the fuel line 2 for cracks deterioration damage or leakage Replace the fuel line if necessary 4 Check for interference between the frame and tank and adjust if necessary Fuel 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 Fuel System 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 4 e 1 fuel valve 2 bolt 3 fuel filter 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 in the fuel tank Refill the fuel tank Attach the fuel line and turn the fuel valve to ON check for leaks Servicing Your Honda 35 Transmission Oil Refer to Safety Precautions on page 19 Using the proper oil and regularly check
2. 977 Carburetor Adjustments amp Tuning Tips 100 Chassis Adjustments eeeeeeeeeessss 107 SCILICET entre ner 108 Tire Selection for Track Conditions 109 Personal Fit Adjustments srerccacivverceivercenivasweverss 110 TRUS e M 111 Transporting Your Motorcycle 112 Storme Your Honda ise eootes toten qoaa hono tentus 113 You amp the Environment uoscieibeseo tides desse noc ena0d2 114 Troubles MO OUI sencese 115 TECHNICAL INFORMATION 117 Vebicle THe nori ANON oaseo pto teem eme np ridet eireos 118 SIS SUISSES RETO 119 Totdt e SDSCIHICODOTIS esscr 120 High Altitude Carburetor Adjustment 123 OO seated FIEIS setti so vo Eu bEItRo pues 124 Competition LOgDOOR 2 ores tatioss tabes aset oos 125 Optional Parts MiSs essocedvscasedcaxsdeccensdenienctsaves 127 spare Parts amp Equipment eu 128 Winne BIDEN m 129 CONSUMER INFORMATION 131 Authorized Manuals ssusssss 132 C ODtaegni Hondas ersi 133 Your Honda Deal sees ccaccotsecsenetaccesosenensu ae sases 134 The Honda Rider s Club USA only 135 TABLE OF CONTENTS eeeeeennne 136 DIN DE X dmm O 137 QUICK REFERENCE This section presents some of the most important information and recommendations to help you ride your CR safely Please take
3. 46 Servicing Your Honda 5 5 6 6 7 7 clutch lifter 8 clutch lifter rod Remove the clutch pressure plate 6 4 x wi a hn AN n gt E n c os a A C 4 A 2 LA a gt SS 3 i v x 7 Clutch Disc Inspection Replace the clutch discs 1 if they 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 clutch spring bolts clutch pressure plate Remove the clutch lifter 7 and clutch lifter rod 8 Remove the eight clutch discs and seven clutch plates 9 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 disc Clutch Spring Inspection 1 1 clutch spring Measure the free length of each spring Service Limit 1 39 in 35 2 mm 9 clutch discs and plates Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch plates have been burnt heat discolored Clutch System 6 Install the clutch pressure plate 5 11 Lubricate the rear brake pedal pivot 9 and Clutch Disc Plate Cover Installation 7 Install the five clutch springs and bolts 6 pivot bolt 10 with Honda Lithium Grease or 8 Tighten the bolts in a crisscross
4. 7 N m 0 7 kgf m 7 7 Over tightening the pinch bolts can deform the fork tubes Deformed fork tubes must be replaced v 14 12 5 upper pinch bolts 20 fork tube P3 T AK 6 fork cap 32 upper fork clamp vy Gs 17 lower pinch bolts A 38 Position the wear ring 33 with its end gap 12 fork protector bolts facing rearward 13 brake hose clamp bolts 14 fork protectors 33 wear ring Adjustments for Competition 89 Front Suspension Adjustments 40 Clean the surfaces where the front axle shaft 44 Align the brake caliper 16 and hose with 48 Install the handlebar 4 mounting rubbers and axle clamps contact each other the left fork leg making sure that the brake 34 washers and handlebar holder nuts 3 4 Install the left and right side collars into the hose is not twisted An improperly routed and tighten the handlebar holder nuts to the wheel hub brake hose may rupture and cause a loss of specified torque 42 Insert the front axle shaft through the wheel braking efficiency Route the hose carefully 32 Ibf ft 44 N m 4 5 kgf m hub from the right side Make sure the axle 45 Clean the threads of the caliper mounting shaft is seated firmly onto the left fork leg bolts 15 and brake caliper thoroughly clamp inner surface 46 Apply locking agent to the bolt threads 43 Tighten the axle nut 9 to the specified 47 Install the brake caliper on the fork slider torque and tighten the ca
5. 8 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 1 fuel valve 2 3 4 breather tube air cleaner case cover fuel tank band fuel tank bolt Remove the seat page 29 Remove the shroud A bolts collars 2 Remove the shroud B bolts collars 3 and shrouds 4 5 6 7 8 enu 1 fuel valve WS S N 9 fuel line P E S N Gs ex shroud A bolts collars S shroud B bolts collars 4 shrouds 30 Servicing Your Honda Installation 1 Install the fuel tank on the frame 2 Connect the fuel line 1 to the fuel valve 2 1 fuel line 2 fuel valve Install the fuel tank bolt 3 Hook the fuel tank band 4 Hook the air cleaner case cover 5 Put the breather tube 6 in the steering stem nut NN iU fuel tank bolt fuel tank band 3 4 5 air cleaner case cover 6 breather tube 7 Install the shrouds 7 and shroud B bolts collars 8 8 Install the shroud A bolts collars 9 a A DR 2 Pps Qu 7 shrouds 8 shroud B bolts collars 9 shroud A bolts collars 9 Install the seat page 29 Fuel Tank Removal Servicing Your Honda 3l Subframe Removal Refer to Safety Precautions on page 19 4 Loosen the screw 5 on the air clea
6. IGNITION COIL SPARK PLUG i 0030Z KSR 7100 Technical Information 129 130 Technical Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals cccssscesicccssstsscecsesicsdaresseteses 132 Contacune TONGA eccere 133 Your Honda Deall estesse 134 The Honda Rider s Club USA only 135 Consumer Information Consumer Information 131 Authorized Manuals The Service Manual used by your authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Publication Item No Description Price Each 61KSR03 2007 CR125R Service Manual 48 00 61CM002 Common Manual 48 00 31KSR630 2007 CR125R Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST OR By completing this form you can order the
7. If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page 68 there 1s probably air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system Front Brake Lever Adjustment 1 lock nut 2 adjuster 3 piston 1 Loosen the 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 the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay Less than 0 8 in 20 mm 6 Apply grease to the contacting faces of the adjuster and piston 3 Brakes 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 2 adjusting bolt 3 rear brake pedal raise the pedal height lower the pedal height Servicing Your Honda 65 Brakes Rear Brake Fluid Level Ch
8. Remove the screws 1 reservoir cap 2 and diaphragm 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 3 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m Adding Rear Brake Fluid The recommended brake fluid is Pro Honda DOT 4 brake fluid from a sealed container or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 4 bolts 5 reservoir cap 6 upper level mark 1 Remove the bolts 4 reservoir cap 5 and diaphragm 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 6 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the bolts to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m Other Inspection Brakes e Make sure there are no fluid leaks e Check for deterioration or cracks in the hoses and fittings Servicing Your Honda 67 Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear faster on wet and dirty tracks Inspect the pads at each regular maintenance interval page 21 Front Brake Pads Inspect the pads 1 through the front wheel 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 minimum thickness indicat
9. The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 30 positions or more Turning the adjuster one full turn advances the adjuster 8 positions e Rebound damping can be increased by turning the adjuster clockwise rr 3 rebound damping adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 20 24 clicks with the punch marks on the adjuster and the shock absorber aligned Adjustments for Competition 93 Rear Suspension Adjustments Rear Suspension Race Sag Setting the proper race sag ride height is very important for competition use Race sag refers to the amount of rear wheel travel used by your CR at rest ready to ride with you on the seat As a general rule of thumb the race sag dimension should be about one third of the maximum travel On your CR ride height is changed by adjusting the rear suspension spring pre load Spring Pre load amp Race Sag Adjustment The following adjustment procedure establishes the correct starting point for any suspension tuning the proper rear spring pre load adjustment for your specific needs Your CR should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustmen
10. comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also cause wheel damage on hard terrain Overinflated tires make your CR ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install a new cap Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your CR has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are Front Hear If you decide to adjust tire pressures for a particular riding condition make changes a little at a time 15 psi 100 kPa 1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm Inspection Take time to inspect your tires and wheels before you ride 1 tire tread depth nspect 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 depth at the center reaches 0 12 in 3 mm or any time you notice a red
11. coolant changes and related component replacements spark plug brake pad and control cable replacements In addition you should record any irregularities noted in component wear so you ll remember to keep a close eye on these areas in the future Technical Information 125 5 e e ct S LE e g g 3 Date Running Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use j 26 Technical Information These parts and tools may be ordered from your authorized Honda dealer Driven sprocket Higher gearing Standard Lower gearing CARBURETOR Main jet Standard 430 Handlebar lower holder Standard Optional Front wheel Standard 45 65 in increments of 5 Slow jet Standard 55 Jet Needles Standard needle 6DGY28 68 Straight diameter 92 68 mm Optional Jetneedle number Jet needle number 1 2 clip position richer than standard series at 1 8 to 3 4 throttle 6DGY28 65 6DGY29 65 2 65 mm 2 65 mm 6DGY28 66 6DGY29 66 2 66 mm 2 66 mm 6DGY28 67 6DGY29 67 2 67 mm 2 67 mm Jet needle number standard series TOOLS Pin spanner A P Workstand pA Richer Air gauge standard needle 6DGY28 68 6DGY29 68 2 68 mm 2 68 mm 6DGY28 69 6DGY29 69 2 69 mm 2 69 mm 6DGY28 70 6DGY29 70 2 70 mm 2 70 mm 6DGY28
12. 118 washing your motorcycle acest sanc vs aeree 78 QUSE IS iioc iossesc he E 69 wanne OL LOS EOHETIGso ce ieeap niuenta tutto etti aG eq aoc ae HESS 129 Index Index 139 Quick Reference The following is a brief but important collection of information you need to know about your Honda You ll also find space to record important notes How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly engine repairs are Transmission oil amp premix oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal Quick Reference Record important information here wooo pooo C SSCS Owner s Name a Maintenance Pre ride Inspection Fuel Capacity Transmission oil Tire Pressure cold Spark Plug 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 about 22 5 hours Check the items listed on the Pre Ride inspection checklist each time before you ride page 9 tires spokes amp rims leaks transmission oil fuel drive chain drive chain guide amp sliders amp guide rollers cables nuts amp bolts spark plug and cap throttle brakes clutch lever expa
13. 2 RC valves Inspect the RC valve valve shaft assembly for Valve Shaft Oil Seal Inspection Check the valve shaft oil seals 1 for wear or damage Replace the oil seals if necessary SS GNE UO n E 1 valve shaft oil seals Exhaust Valve Installation 1 Install the RC valves 1 into the slot on the cylinder 2 Position the RC valves fully open 3 Install the valve shaft assembly 2 with its position 4 Install the collar 3 1 RC valves 3 collar 2 valve shaft assembly 5 Make sure that the cut outs of the valve shaft 4 and collar 5 are aligned 4 cut out of the valve shaft b cut out of the collar 6 Install the washer 6 and nut 7 then tighten the nut to the specified torque 6 6 Ibf ft S N m 0 9 kgf m 7 Install the stopper plate 8 and tighten the socket bolt 9 to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 6 washer 8 stopper plate 7 nut 9 socket bolt 8 Install the cylinder page 52 RC Valve Servicing Your Honda 57 Reed Valve Refer to Safety Precautions on page 19 Reed Valve Removal 2 4 Remove the reed valve inner 4 from the reed 58 1 insulator 3 carburetor insulator reed valve valve assembly 5 reed valve inner reed valve assembly Servicing Your Honda Remove the carburetor page 104 Remove the insulator 1 and reed valve 2 from the cylinder by removing the six carburetor ins
14. 3 from the unloaded dimension step 2 Standard Race Sag 3 9 in 100 mm Adjust spring pre load as necessary to obtain the desired handling results Decreasing the race sag dimension example 3 5 in 90 mm improves turning ability for tight terrain at the 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 of its range 5 Measure the loaded without rider dimension Do this with your CR set at the standard race Sag LOADED MEASUREMENT on ground without rider EXAMPLE 23 0 in 583 mm Free Sag Calculation unloaded loaded without rider 23 0 in 583 mm 23 6 in 600 mm Free Sag 0 6 in 17 mm 6 Calculate the free sag dimension To do this subtract the loaded without rider dimension step 5 from the unloaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CR With the spring pre load set to obtain the proper race sag the rear suspension should sag 0 4 to 1 0 in 10 to 25 mm If the rear of your CR sags more than 1 0 in 25 mm from its own weight the spring is too stiff for
15. 3 kgf m cx SES 7 disc cover 8 bolts 57 Turn the rebound damping adjuster screws back to their original settings Adjustments for Competition 91 Rear Suspension Adjustments The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only Puncture or exposure to flame may also result in an explosion causing serious injury Service or disposal should only be done by your authorized Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the official Honda Service Manual If your CR is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the silencer page 32 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place an optional workstand under the engine to raise the rear wheel off the ground 2 Loosen the connecting tube clamp screw and remove the rea
16. Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Storing Your Honda 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 filler neck Capacity 1 06 US qt 1 00 2 at disassembly 0 98 US qt 0 93 at draining Lean your CR slightly right and left several times to bleed trapped air in the cooling system If the coolant level lowers add coolant and repeat the above procedure Install the radiator cap securely 5 Perform all maintenance checks page 9 Tips 113 You amp the Environment Owning and riding a motorcycle can be enjoyable but you must do your part to protect nature When you show respect for the land wildlife and other people you also help preserve the sport of off road riding Following are tips on how you can be an environmentally responsible motorcycle owner Choose Sensible Cleaners Use a biodegradable detergent when you wash your CR Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents
17. Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width 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 further adjustment to riding position and may better suit your particular body size or riding style Each of the ergonomic dimensions of the machine were determined to suit the greatest possible number of riders based on an average size rider Tips Here s helpful advice on how to transport and Transporting Your Motorcycle 112 store your Honda as well as two troubleshooting Storing Your Honda ssri 113 flow charts You amp the Environment eeose 114 TEOUDIESITOOLDDP coos ceaarcarscctcaceccestacsncersersenses 115 Tips 111 Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CR brace the front wheel against transport your Honda we recommend that you the front of the truck bed or trailer rail Attach follow these guidelines the lower ends of two straps to the ti
18. Sag 0 2 to 0 4 in 5 to 10 mm Symptoms and Adjustment e Always begin with the standard settings e Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 12 turn increments at a time Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment e f after setting the suspension feels unusual find the corresponding symptom in the table and test stiffer or softer compression and or rebound damping adjustments until the correct settings are obtained as described CMM 9mm a 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Stiff suspension Soft suspension Suspension bottoms Suspension feels stiff on small bumps Suspension feels stiff on large bumps Entire travel too stiff Entire travel too soft 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 If it still feels stiff replace the spring with a softer spring optional and begin with the standard settings to softer settings 1 Test stiffer high and low speed compression adjustments simultaneously 2 f it still feels soft re
19. a few moments to read these pages This section also includes information about the location of safety labels on your CR Important Safety Information Important Safety Precaution Accessories amp Modifications Safety Labels Motorcycle Safety Motorcycle Safety 1 Important Safety Information Important Safety Precautions Your CR can provide many years of pleasure if you take responsibility for your own safety and understand the challenges you can meet in competitive racing As an experienced rider you know there is much you can do to protect yourself when you ride The following are a few precautions we consider most important Never Carry a Passenger Your CR is designed for one operator only Carrying a passenger can cause an accident in which you and others can be hurt Wear Protective Gear Whether you re practicing to improve your skills or riding in competition always wear an approved helmet eye protection and proper protective gear Take Time to Get to Know 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 Learn and Respect Your Limits Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs illness and fatig
20. adjustment page 94 in the 3 5 3 9 in 90 100 mm range Fork Height Angle The position of the fork tubes in the clamps is not adjustable Standard Position The standard position 1 aligns the index groove 2 with the top of the upper clamp 3 3 1 X 1 standard position EN 0 3 in 7 mm 2 index groove 3 upper fork clamp 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 fork clamp 6 4 standard position for optional front wheel 0 in 0 mm 5 top of fork tube 6 top of upper fork clamp Chassis Adjustments Wheelbase Adjusting your CR s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to re check race sag and adjust if necessary In the past a general rule was lengthen the wheelbase to add straight line stability 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 With your CR
21. approved gasoline container Turn the fuel valve OFF and remove the carburetor drain plug Drain gasoline into an approved container Reinstall the drain plug A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 4 Remove the radiator cap and coolant drain bolt 1 at the water pump 2 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washer is in good condition and reinstall the oon bolt and radiator cap d S A Ip a dev 1 drain y 2 water pump 5 Lubricate the drive chain 6 Remove the spark plug and pour a tablespoon 0 51 0 68 US oz 15 20 cm of clean engine oil into the cylinder With the spark plug grounded or the engine stop button pressed in crank the engine several times to distribute the oil then reinstall the spark plug 7 Inflate the tires to 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 silencer to prevent moisture from entering 10 Store your CR in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 11 Cover your CR with a porous material
22. away see the following 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 that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and get instructions on how to dispose of nonrecyclable wastes 114 Tips Improper disposal of drained fluids is harmful to the environment The items that are serviceable using this Manual are followed by the page number reference in parenthesis The items that require use of the Honda Service Manual are followed by an asterisk POOR PERFORMANCE AT LOW AND IDLE SPEEDS CHECK POSSIBLE CAUSES 1 Check ignition INCORRECT e Improper ignition timing timing Faulty ICM e Faulty alternator CORRECT 2 Check carburetor INCORRECT e Fuel air mixture too air screw lean Turn the air adjustment screw in P 103 P 103 Fuel air mixture too rich Turn the air screw out P 103 CORRECT 3 Check if air is e Deteriorated reed i valve gasket e Loose insulator clamp leaking past manifold NOT LEAKING e Faulty insulator
23. caliper 14 fork protectors Front Suspension Adjustments 11 Loosen the fork leg lower pinch bolts 17 then pull the fork legs down and out E 17 lower pinch bolts 12 Clean the fork assembly especially the sliding surface of the slider pipe 18 and dust seal 19 The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper 18 slider pipe 19 dust seal 20 fork tube 21 guide bushing Adjustments for Competition 85 Front Suspension Adjustments 13 Record the rebound damping adjuster 17 Pour the recommended fork oil into the fork position and turn the adjuster screw 22 tube 20 until a little oil flows out of the top counterclockwise until it stops of the damper rod Leave the damper rod for 14 Hold the fork tube 20 then remove the about one minute fork cap 6 from the fork tube Gently 18 With the fork held upright measure the oil slide the fork tube down onto the lower end level 28 from the top of the fork tube to the of the slider pipe 23 fork oil Lg li 20 p 6 fork cap 22 adjuster screw 20 fork tube 23 slider pipe lower end 20 fork tube 28 oil level 15 Remove the fork cap 6 from the damper rod 24 by holding the lock nut 25 19 Adjust the oil level by adding or removing 16 Remove the spring sea
24. cleaner maintenance can cause poor performance and premature engine wear 40 Servicing Your Honda Cleaning 1 Remove the seat page 29 2 Loosen the air cleaner retaining bolt 1 3 Remove the air cleaner assembly 2 1 air cleaner retaining bolt 2 air cleaner assembly 4 Remove the air cleaner 3 from the air cleaner holder 4 1 air cleaner retaining bolt 3 air cleaner 4 air cleaner holder Wash the air cleaner in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner is made in two pieces inner and outer which can t be separated Clean the inside of the air cleaner housing 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 excess oil 8 Apply a thin coat of Pro Honda White Lithium Grease or an equivalent to the sealing surface 9 Assemble the air cleaner and holder Insert the pin 5 to the hole 6 and the air cleaner retaining bolt through the assembly 5 pin 6 hole 10 Insert the pin in the air cleaner housing hole 7 and install the assembly into the air cleaner housing 8 while aligning the tab 9 on the air cleaner and the reference mark 10 on the air cl
25. event to help ensure you get in a full day of riding In addition to the usual nuts and bolts consider the following Spare Parts spark plugs air cleaner clean amp oiled sealed in a plastic bag optional carburetor jets needles chain amp masterlinks chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs front amp side number plates handlebar grips levers brake amp clutch clutch lever handlebar mount clutch cable throttle assembly throttle cable shift lever brake pedal spokes front amp rear each side sprockets larger amp smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins 128 Technical Information Additional Spares front brake master cylinder rear brake assembly wheels amp tires front amp rear mounted clutch plates amp transmission oil seat ignition components top end complete radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end amp 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 tire pressure gauge tire irons tire pump or air tank feeler gauge s
26. gtm PE Engine f Cy nderheadnut 20 27 28 Cylinder mounting nut 20 27 2 8 2 3 Carburetor insulator bolt 7 10 1 0 RIGHT SIDE 4 Clutch cover bolt 7 10 10 Water pump cover bolt 12 1 2 Right RC cover bolt 9 12 1 2 6 7 Right RC cover E screw Dis 2lo2 EJ 9 Alternator cover bolt 7 10 10 Left RC cover bolt 9 12 12 120 Technical Information Frame Torque Specifications o tm rsen ii Ibit Nem kgfem FRAME NENNEN NNI T Steeringstem nut 80 108 110 eee mH P bolts 16 22 2 2 Cue as ae Loaf bolts 15 20 2 0 Handlebar upper holders 16 22 2 2 2 44 5 Handlebar lower holder nut 3 4 5 6 Frontaxlenut sf 65 88 90 7 Front axle pinch bolts 15 20 2 0 8 Rearaxlenut 94 128 13 1 NOTE 4 9 Chain adjuster lock nut 20 27 2 8 NOTE 5 10 Engine mounting bolts 40 54 55 V E Engine hanger plate bolts 2 1 1 b 34 3 5 luda OH te lower 32 44 45 NOTE4 13 Swingarm pivotnut 65 88 9 0 NOTE 4 1 0 1 14 Forkcap 1 2 30 31 5 ilii omm PERPE swingarm side 39 53 5 4 NOTE 2 4 shock link side 39 53 5 4 JNOTE2 A Ceres reel s m sa nore 2a Frame side 39 53 5 4 NOTE 2 4 17 Shock spring lock nut_ 21 29 30 18 Kickstarter arm bolt 28 38 39 gt eyinge
27. motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more 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 genuine air cleaner or an equivalent air cleaner specified for your model Using the wrong Honda air cleaner or a non Honda air cleaner which does not have equivalent quality may cause premature engine wear or performance problems Air Cleaner Housing Sealing Remove and reseal the air cleaner connecting boot where it connects to the air cleaner housing with silicone sealer if there is any doubt to its sealing integrity Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration Servicing Your Honda 23 General Competition Maintenance Spark Plug Cap Gaskets Fuel Filter Install a small plastic tie wrap around the spark plug cap to Always use new gaskets when reassembling components Periodically drain the fuel from the tank remove and clean reduce any possibility of it loosening or of water the fuel valve filter Repl
28. 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 i f J x 71 JU a p uu E o0 1 cylinder base gasket 2 dowel pin 4 Lubricate the piston and ring with 2 stroke oil Align the ring end gap with the piston ring pin 3 in the ring land and slip the cylinder 4 over the piston while compressing the piston ring Do not rotate the cylinder since this may cause the piston ring to snag a cylinder port and break 3 piston ring pin 4 cylinder Before tightening the cylinder nuts make sure that there 1s no clearance between the cylinder and crankcase mating surface 5 Install the four flange nuts 5 and tighten to the specified torque in a crisscross pattern in 2 Or 3 steps 20 Ibf ft 27 N m 2 8 kgf m Be careful not to overtighten the mounting nuts This is the most common cause for leaks here 5 flange nuts 6 Install the RC valve rod 6 setting collar 7 and B clip 8 7 Install a new gasket 9 onto the right RC valve cover 10 8 Install the grommet 11 onto the brim of the right crankcase cover C valve rod 6 9 gasket 7 setting collar 10 right RC valve cover 8 B clip 11 grommet 9 Install the right RC valve cover 10 tighten the bolts 12 and screw 13 to the specified torque Right RC valve cov
29. official Honda Service Manual for your CR is available page 132 It is the same manual your dealer uses If you plan to do any service on your CR beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CR best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding California Proposition 65 Warning WARNING This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely is an important responsibility To help you make informed decisions about safety this manual contains a section devoted to Motorcycle Safety as well as a number of Safety Messages throughout the manual Safety Messages are preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions A WARNING You CAN be KILLED or SERIOUSLY HURT if you don t
30. oil will cause excessive smoking and spark plug fouling Too little oil will cause engine damage or premature wear Vegetable oils separate from gasoline more easily than mineral oils especially in cold weather It is advisable to use mineral oil when ambient temperatures below 32 F 0 C are expected If the gasoline oil mixture is left standing in a container for a long period of time lubricity will deteriorate Use the mixture within 24 hours or the time period recommended by the oil manufacturer Once an oil container is opened the oil must be used within one month since oxidation may occur 32 1 FUEL OIL MIXING CHART Refueling Procedure Fuel Tank Capacity 2 0 US gal 7 7 i Tat 5 T 2 P cL 1 fuel fill cap 2 breather tube 3 steering stem nut 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube to the steering stem nut A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately Fuel Line
31. pressure LEOTE SUS DCMSIOM resno pen nE 82 gers ce consent E 70 American Honda contacting 133 apparel DIOIGCIUD seca ecerestee cosesenpatecaccusacostuaaites 2 COOLT serere EA 38 appearance CULO sears sosassetosteactasatatetoaiensacateseesees 78 authorized Thanudalsuceei i ph otro eth 132 BASIC ODE EU ON csr e Us UNPEE a a US CE ORIS 11 Dooe TN ecce a E E 7 between motos amp practice maintenance 26 brakes IBI TS Nr T 66 lever front ACIUSUMCIN icrbesccsssorsaseeassasatesanaetes 65 Pt CAE EN RO 68 pedal TOG srosarcancainccfeencicuataincrssidesssenletiasnes 65 Dreak in guidelines visccscsrvesscorcocsetesousersmsonstessoucss 15 canac e a E 35 carburetor Bia HSEITIO UU seessthaseaethedsonccationsantecustcoatvoiaucsents 101 circuit TONCUONS sssrinin re 100 COMIPOMCTES 2 2 52 50 0931 0 90 9 2 95 99 9 9 092996 100 disassembly assembly 104 high altitude adjustment 123 TONS SC a E E D TT 103 ATUOU TRIGO PEIE TEE E TE HE SSMO QEON 104 minor adjustments ossicere esas sccverransanexacseaencer 103 care AC Al ANC dacuesssseps esee Sortes esti iita 78 CA AMIE e EE Ip chassis adjustment for track conditions 96 CHOKE KNOU cccuuccoecitossssiso ster vett don caress ienteacserssen 13 eleen A 40 cleaning appearance Care escisrsnissriisiseiias 78 clutch system adjustment 252i 44 component locations maintenan TETT
32. replace if necessary clean lubricate replace AITO 5 em eo 5 5 e e Un e eo E eo 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 Each race Every 3 races Every 9 races or about or about or about 22 5 hours Ref page Throttle Operation O Air Cleaner co Spark Plug Q CO Radiator Coolant C2 co Cooling System Cylinder Head Decarbonizing c1 O Exhaust Valve Decarbonizing Piston and Piston Ring Piston Pin and Connecting Rod Small End Bearing 51 52 C1 co Reed Valve Only Transmission Oil N Drive Chain Drive Chain Sliders Drive Chain Rollers NININ C Drive Sprocket N Driven Sprocket Brake Fluid Brake Pad Wear Brake System O C1 gt C2 C1 C1 ARR A ARYA MINIO no Clutch System N O Control Cables N c1 Expansion Chamber Silencer Suspension 60 61 owingarm Shock Linkage 25 61 L NusBosFatmes 0 4 0 T T aa IWeesTes OOOO S 4 SS 9 SeemngHeaBeng E A IS 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 Servic
33. replace the piston pin and small end bearing i 1 small end bearing 2 piston pin 3 Place the shop towel back in the crankcase Cylinder Head Inspection Check the cylinder head 1 for warpage in diagonal directions with a straight edge 2 and a feeler gauge 3 Service Limit 0 002 in 0 05 mm 1 cylinder head B 3 feeler gauge 2 straight edge 52 Servicing Your Honda Piston Installation Clean the piston ring groove 2 Lubricate the piston ring and piston ring groove with clean 2 stroke oil 3 Install the piston ring on the piston with the marks facing up Locate the piston ring end gap on the pin in the ring groove 4 Lubricate the small end bearing and piston pin 1 with clean 2 stroke oil 5 Install the connecting rod small end bearing piston and piston pin 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 Never reuse old clips Take care so that the clips do not fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 1 piston pin 2 IN mark 3 hole 4 piston pin clip Cylinder Installation 1 Clean off any gasket material from the gasket surface of the crankcase being careful not to let any material fall into the crankcase Be careful
34. the oil level Optional Softer 0 42 kgf mm Fork Spring If it isn t used air may get into the fork GER If a syringe is not available first set the oil 3B ODE mAN level somewhat lower than the normal level then add small amounts of oil until the correct Standard oil 2 6 in level is obtained measuring the level each Maximum oil 1 3 in Slightly stiffer as level 33 mm it nears full compression Minimum oil 4 3 in Slightly softer as level 108 mm it nears full compression 30 O ring cont d Adjustments for Competition 87 Front Suspension Adjustments 24 Loosen the lock nut 25 slightly 25 Attach a two foot length of mechanic s wire 31 to the threaded portion on the lock nut Wrap the wire securely around the threads 26 Install the fork spring 27 as follows With the fork spring held upright on its marked end feed the mechanic s wire up through the spring Angle the fork spring and slowly slide it down into the fork using a gentle rocking motion 25 lock nut 31 mechanic s wire 27 fork spring 27 Pull the mechanic s wire 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 88 Adjustments for Competition 28 Place the spring seat 26 on the fork spring 27 with its flat side facing up 26 spring seat 27 fork spring 29 Screw the fork cap 6 on the da
35. you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits Adjustments for Competition 107 Gearing You can adjust the power delivery of the standard engine to suit track conditions by changing gearing This allows you to utilize a different portion of the engine s power range at a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion of your engine s power range you use can be adjusted by changing the final drive ratio with different sized rear sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There is a choice of both higher and lower final drive ratios with two optional aluminum driven sprockets For muddy or sandy courses there is a more durable steel driven sprocket with the standard number of teeth Like the optional springs these sprockets are listed in the Optional Parts List section of this manual Unless you have the required mechanical knowhow tools and an official Honda Service Manual sprocket changing should be done by your Honda dealer Higher Gearing less rear sprocket teeth increases top speed in each gear provided the engine will pull the higher gearing reduces frequency of shifting wider gear ratios reduces
36. your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will not extend as far as it should Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre load consider an aftermarket shock absorber spring A spring that is too soft for your weight forces you to 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 rebounds The rear end may top out from light braking or kick sideways over lips and square edged terrain It may even top out when you dismount your CR Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CR s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that 1s too firm for your weight will not allow the rear tire to h
37. 0 and clamp 11 11 Remove the cylinder 19 by removing the Cylinder Removal 6 Remove the left RC cover 12 and gasket four flange nuts 20 es i CROY aa A 1 Remove the expansion chamber page 75 2 Remove the bolts 1 exhaust pipe joint 2 1 and gasket is s lt 7 CON va 0 UE LE k ve 3 7 p MU P gt a n j 11 10 bolts 12 left RC cover 19 cylinder 20 flange nuts nau 11 clamp pols ie Satoh pe O10 12 Remove the gasket 21 and dowel pins 22 3 Remove the bolts 3 screw 4 right RC 7 Loosen the radiator hose clamp screw 13 m ow cover 5 gasket and grommet 6 and disconnect the radiator hose 14 A 4 Remove the B clip 7 and setting collar 8 8 Remove the radiator shrouds 15 on both then remove the valve rod 9 from the RC sides valve arm 9 Loosen the upper mounting bolts 16 on both sides 10 Remove the lower mounting bolts 17 then swing the radiator grills 18 forward on both Be careful not to drop the B clip and collar into aides the right crankcase Po p 3 VIE OR 21 gasket 22 dowel pins ka i 4 L h 4 a 3 7 B clip 13 screw 16 u pper mounting bolt M Lun e p d 14 radiator hose 17 lower mounting bolt am 9 valve ro 15 radiator shroud 18 radiator grill 50 Servicing Your Honda Piston Removal Place the s
38. 092207 118 DPC CR CAI ONS acs eter fusce ce ree dog usse sco pe RE 119 Torque Specifications ic issccccsasacecsrstercectincrerseesens 120 High Altitude Carburetor Adjustment 123 Oxyrenated FOCIS aoc isa seacees teserstececacctactswetweas 124 Competition Logbook 2 ott tonius totus 125 Optional Parts T8 ocio oehieiti hti eoi obit auper da 127 Spare Parts amp Equipielit z eese eint ott esios 128 Winne TOAST HE 179 CONSUMER INFORMATION 131 Authorized Manuals eee eta rever beet oso deo7os 132 Contacting TORO as sie cesascoripesccncssteceaseoatascusatenses 133 Xo r Honda Deletes 134 The Honda Rider s Club USA only 135 TABLE OF CONTENTS eee eene 136 INDEX cerco indes a E ee DEDr Eden dau esae naeh 137 QUICK REFERENCE AICCCR SO TICS EIEEE E EET E 3 adjustments altitude and temperature 102 CAREC F0 TT TOTO 100 CHOSBIS TEATE TE E E 107 COILEOLTEIGODION e iste feas adio q d 44 for competition csccsna cccacstaueanarstsdiedosioseaseas 81 DEGEHIO o ciecsiereet istoc DNE xen iode o qd ciaE 108 high altitude catb telOEs sese iro 123 PCS OMAN D E rien etos ue cota e EA 110 suspension front sssesseseeeeeer 82 Suspension TEAT vance casa n TEENS 92 suspension track conditions 96 DEC SO ECHO rer 109 after competition maintenance 22 Bir CNC ANCL E EA tenti ue visas iem mici T 40 air
39. 4 Try spark test WEAK OR e Faulty carbon or wet INTERMITTENT fouled spark plug P 48 SPARK e Faulty ignition control module GOOD SPARK e Faulty alternator e Faulty ignition coil e Broken or shorted spark plug wire 5 Check the throttle INCORRECT position sensor e Faulty throttle position sensor CORRECT 1 6 Check the RC e Excessive carbon valve system build up on the RC P 55 valve e Faulty RC valve POOR PERFORMANCE AT HIGH SPEED CHECK 1 Check ignition INCORRECT timing CORRECT 2 Disconnect fuel line at carburetor RESTRICTED and check for clogging P 35 UNRESTRICTED FUEL FLOW 3 Remove air cleaner P 40 Troubleshooting POSSIBLE CAUSES e Faulty alternator e Faulty ignition control module e Faulty ignition pulse generator e 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 DIRTY e Not cleaned frequently enough P 40 AIR CLEANER NOT DIRTY 4 Check carburetor CLOGGED e Contaminants in the jets for clogging fuel NOT CLOGGED 5 Install a larger CONDITION carburetor main WORSE jet P 103 CORRECT 6 Check the RC INCORRECT valve system P55 CORRECT e Jet size wrong rejet in the opposite direction P 103 e Faulty RC valve Tips 115 116 Tips Technical Information This section contains dimensions capac
40. 71 6DGY29 71 2 71 mm 2 71 mm at 1 16 to 1 8 throttle o c V ab General flow characteristics Drive chain links 51 Teeth Aluminum 116 52 Teeth Aluminum 116 53 Teeth Aluminum 116 3 mm offset 21 inch Fork height 0 3 in 7 0 mm align the index groove with the top of the upper clamp 20 inch e wheel assembly except brake disk e tire tube e tire flap e rim lock bead stopper e front tire 90 100 20 56M Fork height O in 0 mm align the top of the fork tube with the top of the upper clamp To adjust shock spring preload two spanners required For maintenance For checking tire air pressure Shock spring oofter Standard Stiffer Fork springs Softer Standard Optional Parts List 246 4 Ibf in 4 4 kgf mm 8 Green mark 257 6 Ibf in 4 6 kgf mm No mark factory products White mark aftermarket parts 268 8 Ibf in 4 8 kgf mm Blue mark 280 0 Ibf in 5 0 kgf mm 23 52 Ibf in 0 42 kgf mm CEQ N 1 scribe mark CO factory products 25 76 lbf in 0 46 kgf mm B ey ae 2 scribe marks The standard fork and shock springs mounted on the motorcycle when it leaves the factory are not marked Before replacing the springs be sure to mark them so they can be distinguished from other optional springs 127 Technical Information Spare Parts amp Equipment There are numerous spare parts you can take to an
41. 9 3 subframe 4 upper subframe mounting bolt 5 lower subframe mounting bolts 8 right side cover 9 bolt collar 9 Install the seat page 29 Servicing Your Honda 33 Fuel System Refer to Safety Precautions on page 19 Fuel Recommendation Pump Octane Number 91 or higher We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components Your engine is designed to use any gasoline that has a pump octane number of 91 or higher Gasoline pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page 124 Use of lower octane gasoline can cause persistent pinging or spark knock a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank 34 Servicing Your Honda Premix gasoline and oil in a ratio of 32 1 Prepare the 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
42. E TOT 28 PG VO ees E 6 competition NOS DONG sac cesasasrscaacemaretansesotesercen 125 consumer information uius acea ritmo tee pcvons 131 contacting Honda aoscesnioioss vene ioeenco iti seta oid Udegts 133 Controls ODOEPOEIIO secip 5 COOL eree N 38 CS Omier C0 VOE ees ote eo oEE OE E PESSDSE 134 cylinder By SECM cd ctoseorshetarsesiotiensacieretactametatetetin 49 LEE damping adjustments TEGAN MON T 83 TG AM NN E OT 96 dealer your TIONG coo ione itae denuo otra EPI OE 134 diagrami NVI cc5cecscseciescasaiecasenacecaiaeotatansass 130 CEDE CMAN ero Satan tex ue MALE PRE PEE edes 72 engine idee M M 13 NOUNS er d T H 103 DUTE DOE occ eee ep ecesote E nM ORAN NDS I VENE 118 DROI 25850051599 UOI PUN IEEURSSEOEE OI MUUE 48 SI VIEN Uo 13 SEO DOMOU uode ti deant dits este iiaeia 14 BIODBEIID e e E E AE 14 MOT 90 698 020 5 000000800007 13 environment protecting oaco esie toe orav ces 114 expansion CDaHIDEE s sacsscsahetcencsactuenineiccasncsovaneet 75 filter gm 40 flooded engine starting ouessscaiteseptasesesosesscse2ose 13 fork front suspension adjustment 82 front suspension INSPECTION cceceeeeeeees 60 oil qecommtie dato oso uci iaupa iroscos e rovc ap d ta 62 front brake lever ad ustmietit soe rauco 65 front suspension maintenance 82 fuel DE E E 35 lir E AE A 35 reco
43. IMPORTANT NOTICES FOR COMPETITION USE ONLY This motorcycle is designed and manufactured for closed course competition conducted under the auspices of a recognized body or by permit It does not conform to federal motor vehicle standards and operation on public streets roads or highways is illegal This vehicle is sold as is with no warranties FOR EXPERIENCED RIDERS NO PASSENGERS This motorcycle is designed as an operator only vehicle and for use by experienced riders only The load limit and seating configuration do not safely permit the carrying of a passenger This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold All information in this publication is based on the latest product information available at the time of approval for printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured on the front cover may not match your vehicle Honda Motor Co Ltd 2006 2007 Honda CR125R OWNER S MANUAL amp COMPETITION HANDBOOK Introduction Congratulations on choosing your Honda CR motocross motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your CR is a high performan
44. OOD Use of a new chain with worn sprockets will cause rapid chain wear 5 Measure a section of the drive chain to determine whether the chain is worn beyond its service limit Put the transmission in gear and then turn the rear wheel forward until the lower section of the chain is pulled taut With the chain held taut and any kinked joints straightened measure the distance between a span of 177 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service Replacement chain DID 520MA2 Service limit 10 20 in 259 0 mm han MEASURE A SPAN OF 17 PINS 16 PITCHES Lubricate the drive chain 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 Recheck chain slack and adjust as necessary More About Drive Chain e The master link is the most critical element of drive chain security Master links are reusable as long as they remain in excellent condition We recommend installing a new master link retaining clip when the drive chain is reassembled You may find it easier to install a new chai
45. RIDIN GG riscon Are Xou Ready tO Ride seccsesecteicntvevesciesivsctesvan Is Your Motorcycle Ready to Ride PRES TASC CD Oboe occasio Ct o roto udes BASIC OPERATING INSTRUCTIONS Sate Riding Precautions scccsctsssesestssisesaieeeeasanctese Starting amp Stopping the Engine Preparation sca casside sevi idesesdidesnionc i da PME Dt aC Procedure cersesc Flooded Il ah 12 0 cee eee eee 390220909005 0 009 How to Stop the B plttJe e arco Break in Guidelines 2222253022 22222 28 tetra bhados SERVICING YOUR HONDA Before You Service Your Honda The Importance of Maintenance Mantenance Sdleiy oo ieeap deserto ttt REDE eis Important Safety Precautions Maintenance Schedule isseeseestsesentdp esca o secas General Competition Maintenance Before amp After Competition Maintenance Between Motos amp Practice Maintenance After Competition Maintenance 136 Table of contents 8 ad Service Preparations Maintenance Component Locations 28 seat REMOVA oeda 29 Fuel Tank R foydl uci seee cesset etae Spe retta 30 Subframe Removal eesecisessoi bets orsor eo oeteo ede 32 Service Procedures Fluids amp Filters Poel Sy SUET ocdcspecatocecsscccetecicatvatitensevssasessecacems 34 Transmission Oil sci cscesnesarcsescaceseosadevcusyawaneseanics
46. Remove the alternator cover and keep it off for a few hours after each washing to let condensation evaporate Pull the flywheel rotor every few rides and clean it and its crankshaft mounting surface the alternator stator the ignition pulse generator pickup and the entire ignition cavity thoroughly The presence of dirt between the ignition pulse generator Engine Mounting Bolts Make sure the engine mounting bolts are tightened to the proper torque specification For added peace of mind and the flywheel makes the ignition control module remove the nuts clean the threads and apply Pro Honda compensate to maintain the ignition curve Cleaning dirt Hondalock or an equivalent prior to torquing the nuts from the ignition side main seal helps to prevent premature seal wear Close inspection of this seal can reveal a leakage problem before engine damage occurs 24 Servicing Your Honda Swingarm Pivot Lubrication Clean inspect and lubricate when servicing suspension linkage pivots Be sure all of the suspension pivot seals are in good condition Use Honda Moly 60 paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Suspension Linkage Lubrication Disassemble clean inspect and lubricate all pivot bearings after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear Use Honda Moly 60 paste U S A only or molybdenum disulfid
47. Sepa INDICES osos qu95 Hos ad LIOSU SD IESU E SP LEE NERO IUOS 118 service CUS CGT S doceo estses sa teeeenticcosasseense Manton 134 TRINA M 132 BAECS DOES E 128 spark ROC NNI E 48 spark plug LEES EIS TUI S NET TET IO 48 IOS oru DIS UISINI SUONI DM UR 106 BC CIC MOIS casattaccenarencossiscecusdeacesecssnscacumamesnivas 119 spring pre load rear suspension 92 starting GITE E eera O LETS USOS MUERE 13 trOUDIC SHOOT geneesi 115 steering stem inspection ccc eecececeeeeeeeeeeeeeeees 76 BOP MN ENE DE essene E 14 Or O e 113 SUO G ar E E O E 32 suspension inre r 60 Od ESETE AEE IEEE 09090004 00 1 SuSE 61 suspension adjustment R07 1 URP RET 82 O n E 92 for track conditions sczcosscncsssscesusaiantasastesageena 96 NCS E E E E AAA 97 Hans mission Oll eresse RET E 36 Wane TINS serrera 100 throttle iae A E y ERO SETET EE ES 42 NE E a NEN Om 43 tires OEIC SUS ea 70 ur e S 70 BE OC COB e seta edet e iestn e ipteE UM owencen 109 io A P 128 LONGUS sp eciHcafloNS cecststercaastvatsenereneteiennetonteen 120 Lans DOLLUDE arae EEE 112 ge ble ers 11010 Wb Lae eerenee mete nr renee ater oer ree 115 tubes replacino siessen aiiai ei 70 valve fuel 1ussuacesesseesemt er esen ced UE om RETO iieri 35 yale es QNEM RR RR 55 yvalye TOBU s cocoonseniesios Ee sImOcaPI DISAIS eM DNO USIS CEDE 58 vehicle identification no VIN
48. U nut 5 UBS nut 6 SH bolt 122 Technical Information High Altitude Carburetor Adjustment When operating this motorcycle at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased 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 your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may cause engine overheating and damage Technical Information 123 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by Volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing et
49. Wet Wet or sooty rich Rich 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 primary drive side seal that draws transmission oil into the fuel air mixture Excessive smoking will occur The same simple throttle opening identification system used in the Break In section of this manual can also be used to accurately identify where carburetion problems occur should they arise page 15 The following suggestions may improve a specific concern Subtle changes in overall handling may also be noted Rear End If you have a problem with rear wheel traction raise the rear end of your CR by increasing the rear spring pre load Instead of running 3 9 in 100 mm of sag you can run 3 5 in 90 mm so the rear of the bike will sit a little higher This should produce more traction because of the change to the swingarm and the location of your CR s center of gravity If you have a problem with the steering head shaking when you use the front brake hard or if your CR wants to turn too quickly lower the rear of the motorcycle by reducing the rear spring pre load This will increase fork rake and trail and should improve stability in a straight line The effective suspension travel will be transferred toward the firmer end of wheel travel Keep the race sag
50. ace the fuel valve O ring if there penetration are any signs of damage or deterioration page 35 Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 50 Fuel Contamination Periodically drain the float chamber and inspect the carburetor for contamination from dirt page 34 meme m Spark Plug Some non resistor plugs may cause ignition problems Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range Replace periodically as specified in the Maintenance Schedule page 21 48 Inlet Tract Sealing Air leaks around the carburetor insulator and reed valve assembly should be cured by disassembling cleaning and resealing with new gaskets and some sealing agent Be careful not to overtighten the mounting bolts this is the most common cause for leaks here Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Additional corrosion protection is offered by using Pro Honda Dielectric Grease on all electrical connections Pressure Vacuum Leak Down Test Perform this test at regular intervals to minimize the possibility of engine damage from air leaks Ignition
51. ain roller 7 and lower drive chain roller 8 for wear or damage Replace if necessary Upper roller 1 5 in 39 mm Lower roller 1 2 in 31 mm RNINA 3 d Ya 7 Q Ae XK Wii w N o 7 upper drive chain roller 8 lower drive chain roller If the upper drive chain roller was removed install the drive chain roller with its gt mark 9 side facing out Install the lower drive chain roller Upper and lower rollers 9 Ibf ft 12 N m 1 2 kgf m 7 upper drive chain roller 8 lower drive chain roller 9 gt mark 8 Check the driven sprocket nut torque values after each race 24 bf ft 82 N m 3 3 kgf m Adjustment 1 Loosen the rear axle nut 1 2 Loosen both the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decrease slack or clockwise to increase slack Align the index marks 4 of the axle plates 5 with the same reference marks 6 on both i 4 index mark 5 axle plate 6 reference marks 1 rear axle nut 2 lock nut 3 adjusting bolt 3 Tighten the rear axle nut to the specified torque 94 Ibf ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 Loosen the adjusting bolt counterclockwise lightly until it touches the axle plate Then while holding the adjusting bolt with a wrench tighten the lock nut to the specified torque 20 Ibf ft 27 N m 2 8 kgf m Drive Chain Lubrication Commercially prepare
52. 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 the carburetor for your specific racing conditions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition Refer to the list on page 127 for the optional carburetor parts To prevent engine damage always adjust the main jet before adjusting the jet needle If there is any doubt always choose the next richer jet so there is a margin for safety Carburetor Minor Adjustments The standard carburetor settings are ideal for the following conditions 32 to 1 premix ratio using Pro Honda HP2 2 stroke oil or its equivalent sea level altitude and 68 F 20 C air temperature If your conditions are different you may need to adjust the carburetor settings using the tuning information on page 101 and 102 Confirm your settings are correct before proceeding Minor Adjustments L PA Adjust the carburetor setting using the turning information on page 101 and 102 When the engine is warm enough to run without the choke push the choke knob down to its off position Loosen the lock nut 1 and turn the throttle stop screw 2 to obtain the smoothest idle To decrease idle s
53. all the new cylinder head gasket 2 with its UP mark 3 facing up and locating tab 4 facing rearward 1 dowel pins 3 UP mark 2 cylinder head gasket 4 tab 3 Install the cylinder head 5 and tighten the five cylinder head nuts 6 to the specified torque in a crisscross pattern in 2 or 3 steps 20 Ibf ft 27 N m 2 8 kgf m 5 cylinder head 6 cylinder head nuts Install the clamp 7 hanger plates 8 and tighten the nuts 9 to the specified torque 25 bf ft 34 N m 3 5 kgf m Connect the water hose 10 to the cylinder head Install the spark plug and spark plug cap 11 E 4 8 e AA K s A 7 clamp 10 water hose 8 hanger plates 11 spark plug cap 9 nuts 5 8 Pour the recommended coolant mixture into the radiator up to the correct level page 38 Install the following fuel tank and seat page 29 30 Start the engine and check for the following compression leaks abnormal engine noise secondary air leaks coolant leaks RC Valve Refer to Safety Precautions on page 19 Operating Inspection The exhaust valves open and close according to the engine speed to ensure sufficient torque throughout the entire engine rpm range The valves should be fully closed at low rpm and fully open at high rpm 1 Remove the B clip 1 and setting collar 2 then remove the tie rod 3 from the valve The exhaust valve system is a
54. an water to remove any residue 5 Dry your CR with a chamois or a soft towel 6 Lubricate the drive chain to prevent rusting 7 Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance Condensation Control Changes in temperature combined with humidity allow moisture to form in some confined areas on your CR The most affected area is the alternator ignition cavity in the left side of the crankcases Each time you wash your CR you should remove the alternator cover 1 wipe out any visible moisture and allow the cavity to air dry for at least a couple of hours before installing the cover Replace the gasket with a new one if it is not in good condition before installing the cover Some condensation can form within the transmission cavity as well This is natural and just one more reason you should change the transmission oil often 1 alternator cover After Cleaning Lubrication 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 an
55. asena cd 38 A WARNING Cooling system and hoses for condition 39 Spark plug for proper heat range carbon Improperly maintaining this motorcycle or fouling and high tension cord terminal for failing to correct a problem before riding NOOR Cle S r ue ORI REIN APER MM DUNS 48 can cause a crash in which you can be Air cleaner for condition and seriously hurt or killed COME AON cae perestema n deed cUm ed 40 e Clutch lever adjustment and freeplay 44 Always perform a pre ride inspection e Steering head bearings and related parts before every ride and correct any TOR OM COU ten Qood E LESER SEMI UE 76 problems e Carburetor throttle operation 42 Tires for damage or improper inflation cri P T A 70 e Spokes for JOOSelioS Suc ccu mnid vea s ouesos asas aeus 69 e Rim locks Tor looseness 69 e Front and rear suspension for proper oDer ese an OSE 60 6l e Front and rear brakes check operation 65 Drive chain for correct slack and adequate MV IMC AON escena Rr Rond eme PI en DE 72 Drive chain guide sliders and guide rollers for damage OF WAL ixsacsea cesis teca n aded 72 e Expansion chamber springs for damage or WACK OD fensi ON saarea 75 Every possible part for looseness such as cylinder head nuts carburetor insulator bolts engine mounting bolts axle nuts handlebar holder bolts fork triple clamp bolts drive chain adjuster drive chain guide wire harness connectors k
56. at range Using a spark plug with an improper heat range or incorrect reach can cause engine damage Using a non resistor spark plug may cause ignition problems 48 Servicing Your Honda 1 Measure spark plug gap 1 with a feeler gauge and adjust by carefully bending the side electrode 2 The recommended spark plug gap is 0 020 0 024 in 0 5 0 6 mm 2 Check the electrode for wear or deposits the gasket 3 for damage and the insulator for cracks 1 plug gap 3 sealing gasket 2 side electrode 3 To obtain accurate spark plug readings accelerate up to speed on a straightaway Push the engine stop button and disengage 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 and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere page 106 Check the fuel oil mixture carburetor and fuel system and ignition timing 5 Tighten the spark plug 4 e If the old plug is good 1 8 turn after is seats e f installing a new plug tighten it twice to prevent loosening a First tighten the plug NGK 3 4 turn after it seats DENSO 1 2 tu
57. button Normal Engine Stop 1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle grip 1 two or three 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 crankcase with fuel and result in hard starting Emergency Engine Stop To stop the engine in an emergency press the engine stop button 14 Basic Operating Instructions Break in Guidelines Help assure your CR s future reliability and performance 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 rapid acceleration This same procedure should be followed each time when piston is replaced e piston ring is replaced cylinder is replaced e crankshaft or crank bearings are replaced Basic Operating Instructions 15 16 Basic Operating Instructions Keeping your CR well maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CR in good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your CR loo
58. care to avoid spraying any oil near the brake pads or the brake discs Remove the drive chain clean and lubricate it page 73 Be sure the chain is wiped clean and is dry before lubricating the chain Take care to prevent catching your fingers between the chain and sprockets Before amp After Competition Maintenance 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 brush and some clean rags Take care to prevent catching your fingers between the chain and sprockets A variety of reasonably priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CR Avoid using stiff abrasive brushes on the plastic or rubber parts If your CR was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash your CR or use cleaners refer to Appearance Care page 78 Servicing Your Honda 27 Maintenance Component Locations front brake lever front brake fluid reservoir clutch lever A 0 EE y SE J j SII A pS 4 i A throttle grip Gj wy 7 Q O C aN N radiator cap fuel fill cap rear suspension spring pre load adjuster front suspension rebound damping adjuster front suspension reb
59. ce racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned closed course events by experienced riders only Be aware that motocross is a physically demanding sport that requires more than just a fine CR To do well you must be in excellent physical condition and be a skillful rider For the best results work diligently on your physical conditioning and practice frequently Before riding take time to get acquainted with your CR and how it works To protect your investment we urge you to take responsibility for keeping your CR well maintained Scheduled service is a must of course But it s just as important to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual You should also read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy 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 Introduction As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your CR other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in this manual The
60. ch 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 Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster Cable end adjuster 2 cable end adjuster increase freeplay decrease freeplay Turning the cable end adjuster 2 in direction will increase freeplay and turning it in direction will decrease freeplay If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn and make the adjustment with the integral cable adjuster Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained Integral cable adjuster increase freeplay decrease freeplay 3 lock nut 4 integral cable adjuster 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 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 Ma
61. d before your CR is ridden After break in test run your CR with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CR for 3 hours See page 85 for fork disassembly Replace the fork oil every 3 races or 7 5 hours of running See page 62 for oil level adjustment after changing the fork oil Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CR s front suspension Periodically check and clean all front suspension parts to assure top performance IN EE 4 Check the dust seals for dust dirt and foreign NUR grad materials Check the oil for any ze X contamination 1 fork protector 2 dust seal 3 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times 3 Inspect the wear rings 3 for wear or damage Replace the wear ring if it is 0 06 in 1 5 mm or flat with the outer tube 4 Install the wear ring with its end gap facing rearward 60 Servicing Your Honda Suspension 1 Bounce the rear of the motorcycle up and down Rear Suspension Inspection and check for smooth suspension action The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure The gas pressure in the reservoir is c
62. d 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 adjacent surfaces of the link plates and rollers Servicing Your Honda 73 Drive Chain Removal Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing 1 Remove the master link retaining clip 1 with pliers Do not bend or twist the clip Remove the master link 2 Remove the drive chain 2 master link 1 retaining clip 2 Clean the drive chain in high flash point solvent and allow it to dry Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceable Replacement chain DID 520DMA2 s 74 Servicing Your Honda REPLACE Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed 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 damaged or excessively worn Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE Normal Sprocket Teeth G
63. d is dry before applying the chain lube Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Appearance Care Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust 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 it could damage or discolor the frame surface Muffler stain remover Scotch Brite Hand Pad 7 447 maroon is for removing stains on the non coated aluminum frame only Servicing Your Honda 79 80 Servicing Your Honda This section tells you how to fine tune your CR for maximum competition performance Initial suspension adjustments should be performed after a minimum of two hours of easy break in time Optional front and rear suspension springs are available in both firmer and softer than standard rates in order to tailor your CR specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag setting section of Rear Suspension Adjustments to determine if your combined ride
64. d or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cable with a commercially available cable lubricant to prevent premature rust and corrosion Servicing Your Honda 43 Clutch System Refer to Safety Precautions on page 19 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns Clutch Lever Adjustment Cable end adjuster The distance between the tip of the clutch lever and the grip may be adjusted Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch 3 cable is disconnected 3 cable end adjuster increase freeplay decrease freeplay UA Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay 3 8 3 4 in 10 20 mm at the tip of lever Tighten the lock nut 1 lock nut 2 adjuster Integral cable adjuster 1 Loosen the lock nut 1 2 To position the clutch lever farther away from the handgrip turn the adjuster 2 counterclockwise To position the clutch lever closer to the handgrip turn the adjuster clockwise 5 3 Tighten the lock nut lock nut integral cable adjuster increase freeplay decrease freeplay 6 Adjust the cable end adjuster for minor adjustment 44 Servicing Your Honda Clutch Lever Freeplay 1 clut
65. dures described below to accurately adjust your CR using the methods described on pages 82 96 Remember to make all adjustments in one click increments Test ride after each adjustment Front Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below Sand track Adjust to a stiffer position Example Turn the compression damping adjuster to a stiffer position Install the optional stiff spring Adjust compression damping to a softer position and rebound damping to a harder position at this time Mud track Adjust to a stiffer position because mud build up increases your CR s weight Example Turn the compression damping adjuster to a stiffer setting Install the optional stiff spring Adjustments for Too Soft Stiff Damping Cp m a Soft Initial travel too soft Test stiffer compression damping adjustments in one click increments suspension e Steering is too quick Test stiffer rebound damping in one click increments e Front end darts while cornering or riding in a straight line Middle travel too soft If suspension isn t stiff in initial travel e Front end dives when cornering Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer com
66. e Selection for Track Conditions If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands on the transmission Complete consumer information can be obtained from the various tire manufacturer representatives and dealers Some general recommendations for specific terrain follow Hard Slick Soil Use tires with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface The rubber compound needs to be softer for hard ground in order to hook up but not so soft that the knobs roll over easily and affect holding a straight line These tires tend to wear more quickly than standard tires because of the combination of soft rubber and hard terrain Muddy Soil Use a more open tread pattern to avoid clogging For these conditions the relatively long knobs will probably be made from a harder rubber compound to reduce any tendency to bend back under acceleration or wear quickly Loose Sandy Soil Use a tire that is similar in construction to those needed for tacky soil and mud but with a few more knobs Adjustments for Competition 109 Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input Control Positioning P
67. e down Use a loading ramp hooks on your vehicle Attach to the upper ends e Make sure the fuel valve is off of the straps to the handlebar one on the right e Secure the motorcycle in an upright position side the other on the left close to the fork using motorcycle tie down straps Avoid using rope which can loosen and allow the Check that the tie down straps do not contact any motorcycle to fall over control cables or electrical wiring Y CLAN Tighten both straps until the front suspension is AS compressed about half way Too much pressure is unnecessary and could damage the fork seals Qe lua UR N Use another tie down strap to keep the rear of the SS b motorcycle from moving D We recommend that you do not transport your Uy CR on its side This can damage the motorcycle and leaking gasoline could be a hazard 112 _ Tips If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CR running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CR If your CR has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Replace the transmission oil page 37 3 Drain the fuel tank and carburetor into an
68. e paste containing more than 40 molybdenum disulfide additive Swingarm Do not attempt 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 Be aware that filing 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 General Competition Maintenance Brake Fluid Replacement Refer to Brake Pad Wear on page 68 Brake Caliper Inspection Be sure both the front and rear calipers are able to move freely on the caliper bracket pins Check pad thickness periodically and replace the pads when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Replace the hydraulic fluid in the brake system every two years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service life of brake fluid Water Pump Inspection Hole After every race check the inspection hole located just below the water pump c
69. eaner housing Tighten the retaining bolt securely Carefully position the sealing flange of the element to prevent dirt intrusion Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder 3 air cleaner 8 air cleaner housing 4 air cleaner holder 9 tab 5 pin 10 reference mark 7 air cleaner housing hole Air Cleaner 11 Reinstall the seat page 29 making sure it is securely attached Servicing Your Honda 41 Throttle Refer to Safety Precautions on page 19 Throttle Freeplay RIGHT SIDE 1 1 freeplay Inspection Check freeplay 1 Freeplay 1 8 3 16 in 3 5 mm If necessary adjust to the specified range 42 Servicing Your Honda Upper Adjustment Minor adjustments are generally made with the upper adjuster 2 dust cover increase 3 lock nut decrease 4 upper adjuster 1 Pull the rubber dust cover 2 back 2 Loosen the upper lock nut 3 on the throttle cable mechanism 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten the lock nut Return the dust cover to its normal position 5 After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions If the adjuster is threaded out near its l
70. ear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad wear 26 Servicing Your Honda e Suspend the front wheel above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at higher altitude remember that fork pressure of O at sea level will increase as elevation increases 2 pressure release screw Be sure the fuel and oil is mixed well by agitating it thoroughly before pouring pre mix into the fuel tank A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately After Competition Maintenance It is important to the long term performance of your CR to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rust inhibiting oil more heavily if the event was particularly wet or muddy Take
71. eck Fluid Level Inspection EE Front Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check 1 LOWER level mark the fluid level It should be above the LOWER level mark 2 If With the motorcycle in an upright position check the level is at or below the LOWER level mark the fluid level check the brake pads for wear page 68 It should be above the LOWER level mark 1 If Worn brake pads should be replaced If the pads the level is at or below the LOWER level mark are not worn have your brake system inspected check the brake pads for wear page 68 for leaks Worn brake pads should be replaced If the pads If the brake pedal freeplay exceeds 0 9 in are not worn have your brake system inspected 23 mm there is probably air in the brake for leaks system and it must be bled Refer to the Honda If the brake lever freeplay exceeds 0 8 in Service Manual or see your Honda dealer for 20 mm there is probably air in the brake brake bleeding system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding 66 Servicing Your Honda Adding Front Brake Fluid The recommended brake fluid is Pro Honda DOT 4 brake fluid from a sealed container or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 1 screws 2 reservoir cap 3 upper level mark 1
72. el 41 mm it nears full capacity 16 7 US oz compression 493 cm Minimum oil 4 6 in level 117 mm Slightly softer as it nears full capacity 14 1 US oz compression ate cm e Be sure to check the oil level Some oil will be left in the fork tube when the oil is drained and causes the oil level to be raised slightly e Be sure the oil level is the same in both fork legs e Always use the after market syringe while adjusting the oil level If it isn t used air may get into the fork e Ifa syringe is not available first set the oil level somewhat lower than the normal then add small amounts of oil until the correct level is obtained measuring the level each time oil is added 64 Servicing Your Honda 13 Remove the lock nut and spring guide together Install the partition plate 5 5 partition plate 14 Install the spring guide 3 as shown Loosely install the lock nut 2 AN JAN 2 lock nut 3 spring guide 15 Install the fork spring spring seat and fork cap as described in Front Suspension Oil Level Adjustment page 84 91 Refer to Safety Precautions on page 19 Both the front and rear brakes are the hydraulic disc type As the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop Frequently inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear
73. engine rpm at a given throttle setting or ground speed which may allow better rear wheel traction on slippery or loose terrain 108 Adjustments for Competition However the engine may not pull the higher gearing the spacing between gears may be too wide engine rpm may be too low Lower Gearing more rear sprocket teeth decrease top speed in each gear increases frequency of shifting narrower gear ratios increases engine rpm at a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However e spacing between gears may be too narrow engine rpm may be too high Some tracks may be watered heavily prior to the first race then lightly or not at all during the day This results in a track surface that is slippery during the first few races 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 e Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use the standard sprocket Hard but not slippery track conditions use lower gearing more teeth to keep the engine rpm high where the engine produces the most
74. epairs It has the latest available service information from Honda The parts department offers Genuine Honda parts Pro Honda products Hondaline accessories USA only and Honda accessories 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 the parts department 134 Consumer Information Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider s Club of America Your purchase of a new motorcycle scooter ATV or PWC from a participating U S Honda dealer entitles you to a complimentary one year membership in the Club There are hundreds of HRCA Chapter sponsoring dealers across the USA with events and activities almost every weekend Membership benefits include e 24 hour toll free roadside assistance for your new Honda includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow For street legal motorcycles and scooters only An exciusi
75. er bolt 9 Ibf ft 12 N m 1 2 kgf m Right RC valve cover screw 1 5 Ibf ft 2 N m 0 2 kgf m 2 in TAL E 10 right RC valve cover 3 12 bolts 13 screw Cylinder System 10 Return the radiator grills 14 to the original positions on both sides 11 Tighten the radiator mounting bolts 15 then install the radiator shrouds 16 on both sides 12 Connect the radiator hose 17 and tighten hose clamp screw 18 Live eS Lite mu 14 radiator grill 17 radiator hose 15 radiator mounting bolts 18 screw 16 radiator shroud 13 Install a new gasket 19 onto the left RC valve cover 20 14 Install the left RC valve cover and clamp 21 tighten the bolts 22 to the specified torque 9 Ibf ft 12 N m 1 2 kgf m on x NN J al Tal a d a T f i i j j F F 21 clamp 22 bolts 19 gasket 20 left RC valve cover cont d Servicing Your Honda 53 Cylinder System 15 Install a new gasket 23 as shown 16 Install the exhaust pipe joint 24 with the flat facing 25 down 17 Install and tighten the bolts 26 to the specified torque 6 6 Ibf ft 8 N m 0 9 kgf m 18 Install the expansion chamber and springs page 75 2 c 23 gasket 25 flat face 24 exhaust pipe joint 26 bolts 54 Servicing Your Honda Cylinder Head Installation 1 Clean the cylinder head mating surface and install the dowel pins 1 2 Inst
76. et Vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CR purchased from your Honda dealer spoke wrench 6 6 mm 070MA KZ30100 spoke wrench 5 8 x 6 1 mm 07701 0020300 lock nut wrench 46 mm 070MF KSRO0100 Chemical Products Pro Honda HP Trans Oil or Pro Honda GN4 or HP4 without molybdenum additives only Pro Honda HP Fork Oil 5W Pro Honda HP2 2 stroke Oil Pro Honda HP Coolant Honda thread Lock Honda Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda brite Cleaner Honda Contact Cleaner Honda Dielectric Compound Pro Honda Hand Grip Cement Pro Honda Hondalock Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 4096 molybdenum disulfide additive Pro Honda White Lithium Grease Wheel Bearing Grease Silicone Sealer high temperature grease Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape ENGINE STOP BUTTON 3 TP SENSOR BI W BI iL d Bu G Y Bu Y R sa BI s oo TCU e eo wa Q co c Q OS j a gt 3P WPC Bl dM ose piiri BLACK Brees BROWN one YELLOW O ORANGE Burasi BLUE Less LIGHT BLUE api GREEN Lg LIGHT GREEN IGNITION idees EB pos PINK mE PULSE Wr WHITE Gress GRAY GENERATOR ALTERNATOR Wiring Diagram G BI Y _ kt Y W P
77. follow instructions A CAUTION You CAN be HURT if you don t follow instructions Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgement Safety Messages Contents MOTORCYCLE SAFETY eee eee 1 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications 3 DAE LADE 8o tidodidecusceli cas pe sti ia 4 OPERATING CONTROLS ssseooooscocsssssssssss 5 Operation Component Locations 6 BEFORE RIDUINQG aniticscsseeecuiseescivsseesesasessassse 7 Ate xou Ready to Ride sce cottcctanetisrccstsboseeasacnnaaes 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection eeeseseeesss 9 BASIC OPERATING INSTRUCTIONS 11 Sate Riding Precau Ons escerai 17 Starting amp Stopping the Engine 13 Prepar ON e 13 py aC Procedure scasecsteavscconcccccocsceneesatenesi 13 Flooded Fe ce sarescensqeesctxanseeivangeentcedenatoon 13 How to Stop the Engine 14 ical WIIG UNG S23 edocs ven aaszscaodeavenpeeseveceasesen 15 SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance S41 CLY T o 19 Imp
78. for dirt in the dust seals Check the fork oil for any contamination e Front end wanders while riding at full throttle in a straight line If the front end dives while cornering reduce the rebound damping in one click increments If that doesn t solve the problem install the optional stiff spring If the stiff spring makes the suspension too 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 Middle travel too stiff If initial travel isn t stiff e Stiff on bumps when cornering Test stiffer compression damping adjustments in one click increments This e Front end wanders when cornering should produce smooth fork action from initial to middle travel e Stiff suspension on bumps especially downhill bumps If initial and middle travel is stiff e While braking front end dives during initial travel then feels stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff If initial and middle travel aren t stiff e Doesn t bottom on landings but feels stiff Test stiffer compression damping adjustments in one click increments This e Stiff on large bumps especially downhill bumps should produce smooth fork action from initial to middle travel e Stiff on large bumps when cornering If final travel is still stiff after
79. g Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CR An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft operators do but without the benefit of an electrical hourmeter All running time is broken down into hours and tenths of an hour each six minutes represents one tenth of an hour Competition Logbook Racing Records Information worth recording for this section of your logbook may include Your placing in each moto and overall finishing position e Thoughts on what you could do to improve your performance next time Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future events e 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 piston and ring examinations Patterns for frequency of need for decarbonization with a particular oil When you last performed shock linkage and swingarm pivot bearing maintenance transmission fork and suspension oil changes chain sprocket chain guide and slider replacements
80. g or removing Fork Oil Level rod 6 until a little oil flows out of the top the oil with an after market syringe 10 of the rod Pump the piston rod slowly 8 Standard 0 44 kgf mm Fork Spring 10 times through a stroke of 10 in 25 cm Gently slide the fork tube 7 down onto the lower end of the slider pipe 8 Wait about 5 minutes 4 NO mark factory products Standard oil level capacity Maximum oil 1 5 in Slightly stiffer as level 3 mm it nears full capacity 16 9 US oz compression 499 cm l Minimum oil 4 4 in Slightly softer as 10 syringe level 113 mm it nears full capacity 14 2 US oz compression 420 cm Optional Softer 0 42 kgf mm Fork Spring 6 damper rod 8 lower end of the slider SED 1 scribe mark 7 fork tube pipe aiii 11 With the fork tube held upright measure the Standard oil 2 6 in oil level 9 from the top of the tube level 67 mm capacity 15 8 US oz 466 cm Maximum oil 1 3 in Slightly stiffer as level 33 mm it nears full capacity 17 1 US oz compression 605 cm Minimum oil Slightly softer as level it nears full capacity compression 9 oil level cont d Servicing Your Honda 63 Suspension Optional Stiffer 0 46 kgf mm Fork Spring a 2 scribe marks Standard oil 3 0 in level 75mm capacity 15 5 US oz per cm Maximum oil 1 6 in Slightly stiffer as lev
81. hanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 596 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system 124 Technical Information If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated the fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately Oxygenated fuels can damage paint and plastic Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events The best way to organize the many bits of information is to record them in a logbook Your logbook can include such information as suspension adjustments carburetor adjustments gearing and tire selection This detailed information along with your comments ca
82. hift pattern system 1 N 2 3 4 5 Wheelbase 1 470 mm Bore and stroke 2 13 x 2 14 in 154 0 x 54 5 mm Seat height 954 mm Displacement 7 62 cu in 124 8 cm Ignition CDI Foot peg height 439 mm Compression ratio 5s Starting system Kickstarter 352 mm Transmission oil P erem Capacity After draining 0 60 US qt Type After disassembly 0 69 US qt Telescopic fork ESI F suspension travel 10 8 in 275 mm Carburetor Optiona stroke 12 0 in 305 mm Type Piston valve Pro link Identification number TMX05A eee R suspension l in i travel 12 6 in 820 mm Main jet standard 430 Spark plug gap 0 020 0 024 in F tire size pressure 80 100 21 51M Slow jet standard 55 0 5 0 6 mm psi kPa kgf cm 15 100 1 0 Air screw opening 1 3 4 turns out R tire size pressure 100 90 19 57M psi kPa kgf cm 15 100 1 0 Float height 0 30 in 5 mm Tire type em yp Ply Clutch type Wet multi plate type ingle di k F brake swept area le ncn Transmission 5 speed constant mesh Single disc brake Primary reduction 3 150 R brake swept area 60 6 in 391 1 cm Gear ratio 2 308 Gear ratio II 1 867 Fuel capacity 2 0 US gal CU REF Gear ratio III 1 529 Caster angle 25 45 Gear ratio IV 1 294 Trail length 100 mm Gear ratio V 1 130 tee len Level Std 28in 71mm Technical Information 119 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts fasteners before every outing Tott Nm
83. hop towel in the crankcase 2 Remove the piston pin clip 1 using a pair of needle nose pliers Press the piston pin 2 out of the piston 3 and remove the piston 3 Remove the connecting rod small end bearing 4 Under racing conditions the piston and ring should be replaced after 7 5 hours of running Replace the piston pin and connecting rod small end bearing after 22 5 hours of running 1 piston pin clip 2 piston pin 3 piston end bearing 5b piston ring 4 Spread each piston ring 5 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 4 connecting rod small Cylinder Head Cylinder Decarbonizing 1 Remove the carbon deposits from the cylinder head 1 and piston dome Take care to avoid scratching the cylinder head piston dome or the head gasket surface 1 cylinder head 2 Clean carbon deposits from the exhaust port 2 area 2 exhaust port Cylinder System 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 Cylinder System Connecting Rod Inspection 1 Temporarily remove the shop towel 2 Install the small end bearing 1 and piston pin 2 in the connecting rod small end and check for excessive play while holding the connecting rod If it feels loose
84. ich than a little lean It is advisable to record the settings course conditions lap times and climatic and barometric conditions for future reference 104 Adjustments for Competition Carburetor Disassembly Assembly 1 Remove the fuel tank Page 30 2 Remove the subframe Page 32 3 Loosen the insulator band screw 1 1 insulator band screw 4 Disconnect the throttle sensor connector 2 and remove the wire band 3 and clamp 4 F y Fj F r i f 4 i E j T m j aE i 1 r A Ej E n A 5 p 2 throttle sensor connector 3 wire band 4 clamp 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 10 collar 11 cable holder Remove the throttle cable 9 and collar 10 from the cable holder 11 Remove the collar and throttle valve spring 12 from the throttle cable Remove the throttle cable holder and jet needle 13 from the throttle valve 14 p 9 throttle cable 12 throttle valve spring 13 jet needle 14 throttle valve Carburetor Adjustments amp Tuning Tips 10 Remove the carburetor to the left side Be careful not to damage the area around the throttle sensor Do not assemble or move the carburetor while holding the throttle sen
85. ickstarter mounting bolt 120 Before Riding 9 10 Before Riding Basic Operating Instructions This section gives basic information on how to Sale Riding Precautions cccccccccssasscessssssseeees 12 start and stop your engine as well as break in Starting amp Stopping the Engine 13 guidelines Pie al ese E 13 Der ae FOC COIS oon SL erns 13 Flooded Engine occ ntocssaesccsdahasiatadersececabeoosen 13 How to Stop the Engine eee 14 Bicakom Guidelines ss ssoroscseecesstiecccostececesssacawenees 15 Basic Operating Instructions 11 Safe Riding Precautions Before riding your CR for the first time please review the mportant 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 contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 12 Basic Operating Instructions Always follow the proper starting procedure described below Your CR can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter Preparation Make sure that the transmission is in neutral Turn the fuel valve ON Starting Procedure Check the transmission oil and coolant levels before starting the engine page 37 38 A 1 fuel valve 2 ch
86. imit or the 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 Adjustment The lower adjuster is used for major freeplay adjustment 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 o V a 5 di N Nw W E LA IKA jo z Q r WEOCO S 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 nut 4 Reinstall the rubber cap securely after adjustment 5 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range contact your Honda dealer Throttle Throttle Inspection 1 throttle grip 1 Check that the throttle assembly is positioned properly and the securing bolts are tight 2 Check for smooth rotation of the throttle grip 1 from fully open to fully closed in all 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 kinke
87. in your riding area is within the indicated range 30 20 10 0 10 20 30 40 50 C ee ee ee ee ee MEEN 20 0 20 40 60 80 100 120 F JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification 1 oil filler cap l 2 Checking amp Adding Oil 2 oil check bolt Run the engine for three minutes then shut it off Wait three minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission Support the CR in an upright position on a level surface Remove the oil filler cap 1 and oil check bolt 2 from the right crankcase cover A small amount of oil should flow out of the check bolt hole Allow any excess oil to flow out of the check bolt hole If no oil flows out of the check bolt 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 4 After inspecting the oil level or adding oil tighten the oil check bolt and filler cap securely and oil check bolt to the specified tor
88. ing adding and changing oil will help extend the service life of the transmission and clutch Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the transmission 36 Servicing Your Honda Oil Recommendation Type transmission oil or 4 stroke engine oil API classification SG or higher except oils 4 stroke engine oil labeled as energy only conserving on the circular API service label Viscosity SAE 10W 30 weight JASO T903 standard 4 stroke engine oil only others without friction modifiers as molybdenum additives Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke engine oil or an equivalent suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label e Your CR does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum 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 lubrication and clutch performance NOT RECOMMENDED OK Other viscosities shown in the following chart may be used when the average temperature
89. ing Your Honda 2 General Competition Maintenance Perform maintenance on firm level ground using the optional workstand or equivalent support When tightening bolts nuts or screws start with the larger diameter or inner fasteners and tighten them to the specified torque using a crisscross pattern Use genuine Honda parts or their equivalent 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 Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre ride Inspection Items Refer to Pre ride Inspection page 9 22 Servicing Your Honda Handgrips Always use Pro Honda Handgrip Cement or equivalent when replacing handgrips Throttle Grip Align the index mark on the throttle grip with the edge of the throttle cable guide Left Handlebar Grip Align the A mark on the left handlebar grip with the paint mark on the handlebar Refer to the Service Manual for installation instructions For added security you may choose to bind the handgrips to the handlebar and throttle pipe with safety wire to prevent the possibility of them loosening Position the twisted wire e
90. irbox modifications or the use of an aftermarket exhaust system may require jetting changes Carburetor Components Starting Circuit A very rich mixture must be delivered to the cylinder when the engine is being started When the choke knob 1 is pulled up fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 to provide a rich mixture for starting The mixture discharges through the orifice 4 into the cylinder 1 i 4 i 1 choke knob 2 starter jet 3 air passage 4 orifice 100 Adjustments for Competition Slow Circuit Fuel is metered by the slow jet 5 and is mixed with air that has been metered by the air screw 6 The mixture enters the venturi through the bypass 7 and slow jet outlet 8 5 slow jet 6 air screw 7 bypass 8 slow 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 The baffle plate 13 prevents foaming of fuel or abnormal fuel level around the main jet Float Chamber The float 14 and float valve 15 operate to maintain a constant level of fuel in the float chamber 9 main jet 13 baffle plate 10 jet needle 14 float 11 needle jet 15 float valve 12 air jet Carburetor Circuit Functions The carburetor has several major circuits each pro
91. ities and other technical data Vehicle Identification s 2ecescnsccussccncesdedeecedaonedenst 118 SPEC ALONG e 119 Torge 5 pecIHC OPI OTIS sieiscrssiriisienepssaieasi 120 High Altitude Carburetor Adjustment 123 Oxvoenated PUCIS ecrire 124 Competition Lo5sbDOIE ose tore poti R EV oRES 125 Op onal Parts LAG ios casereca percusedsaestcnteceesseseeasa 127 Spare Parts amp EQUI pment cess fccetscssseaacevecceneverns 128 NV TAO AI esas EO TS 129 Technical Information 117 Vehicle Identification Serial Numbers The VIN and engine serial numbers are required when you register your CR They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head and also appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 118 Technical Information RIGHT SIDE The engine number 2 is stamped on the left crankcase LEFT SIDE fin eee 2 engine number Specifications Item English Item English Item English Dmosin Eme Overall length 2 163 mm Type Liquid cooled 2 stroke Final reduction 4 000 Overall width 821 mm Cylinder arrangement Single 18 5 inclined from Left foot operated return Overall height 1 282 mm vertical Gear s
92. juster 4 positions Always start with the full hard position when adjusting damping A 1 compression damping adjuster To adjust to the standard position 1 Remove the rubber plug 2 Turn the compression damping adjuster 1 clockwise until it will no longer turn lightly seats This is the full hard position 3 Turn the adjuster counterclockwise 6 clicks This is the standard position 4 Make sure that both fork legs are adjusted to the same position Rebound Damping Rebound damping effects how quickly the fork rebounds The rebound damping adjuster has 18 positions or more Turning the adjuster screw one full turn clockwise advances the adjuster 4 positions Always start with the full hard position when adjusting damping 2 rebound damping adjuster To adjust to the standard position 1 Turn the rebound damping adjuster 2 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 15 clicks This is the standard position 3 Make sure both fork legs are adjusted to the same position Front Suspension Adjustments Fork Springs The fork springs in CR s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping co
93. ke sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your CR should move smoothly and accelerate gradually If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the official Honda Service Manual page 132 Clutch System Other Inspections amp 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 corrosion Clutch Operation 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage Servicing Your Honda 45 Clutch System Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 37 2 Remove the rear brake pedal 1 by removing its pivot bolt 2 A fe ru 2 pivot bolt fy E 1 rear brake pedal 3 Remove the five clutch cover bolts 3 and clutch cover 4 3 clutch cover bolts 4 clutch cover 4 Remove the five clutch spring bolts 5 and clutch springs Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps
94. king good An ICM Ignition Control Module system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to the Honda Service Manual page 132 An optional tool kit may be available Check with your Honda dealer s parts depertment Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety NE 19 Important Safety Precautions 19 Maintenance chedule 2 5 2 2 5 9 2 9 22 222 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 21 Service Preparations Maintenance Component Locations 28 Seal REMOVA lereier e reDaD riter er dia n a 29 Fuel Tank Removal iue certae etre etn tes 30 SUDBHOHIe Removal ae csacconccsscccecsttessecstesecncscescesaane 32 Service Procedures Fluids amp Filters Duel 9 SEC IME uo215059215592150009225 000090005 200900 0 5006055 34 Transmission C canada seco evesceesaensccevensantvenceee 36 rere I RR 38 Alr C IO erecto coire ten veto Ei idea DO NIE PUOI UE 40 Engine TAr 1 een ene ree eee eee neem 2 6 ener Meteo DE 42 CINCH Sy SUC 0 an 44 SPa PPO saaccecconseeceodstoncenebecenetecescattorekicotudseeenicd 48 VICE Syste Messner 49 ARCU A 55 Recd Valy cecccrirer e
95. liper bolts to the specified 65 Ibf ft 88 N m 9 0 kgf m torque n 22 bf ft 80 N m 3 1 kgf m Fit the brake caliper over the disc taking care not to damage the brake pads 3 washers handlebar holder nuts 4 handlebar 34 mounting rubbers 49 Install the number plate 2 by aligning its hole 35 with the tab 36 on the steering stem 15 brake caliper mounting bolts 16 brake caliper 2 number plate 35 hole 90 Adjustments for Competition 50 Install and tighten the number plate bolt 1 51 Install the handlebar pad 37 b ay EN y j 1 number plate bolt 37 handlebar pad 52 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 53 Tighten the left axle pinch bolts 38 alternately first While keeping the forks parallel alternately tighten the right axle pinch bolts 39 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m Et 38 left fork pinch bolts To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 39 right fork pinch bolts Front Suspension Adjustments 54 Clean the threads of the bolts and axle holder thoroughly 55 Apply locking agent to the bolt threads 56 Install the disc cover 7 and tighten the bolts 8 to the specified torque 10 Ibf ft 13 N m 1
96. materials desired You can pay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form Canada See your Honda dealer to order authorized manuals Publication D Q Price Total Item No tem Description ly Each Price Sub Total Purchaser s Sales Tax Mich Add 6 Calif Add 8 25 Prices are Subject to change without notice and without incurring obligation Handlin Orders are mailed within 10 days Please allow Charge adequate time for delivery Grand Total 132 Consumer Information 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 Customer Name Attention Street Address No P O Box Number Apt f City CS tate Zip Code Daytime Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing Master e Hi address is different from the Card VISA Discover shipping address shown above Account Number FL ET IEEE TLE PET ET Expiration Date Mo Yr o o5 Customer Signature These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the origi
97. mmendation s2cscsccsrisctrscssaticniaerdceasctacneds 34 ROC HUNG eae M 35 V Ei 34 OR dbi apie TE 124 tance apad uocis iie ab i9aeoeec e aodes stop nei 35 VIS 35 Index 137 Index gap SPAK PIUS secassscccostescisarsecisoataciecatatareensdenen 48 en srera E E 124 POSOITHO ponere aE E OEE 34 POOBITID e A E E 108 guidelines suspension adjustment 97 handlebar inspection ssssiiissiisisssiscisiisisesiissssisis 76 high altitude carburetor adjustment 123 Honda COTILOGLITI Seco stereo ror Os es ra UR ien R 133 ESTES uir Iro 135 Service Minal cessare sen odsiS dU 132 SOU MOT ssrin innan ii 134 identification vehicle iscicvscnsiswsarOaderiearninraeneacs 118 idle speed CHO Ille sesacrisr nonni ireira enne 103 inspection SDICETRIO sscsiiniissiidrisesoisnsriiiscsinsessai 9 Tabels Sd I cccsecsssevsssacctcatecrrarsasntceotsteraatenasts 4 locations component UICE TRES ECOL RIETI TTE 28 OPEIN O occ estoe appo EE NP EEIEIDIR LUE DSGR OE EAE eR NEA 6 logbook COIHDE ION 2 1 ss22c0stcncesaisccucassoucesaenin 125 138 Index maintenance additional LOC 6 CULES cccretacstecceeusanseceransaceecacs 76 after competition scctccanceodiacsncctiesatssssnanecsseeeans 26 before amp after competition 26 between motos amp practice sss 26 component locations oiosseosneerdeitcob cu tod 28 general competition oiii iesses te cis
98. movement in the steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer 76 Servicing Your Honda Handlebar Inspection Remove the handlebar pad Check the handlebar 1 for bends or cracks Check that the handlebar has not moved from its proper position by inspecting the punch mark Tighten the front bolt first WN Re Un P 16 Ibs ft 22 N m 2 2 kgf m 1 handlebar 2 handlebar upper holder bolts Check the torque of the upper holder bolts 2 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 Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Torque ENGINE 1 Oyindermeadnut 20 27 28 2 Cylinder mounting nut 20 27 2 8 3 Carburetor insulator bolt 7 10 1 0 4 Clutch cover bolt 7 10 10 5 Water pump cover bolt 12 1 2 6 Right RC cover bolt 9 12 12 7 Right RC cover screw 1 5 2 0 2 8 Alternator cover bolt 7 10 10 9 Left RC cover bolt 9 12 42 Additional Main
99. mper rod 30 Hold the lock nut 25 and tighten the fork cap to the specified torque 21 Ibf ft 28 N m 2 9 kgf m 6 fork cap 25 lock nut 30 O ring 3 Temporarily thread the fork cap into the fork tube 32 Insert both fork legs into the fork clamps 33 34 35 36 25 Align the groove in the fork tube 20 with the top surface of the upper fork clamps 32 If installing the optional 20 inch wheel align the top of the fork tube not the top of the fork cap with the top surface of the upper fork clamp Temporarily tighten the fork lower pinch bolts 17 and then tighten the fork cap 6 to the specified torque 22 lbf ft 30 N m 3 1 kgf m For ease of releasing air pressure after the forks are installed loosen the lower pinch bolts and position the fork outer tubes so that the pressure release screws are in front of the rebound damping adjusters Tighten the fork lower pinch bolts to the specified torque 15 Ibf ft 20 N m 2 0 kgf m Tighten the fork upper pinch bolts 5 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m Tighten the bolts alternately in 2 or 3 steps Front Suspension Adjustments 39 Clean the threads of the fork protector bolts 12 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protectors 14 fork protector bolts and brake hose clamp bolts 13 Tighten the fork protector bolts to the specified torque 5 2 Ibf ft
100. ms amp Spokes 1 wheel rim 2 spoke 3 spoke nipple 4 rim lock nut 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spoke nipples 3 and rim lock nuts 4 to the specified torque Front spoke nipple 2 7 lbf ft 3 68 N m 0 4 kgf m Rear spoke nipple 2 7 bf ft 3 7 N m 0 4 kgf m Rim lock nuts 9 Ibf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see the Honda Service Manual for inspection instructions Wheels Axles amp Wheel Bearings See the Honda Service Manual for inspection information Check the axle for runout 2 Check the condition of the wheel bearings Servicing Your Honda 69 Tires amp Tubes Refer to Safety Precautions on page 19 To safely operate your CR the tires must be the proper type off road and size in good condition with adequate tread and correctly inflated A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement 70 Servicing Your Honda Air Pressure Properly inflated tires provide the best combination of handling tread life and riding
101. n by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets Expansion Chamber Refer to Safety Precautions on page 19 Expansion Chamber Removal Expansion Chamber Installation Expansion Chamber Inspection 1 Remove the expansion chamber by removing Install the expansion chamber in the reverse order the expansion chamber springs 1 and of removal Check the expansion chamber springs and mounting bolts 2 replace them if they are damaged or stretched 2 Remove carbon deposits from the head pipe e Tighten the front and rear mounting bolts to 2 Check the flange bolts for tightness of the expansion chamber the specified torque 3 Check the expansion chamber for cracks or Front 9 Ibf ft 12 N m 1 2 kgf m deformation Rear 7 lbf ft 10 N m 1 0 kgf m A damaged chamber may decrease engine performance 1 springs 2 bolts Servicing Your Honda 75 Additional Maintenance Procedures Refer to Safety Precautions on page 19 Steering Head Bearing Inspection 1 With your CR on a box or optional workstand front wheel elevated turn the handlebar to the right and left to check for roughness in the steering head bearings 2 Stand in front of your CR grab the fork at the axle look at the steering head and push the fork in and out toward the engine to check for play in the steering head bearings If any roughness or play is felt but you do not see any
102. n prove valuable when you compete at the same track or on similar terrain Your logbook can also tell you when maintenance was performed and when it will be necessary again Your logbook also lets you record any repairs and lets you keep track of the running time on the engine and suspension components If you choose to sell your CR the accurate maintenance records in your logbook might be the deciding deal maker for a potential buyer Consider using different color pens or pencils to record important information on specific subjects For example record results in black jetting changes in red suspension chassis settings in blue and gearing selections in green Color codes will help you identify the information you want with a glance Tuning amp Adjustment Records Keep track of the settings and adjustments that worked best at a particular location These items include basic track conditions altitude and temperature carburetion changes e suspension settings chassis adjustments tested and selected gearing e tire selection air pressure Competition Records your placings e thoughts to improve performance next time both yours and your CR s e strategy notes Maintenance Records regular interval maintenance repairs e running time on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of runnin
103. nal order HELM P O BOX 07280 DETROIT MI 48207 Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your Honda dealer If he doesn t have the answer right away he will get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the 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 Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the following information in your letter name address and telephone number e product model year and VIN date of purchase e dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 133 Your Honda Dealer Once you purchase your new Honda get familiar with the organization of your Honda dealer so you can utilize the full range of services available The service department is there to perform regular maintenance and unexpected r
104. nds away from your palms and be sure to bend the wire ends well into the handgrip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the throttle pipe and handlebar thoroughly and apply a light coating of silicone lubricant Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way Move the handlebar from lock to lock to be sure there is no cable interference Check to be sure the top of the carburetor is screwed on tight Make certain the throttle operation is perfect after servicing and inspecting General Competition Maintenance Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent changes will also assure consistent performance of both shifting and clutch action page 36 Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between
105. ner Installation connecting tube clamp 6 1 Loosely attach the upper and lower ends of Removal the subframe to the mainframe while connecting the air cleaner connecting tube to the carburetor Tighten the screw 1 on the connecting tube clamp 2 z NI T 1 Remove the seat page 29 2 Remove the right side cover 1 by removing the bolt collar 2 N 5 screw 6 connecting tube clamp nu En 5 Remove the lower subframe mounting bolts 1 right side cover 7 and upper subframe mounting bolt 8 2 bolt collar 6 Remove the subframe 9 by pulling it straight 1 screw backward 2 connecting tube clamp 3 Remove the bolt washer 3 and silencer 4 7 lower subframe mounting bolts S bolt washer 8 upper subframe mounting bolt 4 silencer 9 subframe 32 Servicing Your Honda Subframe Removal 3 Align the subframe 3 with the rear wheel 6 Connect the silencer 6 to the expansion and install the upper subframe mounting bolt chamber with the sealing rubber 4 and lower subframe mounting bolts 5 7 Install and tighten the bolt washer 7 4 Tighten the upper subframe mounting bolt to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 5 Tighten the lower subframe mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m u p gt S LM Y 6 silencer 7 bolt washer 8 Install the right side cover 8 and bolt collar
106. nsion 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 7 2 Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or an equivalent Front 80 100 21 51M Rear 100 90 19 57M Type bias ply tube Front 15 psi 100 kPa 1 0kgf cm Rear 15 psi 100 kPa 1 0kgf cm Standard BR9EG NGK or W27ESR V DENSO Optional BR9EV NGK or W27ESR ZU DENSO Drive Chain DID 520DMA2
107. nt solution Water that is high in mineral content or salt may be harmful to the aluminum engine Using coolant with silicate inhibitors may cause premature wear of radiator pump seals or blockage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and water in this motorcycle This coolant solution is recommended for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection 38 Servicing Your Honda 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 provide additional protection against freezing Check the cooling system frequently during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 19 1 With the engine cold remove the radiator cap 1 and check coolant level The coolant level 1s correct when it is at the bottom of the radiator filler neck dmm me ak x e t Ltd p a fud sd 1 radiator cap A 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 removing the radiator cap 2 Add coolant up to the filler neck 1f the level is low Ins
108. ntrol near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn and lower the oil level in increments of 5 cm 0 2 oz in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil level Minimum oil level Standard Spring 4 45 in 113 mm Softer Spring 4 25 in 108 mm Stiffer Spring 4 61 in 117 mm When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork Fork Travel Characteristics 2500 2000 Oil level 1 46 in 37 mm MAX 1500 Oil level 2 80 in 71 mm STANDARD LL 1000 Oil level 4 45 in 113 mm MIN 500 CENT 0 Litt titty t tt tt et tt oD JO XX X JO 26 5 Cy 6 1 oov DPpcqded Stroke in mm Adjustments for Competition 83 Front Suspension Adjustments Front Suspension Oil Level Adjustment f 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 this service 1 Place your CR on the optional workstand or equivalent support with the front wheel off
109. oke knob Cold Engine Starting Turn the fuel valve 1 ON 2 Shift the transmission into neutral 3 Pull the choke knob 2 up 4 With throttle closed operate the kickstarter Starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion 5 After the engine starts the choke 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 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 Warm Engine Starting Turn the fuel valve ON 2 Shift the transmission into neutral 3 Push the choke knob down 4 Open the throttle 1 8 1 4 and operate the kickstarter Starting amp Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine 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 several times with the kickstarter 4 Release the engine stop button 5 Follow the Warm Engine Starting procedure Basic Operating Instructions 13 Starting amp Stopping the Engine How to Stop the Engine A l i TE a 1 throttle grip 2 engine stop
110. only It does not conform to Federal Motor Vehicle Safety Standards or U S EPA Noise and Emissions Standards i D gt NEVER OPEN WHEN HOT Operation on public streets roads highways or Hot coolant will burn you for off road recreation is illegal gt NE JANAIS OUVRIR A CHAUD Le liquide risque de vous br ler State and Federal laws prohibit operation of this PMU S vehicle except in an organized racing or competitive event on a closed course Or by permit issued by the local governmental agency having jurisdiction 4 Motorcycle Safety Operating Controls Read this section carefully before you ride It Operation Component Locations 6 presents the location of the basic controls on your CR Operating Controls 5 Operation Component Locations clutch lever front brake lever engine stop button throttle grip choke knob kickstarter PAY PRT ao K yo Te ze CONS Nu gor o T SMS Si RA ES S W vy WI y a zv S o2 4 fuel valve shift lever rear brake pedal 6 Operating Controls Before each ride you need to make sure you and your CR are both ready to ride To help get you prepared this 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 Are You Ready to Ride ssccsecicsistoskeassessucesidessesates 8 I
111. ontained within a rubber bladder The shock absorber s spring preload and damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions page 96 Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only 2 Remove the subframe page 32 3 Check for a broken or collapsed spring e When your CR is new break it in for 4 Check the shock for a bent shaft or oil leaks approximately one hour with the standard suspension settings before attempting to adjust the rear suspension Make all compression and rebound damping adjustments in the specified increment or turns described in pages 93 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 adjust it by turning all the compression and rebound adjusters according to the procedures described in page 93 After adjusting the adjusters simultaneously suspension may be 1 rear shock absorber fine tuned by turning one of the compression and rebound damping adjusters in one click 5 Push the rear wheel sideways to check for increments worn or loose swingarm bearings There f you have a problem finding an acceptable should be no movement If there is have the adjustment return to the
112. ook up under acceleration and will pass more bumps on to you Rear Suspension Adjustments Adjustments for Competition 95 Suspension Adjustments for Track Conditions Soft Surface On soft ground sand and especially mud consider increasing compression damping front and rear Sand often requires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover 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 event stiffer aftermarket springs 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 suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and rebound If you run softer rebound damping the wheel will follow the rough ground and small bumps much better and you will hook up better With a lot of rebound damping the wheel returns very slowly and doesn t contact the ground quickly enough after each bump The result is a loss of traction and slower lap times 96 Adjustments for Competition Suspension Adjustment Guidelines Follow the proce
113. or p i i i OM T n LU E 7 f L n 4 4 ff x E i J b LU e M i y X Th AT i ie i i h bs en ie 1 j i i pe d P E Lad replace 1 brake pads 2 front brake caliper 3 brake disc 68 Servicing Your Honda Rear Brake Pads Inspect 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 minimum thickness indicator 0 04 in 1 mm 4 replace 4 brake pads 5 rear brake caliper 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 Refer to Safety Precautions on page 19 Maintenance of spoke tension and wheel trueness roundness is critical to safe motorcycle operation During the first 100 miles 150 km spokes will loosen more rapidly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule page 21 However information for wheel removal is provided for emergency situations Wheel Ri
114. ortant Safety Precautions 19 Maintenance Schedule sseuuuss 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 Service Preparations Maintenance Component Locations 28 Seat Removal ee er ee ee 29 Fuel Tank Rernoyalu serccrcesseesceveeceuevansecsnvestestvens 30 S birame ROO Uus o ccacececostasccecsececestcreseasateuses 32 Contents Service Procedures Fluid amp Filters Pue oso Oe E 34 Transmission Oil eccer eenen 36 RAIN aia E 38 A C OAE era E E EE 40 Engine T e a E 42 CHTS COMO ner terre ante er tre 44 SPa PIE oE 48 C UBnder Syste eien rU rid 49 DAR AUN HPT Y 55 RESAN y M 58 Chassis DUSDOPDSIONL 2 0 022501 912 93 20 E 60 pic e T A ES 65 WY GGUS A Een stseee T TTS 69 TS Se DUO SL ses credits e eE e Siue PERDU 70 Dive Pii P Expansion C Dar DOE asesoo ceti qa direi iu ede i 75 Additional Maintenance Procedures 76 Appearance Care eseeesssessseseecresssssssssecceessssss 78 ADJUSTMENTS FOR COMPETITION 81 Front Suspension Adjustments 82 Rear Suspension Adjustments 02 Suspension Adjustments for Track Conditions 96 Suspension Adjustment Guidelines
115. osition the control levers so that you can use them comfortably when seated and standing Adjust the mounting bolt torque of the clutch and brake lever assemblies so that they can rotate on the handlebar in a fall If an assembly does not rotate it may bend or break a control lever Make sure that the bolts are torqued securely enough to prevent slippage during normal operation Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first 1 control lever mounting bolts As an alternative consider wrapping the handlebar area under the control assemblies with teflon tape Then tighten the assemblies to their normal torque Upon impact the fully tightened assemblies should rotate on the Teflon tape 110 Adjustments for Competition Position the shift lever and brake pedal so they are close to your boot for rapid access but not so close that either is depressed when sitting or standing comfortably on your CR Handlebar Position Width amp 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 and turning Tighten the forward bolts first The handlebar position may be moved forward either 3 mm using optional handlebar lower holders or 6 mm by rotating the standard holders 180 degrees Refer to the Service
116. ound damping AT rear suspension high speed compression damping adjuster AGUSE e rear suspension low speed compression damping adjuster TEE rear brake fluid reservoir front brake caliper drive chain ge ae C i transmission transmission oil front suspention oil filler cap check bolt compression damping transmission oil drain bolt carburetor rear suspension rebound rear brake pedal front suspension compression adjuster damping adjuster damping adjuster 28 Servicing Your Honda Refer to Safety Precautions on page 19 Removal Remove the seat bolts 1 and collars 2 2 Slide the seat 3 back 1 seat bolts 2 collars Installation 1 Slide the seat front prong 4 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 torque 20 Ibf ft 27 N m 2 8 kgf m seat front prong seat bracket seat rear prong tabs Seat Removal Servicing Your Honda 29 Fuel Tank Removal Refer to Safety Precautions on page 19 5 Pull the breather tube 5 out of steering stem 9 Disconnect the fuel line 9 from the fuel nut valve 1 Removal 6 Unhook the air cleaner case cover 6 10 Remove the fuel tank Turn the fuel valve 1 OFF 7 Unhook and remove the fuel tank band 7 8 Remove the fuel tank bolt
117. over on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged water seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced r l l l l l l l l l l l l l l l l l l l l l l l l l 2 Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Use Urea based multi purpose grease with extreme pressure example Kyodo Yushi EXCELITE EP2 Shell stamina EP2 or equivalent Fork Oil Performance Disassemble clean and inspect the front fork and replace oil regularly Contamination due 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 frame should not be overlooked as part of your overall competition maintenance program Periodically inspect the frame closely for possible cracking or other damage It makes good racing sense Spokes Check spoke tension frequently between the first few
118. pattern in 2 an equivalent and install the pivot bolt 1 Coat the clutch plates 1 and discs 2 with or 3 steps to the specified torque Tighten the bolt to the specified torque transmission oil 7 bf ft 10 N m 1 0 kgf m 27 lbf ft 36 N m 3 7 kgf m Aa 7 l Connect the brake pedal return spring 11 if it was removed 2 Install the eight clutch discs and seven clutch plates alternately starting with a clutch disc 5 clutch pressure plate 6 clutch spring bolts 9 Install a new O ring 7 in the groove of the 1 clutch plates 2 clutch discs clutch cover 8 9 brake pedal pivot 11 return spring 10 Install the cover by tightening the five cover 10 pivot bolt 3 Apply grease to the clutch lifter rod 3 bolts to the specified torque EE 4 nsert the clutch lifter rod into the mainshaft 7 bf ft 10 N m 1 0 kgf m 12 Add the transmission oil page 37 5 nstall the clutch lifter 4 onto the rod rw t 4 qU ia GET EE S n bo n A rt d Q 0 Vi prr A Ye V h Y A t clutch cover 3 clutch lifter rod 4 clutch lifter Servicing Your Honda 47 Spark Plug Refer to Safety Precautions on page 19 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions BR9EG NGK or W27ESR V DENSO BR9EV NGK or W27ESR ZU DENSO Optional Use only the recommended type of spark plugs in the recommended he
119. pect the coolant level before each outing A coolant loss of 0 7 2 0 US oz 20 60 cm through the over flow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 06 US qt 1 00 at disassembly 0 98 US qt 0 93 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 Cooling System Inspection Check the cooling system for leaks see the Honda Service Manual for troubleshooting of leaks Check water hoses 1 for cracks deterioration and clamp bands for looseness Check the radiator mount for looseness Make sure the overflow tube 2 is connected and not clogged Check the radiator fins for clogging Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the water pump seal is damaged If oil leaks through the check hole the transmission oil seal is damaged See the Honda Service Manual or consult 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 2 overflow tube 3 water leakage check hole 4 water pump cover Coolant Coolant Replacement Refer to Safety Precautions on page 19 Coolant should be replaced by your Honda deale
120. peed turn the screw counterclockwise To increase idle speed turn the screw clockwise Tighten the lock nut while holding the throttle stop screw to the specified torque 1 5 Ibf ft 2 N m 0 2 kgf m Adjust the air screw 3 to obtain the best off idle performance If the engine blubbers rich exiting a corner turn the air screw counterclockwise to lean the mixture If the engine surges lean exiting a corner turn the air screw clockwise to richen the mixture 2 throttle stop screw Carburetor Adjustments amp Tuning Tips increase decrease 3 air screw The minimum to maximum range of air screw adjustments is 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 turn out the next larger slow jet is needed Adjustment Procedure l PA Warm up the engine Make 2 3 laps of a course with the standard setting or corrected jetting page 101 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening Verify carburetion by removing the spark plug and reading its firing end page 48 102 It may take more than 2 3 laps to get a good spark plug reading with a new spark plug Change carburetor settings or select suitable carburetor jets taking into consideration the engine conditions and factors for temperature and altitude page 102 If yo
121. place the spring with a stiffer spring optional and begin with the standard settings to stiffer setting Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously 1 Test stiffer high speed compression adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary 1 Test stiffer low speed compression adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary 1 Test softer rebound dumping adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and softer rebound damping adjustment and replace the spring with a stiffer spring optional if necessary Adjustments for Competition 99 Carburetor Adjustments amp Tuning Tips The carburetor on your CR should perform suitably with the standard recommended settings under average load climatic and barometric conditions However to fine tune the engine s power output the carburetor may require adjustments for specific competition needs Optional main jets and slow jets are available for your CR See your Honda dealer Any engine or a
122. power This may require an extra upshift on certain sections or perhaps you can just rev it out a bit longer For tight tracks consider lower gearing to avoid having to slip the clutch frequently Repeated fanning or pulling of the clutch lever in a turn to raise engine rpm may eventually damage the clutch system A gearing change may help for riding in sand where you want to keep 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 where you choose to over rev the engine temporarily rather than shifting up higher gearing might help Sometimes you have to sacrifice performance on one section of the track to gain a better overall time Your goal is the fastest overall lap time even if the cost is some sections where the gearing feels wrong If you decide to try a gearing change have someone check your times with a stopwatch before and after the change to get an accurate appraisal of the change Seat of the pants feelings can t be trusted Eliminating wheelspin with a gearing change can make you feel like you re going slower when in reality you ve decreased your time by inc
123. precision assembly Before beginning inspection decarbonizing please shaft arm study the following text and illustrations carefully 2 Check that the exhaust valve 4 turns Before attempting complete disassembly we recommend you consult the Honda Service Manual or your smoothly If the exhaust valve turns Honda dealer Mismatching of parts on reassembly can measurably affect fully engine performance unsmoothly remove the exhaust valve and decarbonize the RC valves and valve shaft page 56 Am fi lt NO Se i 1 B clip 3 2 collar 4 exhaust valve tie rod 1 RC valves 2 valve shaft 3 valve stopper 4 valve rod 5 governor gear 6 governor spring 7 primary drive gear 8 governor rack gear Servicing Your Honda 55 RC Valve Exhaust Valve Removal Remove the cylinder page 50 2 Remove the socket bolt 1 and stopper plate 2 3 Remove the nut 3 and washer 4 from the valve shaft assembly 1 socket bolt 3 nut 2 stopper plate 4 washer 4 Remove the valve shaft assembly 5 collar 6 and RC valves 7 from cylinder 5 valve shaft assembly 7 RC valves 6 collar 56 Servicing Your Honda 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 wear or damage 1 valve shaft assembly
124. pression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring Final travel too soft If initial and middle travel aren t stiff e Bottoms on landings Test stiffer compression damping adjustments in one click increments e Bottoms on large bumps especially downhill bumps 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 compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil level in increments of 0 2 in 5 mm Entire travel too soft Install the optional stiff spring e Front end shakes Test stiffer compression damping adjustments in one click increments e Fork bottoms over any type of terrain Increase rebound damping in one click increments Adjustments for Competition 97 Suspension Adjustment Guidelines Stiff Initial travel too stiff Test softer compression damping adjustments in one click increments suspension e Stiff on small bumps while riding at full throttle in a straight line Reduce the rebound damping adjustments in one click increments e Stiff on small cornering bumps Check
125. que 7 Ibf ft 10 N m 1 0 kgf m Transmission Oil Replacing Transmission Oil Run the engine for three minutes then shut it off Support the CR in an upright position on a level surface Remove the oil filler cap from the right crankcase cover Place an oil drain pan under the engine to catch the oil Then remove the drain bolt 1 Pour the drained oil into a suitable container and dispose of it in an approved manner page 114 Improper disposal of drained fluids is harmful to the environment 6 After the oil has drained completely install the drain bolt with a new sealing washer and tighten it to the specified torque 21 Ibf ft 29 N m 3 0 kgf m Add the recommended oil 0 60 US qt 0 57 at oil change Check the oil level by following the steps in Checking amp Adding Oil 1 oil drain bolt Servicing Your Honda 37 Coolant Your CR s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and corrosion Coolant Recommendation Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze container label Use only distilled water as a part of the coola
126. r unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page 132 A 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 removing the radiator cap To properly dispose of drained coolant refer to You amp the Environment page 114 Improper disposal of drained fluids is harmful to the environment Servicing Your Honda 39 Air Cleaner Refer to Safety Precautions on page 19 The air cleaner uses polyurethane inner and outer pieces which can t be separated A dirty air cleaner will reduce engine power Proper air cleaner maintenance is very important for off road vehicles A dirty water soaked worn out or defective air cleaner will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your CR s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling Improper or lack of proper air
127. r and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 82 Rear Suspension Adjustments 92 Suspension Adjustments for Track Conditions 96 Suspension Adjustments Guidelines 97 Carburetor Adjustments amp Tuning Tips 100 Chassis ZXU USLEHOTLS onore eoo roa reo rot ERR es 107 GOA oss saense conectecesataesenabiaveseistoncedetencestiseceon 108 Tire Selection for Track Conditions 109 Personal Fit Adjustments 110 Adjustments for Competition Adjustments for Competition 81 Front Suspension Adjustments The front suspension can be adjusted for the rider s weight and riding conditions by using one or more of the following methods Oil volume The effects of higher or lower fork oil level are only felt during the final 3 9 in 100 mm of fork travel Compression damping Turning the compression damping screw adjusts how quickly the fork compresses Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends Fork springs Optional springs are available in softer and stiffer types
128. r subframe s three mounting bolts then remove the subframe See page 32 92 Adjustments for Competition 3 Check that the spring preload is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 1 16 in 1 5 1 lock nut 2 adjuster nut 3 pin spanner 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 10 0 in 254 mm To decrease spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to increase the spring length 4 Do not increase to more than 10 8 in 275 mm Each turn of the adjuster changes spring length and spring pre load One turn equals spring length spring pre load 0 06 in 1 5 mm 15 2 Ibs 6 9 kg Pin spanners should be used for turning the lock nut and adjusting nut See page 127 for optional pin spanners Spring preload length Standard spring Standard 10 5 in 266 mm Min 10 0 in 254 mm Spring preload length Optional spring Min Softer 4 4 kgf mm 10 0 in 254 mm Min Stiffer 4 8 kgf mm 10 0 in 254 mm Min Stiffer 5 0 kgf mm 10 0 in 254 mm Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adj
129. raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm 72 Servicing Your Honda 1 drive chain slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links e kinked or binding links excessive wear Replace the drive chain page 74 if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page 73 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed 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 5b chain guide slider 6 wear limit groove 7 Check the upper drive ch
130. re necessary check for air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Condition Main Jet Adjustment long straights next larger uphill sections next smaller high humidity raining hotter than 113 F 45 C 102 Adjustments for Competition Once you ve adjusted the carburetor for temperature and altitude it shouldn t need major readjustment unless race conditions change drastically However there are some unique atmospheric conditions or race day situations that may require additional adjustments They are as follows To prevent engine damage always adjust the main jet before adjusting the jet needle Always choose the next richer jet if there is any doubt so there is a margin for safety Main Jet Go richer on the main jet by one number when the track has a very long straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is hotter 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 jetting changes are necessary check for worn crankshaft seals air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Pre Adjustment Checks Before adjusting carburetor settings check the following
131. reasing your speed with better traction These gearing recommendations should be evaluated by considering your ability your riding style and the track Choosing the correct tire tread pattern and rubber compound can affect your placing in competition The tires on your CR offer a happy medium for the variety of soil conditions the majority of riders are likely to encounter Experienced competitors often switch to tires developed for specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in tires especially the sidewall profile can change the attitude of your CR and its handling Tire variations that raise or lower the rear of your CR have a more significant effect on handling than variations in front tires which generally don t vary as much Often you can see or feel the change in tire size Another way to check is to measure the rolling circumference of the old and new tires A higher profile tire will have a larger rolling circumference If you do switch to tires designed for special terrain use remember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface Tir
132. reed valve assembly E es BN 4 insulator 5 carburetor insulator mounting bolts 5 Install the carburetor page 104 Servicing YourHonda 59 Suspension Refer to Safety Precautions on page 19 Refer to Suspension adjustment Guidelines page 97 Make all rebound and compression 4 Loose worn or damaged suspension components damping adjustments in one click increments EN 0 06 in 1 5 mm may adversely affect the handling and stability of Adjusting two or more clicks at a time may your CR If any suspension components appear cause you to pass over the best adjustment worn or damaged see your Honda dealer for Test ride after each adjustment further inspection Your dealer is qualified to f you become confused about adjustment if determine whether or not replacement parts or settings return to the standard position and repairs are needed start over 3 If the fork is still too stiff soft after adjusting compression damping determine which Front Suspension Inspection portion of the travel is still too stiff soft This is an important step that will help you solve 3 wear ring 4 outer tube e When your CR is new break it in for suspension problems approximately one hour to ensure that the suspension has worked in page 15 Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt Check for signs of oil leakage Damaged or leaking fork seals should be replace
133. rides As the spokes spoke nuts and rim contact points seat in the spokes may need to be retightened Once past this initial seating in period the spokes should hold their tension Still be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis page 69 Nuts Bolts Etc Application of a thread locking agent to essential fasteners offers added assurance and security Remove the nuts clean the threads of both the nuts and bolts apply Pro Honda Hondalock or an equivalent and tighten to the specified torque Servicing Your Honda 25 Before amp After Competition Maintenance Between Motos amp Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments Clean accumulated dirt from under the fenders wheels suspension components hand grips controls and footpegs A stiff nylon parts cleaning brush works well Check tire air pressure Check spoke tension and rim lock nut security wil is s WM OQ Check sprocket bolt and nut security e Clean the sides of the drive chain with a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result e After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the r
134. rn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats i t ia i UNI X WU y an s a Lu Wy inm IT i a E p t 1 Li 4 i A e k j L E o A Wi 4 spark plug 6 Reinstall the spark plug cap Take care to avoid pinching any cables or wires Refer to Safety Precautions on page 19 Cylinder Head Removal Clean the area above the engine before disassembly to prevent dirt falling into the engine Drain the radiator coolant page 39 Turn the fuel valve OFF Remove the seat and fuel tank page 29 30 Loosen the water hose clamp and remove the water hose 1 from the cylinder head 5 Disconnect the spark plug cap 2 and remove the spark plug 43 B WN Re 1 water hose 2 spark plug cap Cylinder System 6 Remove the upper engine hanger plate bolts 8 Remove the cylinder head gasket 8 and and nuts 3 then remove the clamp 4 and dowel pins 9 hanger plates 5 3 hanger plate bolts and nuts 5 hanger plates 8 gasket 9 dowel pins 4 clamp 7 Remove the five cylinder head nuts 6 using the technique described below and remove the cylinder head 7 To avoid warping the cylinder head use a crisscross pattern to loosen each nut about 1 4 then remove the nuts 6 cylinder head nuts 7 cylinder head Servicing YourHonda 49 Cylinder System 5 Remove the bolts 1
135. rnoider 73 99 10 cylinder holder 7 3 1 0 20 Brake hose bolts 1 25 34 35 NOTES 1 Apply Pro Honda Hondalock or an equivalent to the threads 2 Apply oil to the threads and flange surface 3 Stake 4 U nut 5 UBS nut 6 SH bolt Technical Information 121 Torque Specifications Frame 37 Rear brake disc nuts 12 16 1 6 NOTE 4 Brake pedal pivot bolt 27 36 3 7 Eme E cet rear 27 3 7 104 26 Rimlocks tt 12 Ws er ere ret m lower 22 30 31 28 Fork center bolt 40 54 55 Item Mev 34 FRAME lt lt Caliper mount bolts 22 30 31 NOTE 1 Als 27 Front brake disc nuts 12 16 1 6 NOTE 4 WK SE S gt Fork piston rod lock nut 21 28 29 30 Disc cover bolt 10 13 13 Fork protector bolts 5 2 7 0 7 NOTE 1 32 Expansion chamber mounting bolt front stay 12 1 2 33 Sprocket nuts 24 32 3 3 NOTE 4 34 Seat mounting bolts 20 27 28 35 Front brake reservoir cap screw 1 0 1 o7 S cabot itor a on cap bolt 0 7 1 0 1 37 Forkairplug fF 0912 01 38 Upperchainroller 9 12 12 NOTE 6 Lower chain roller 9 12 12 NOTE 4 NOTES 1 Apply Pro Honda Hondalock or an equivalent to the 35 threads 34 36 eee 2 Apply oil to the threads and flange surface 34 IES 3 Stake 4
136. rrn tunne EEEN A 58 Servicing Your Honda Chassis DUSDEDSIOD en E 60 B r AAAA 65 b dde EEIE AE E EEA IEAA 69 Tiros O ea EE EE 70 MC oe apes cae evans cacvsat ea voasneeeomeesreast 72 Expansion Chamber sa ssecanacecsapaseesaeo nc cocossecsseoses Ta Additional Maintenance Procedures 76 Appeare E HEB Lose cuni PUES Uu enn ia uu 78 Servicing Your Honda 17 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 good maintenance are especially important because your CR is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CR before each ride and follow the Maintenance Schedule in this section A WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual 18 Servicing Your Honda Maintenance Safety This section includes instructions on how to perform some important maintenance tasks Some of the most important safety precautions Important Safety Precautions follow However we cannot warn you of every e Make sure the engine is off before you begin conceivable hazard that can ari
137. s Your Motorcycle Ready to Ride 9 Pre ride Inspection Before Riding Before Riding 7 Are You Ready to Ride Before riding your CR for the first time we strongly recommend that you read this owner s manual make sure you understand the safety messages and know how to operate the controls Before each ride it s also important to make sure you and your CR are both ready to ride For information about suspension carburetor and other adjustments see page 81 Whether you re preparing for competition or for practice always make sure you are n good physical and mental condition Free of alcohol and drugs e Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride 8 Before Riding A WARNING Not wearing a helmet increases the chance of serious injury or death ina crash Be sure you always wear a helmet eye protection and other protective apparel when you ride Is Your Motorcycle Ready to Ride Competitive riding can be tough on a motorcycle so it s important to inspect your CR and correct any problems you find before each ride Check Pre ride Inspection the following items page numbers are at the Check the following before each ride right e Transmission oil Ievel seen tenetis seruis 37 e Coolant for proper level aes d
138. s and hand tools Procedures for these items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for purchase from your Honda dealer page 134 Service intervals in 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 ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CR best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability 20 Servicing Your Honda Perform the pre ride inspection page 9 at each scheduled maintenance period Summary of Maintenance Schedule Notes and Procedures Notes 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 Maintenance Procedures I inspect and clean adjust lubricate or
139. se in performing any maintenance or repairs maintenance Only you can decide whether or This will help eliminate several potential not you should perform a given task hazards A WARNING Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation Failure to properly follow maintenance whenever you operate the engine instructions and precautions can cause you to be seriously hurt or killed Burns from hot motorcycle parts Let the engine and exhaust system cool before Always follow the procedures and touching precautions in this owner s manual 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 tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the optional work stand or a maintenance stand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a non flammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Servicing Your Honda 19 Maintenance Schedule To maintain the safety and reliability of your CR regular inspection and service is required as shown in the Maintenance Schedule that follows The Maintenance Schedule lists items that can be performed with basic mechanical skill
140. simply turn off the engine and pull the plug for inspection Use a new spark plug Inspect the plug before installing it 106 Adjustments for Competition Using spark plugs with an improper heat range or incorrect reach can cause engine damage Before removing the spark plug clean the spark plug area thoroughly to prevent dirt from entering the cylinder Ride for 10 15 minutes before taking a plug reading A new plug will not color immediately To obtain an accurate reading of a new spark plug 1 Accelerate at full throttle on a straight 2 Push the engine stop button and pull the clutch lever in to release the clutch 3 Coast to a stop 4 Remove the spark plug 5 Use a magnifying glass to inspect the spark plug The porcelain insulator 1 around the center electrode 2 should appear clean 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 porcelain indicate rich jetting An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 1 insulator 2 center electrode 3 side electrode Spark Plug Coloring Guidelines Condition Spark Plug Appearance Normal Dark brown to light tan correct color with dry electrode Overheating Light gray or white color lean Lean
141. sor lead 11 Remove the float chamber screws 15 and float chamber 16 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 15 float chamber screws 16 float chamber 12 Use a float level gauge 17 to measure 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 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 After installing the carburetor check the air vent hoses 20 and overflow hose 21 for kinking or pinching and correct routing as necessary SAN O EN Woke On PG Pye 20 air vent hoses Adjustments for Competition 105 Carburetor Adjustments amp Tuning Tips 20 air vent hoses 21 overflow hose Spark Plug Reading Refer to Spark Plug page 48 Check any jetting change by reading the spark plug The following procedure is recommended You may not get an accurate reading if you
142. standard position and bearings replaced by your Honda dealer begin again Servicing Your Honda 61 Suspension Recommended Fork Oil suggested oil Pro Honda HP Fork Oil or equivalent Fork Oil Change 1 Remove the fork cap spring seat and fork spring as described in Front Suspension Oil Level Adjustment page 84 91 2 Remove the distance collar 1 lock nut 2 spring guide 3 and O ring 4 0 R D 1 distance collar 3 spring guide 2 lock nut 4 O ring 3 Remove the partition plate 5 from the inside of fork tube 4 Pour out the fork oil by pumping the fork tube and damper rod 6 8 10 times with the rod end down as shown 62 Servicing Your Honda 5 partition plate 6 damper rod 5 Wipe off any excess oil from the spring guide 3 Install the 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 8 Pour half of the recommended fork oil into the fork slider and fork tube Before pouring the fork oil make sure that the partition plate is removed 9 Raise the fork tube 7 and cover the top of the tube with your hand Compress the fork tube fully then release your hand Use your other hand to secure the fork tube Repeat this procedure 3 times 7 fork tube Suspension 10 Pour the remaining fork oil into the damper 12 Adjust the oil level by addin
143. t 26 and fork spring oil with an aftermarket syringe 29 27 29 29 syringe 6 fork cap 26 spring seat 24 damper rod 27 fork spring 25 lock nut 86 Adjustments for Competition Front Suspension Adjustments Fork Oil Level Optional Stiffer 0 46 kgt mm Fork Spring 20 Inspect both ends of the fork spring If you ps find any roughness or burred edge on the end Standard 0 44 kgf mm Fork Spring OSEE ering valk of either spring smooth the roughness with a file and some emery cloth E No mark Standard oil 2 Clean the spring and spring seat thoroughly S factory products idi ferm with a high flash point solvent to remove all Maximum oil 1 6 in Slightly stiffer as metal particles and dirt PME NC level 41 mm Asa 22 Dry the prine and spring seat with air loei 71 mm pressure rather than a shop towel Using a Minimum oil 4 6 in Slightly softer as shop towel allows lint to stick to the springs Maximum oil 1 5 in Slightly stiffer as level 117 mm it nears full Lint or any particles that stick in the puel ean nee compression damping passages can cause inconsistent compression damping Minimum oil 4 4 in Slightly softer as Be sure the oil level is the same in both fork 23 Check that the O ring 30 on the fork cap is level 113 mm it nears full legs in good condition Apply the recommended pha ciate Always use the after market syringe while fork oil to the O ring adjusting
144. t it is necessary to measure between two fixed points from the top of the most rearward point of the subframe down to the machined edge at the rear of the swingarm as illustrated for three different situations unloaded motorcycle on optional workstand with rear suspension fully extended no rider loaded with rider motorcycle on ground with rider loaded without rider motorcycle on ground without rider Support your CR on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 94 Adjustments for Competition UNLOADED MEASUREMENT on workstand without rider XAMPLE 23 6 in 600 mm Measure the oaded with rider dimension Remove the workstand With two helpers available sit as 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 of times to help the suspension overcome any stiction and settle to a good reference point Ask the other helper to measure the oaded with rider dimension PIS EN CZ LOADED MEASUREMENT ve D V on ground with rider XK E E xd f SS Za A EX NE we DORSEY AM Race Sag Calculation unloaded 23 6 in 600 mm loaded with rider 19 7 in 500 mm Race Sag 3 9 in 100 mm 4 Calculate the race sag dimension To do this subtract the loaded with rider dimension step
145. t 36 COTA oE EE 38 Air C Ie OE anne ean eee ween Au ne ne Ae Te 40 Engine TT OU NC PEES P 0295203010 E 09 00 20 20 0005 00000 42 TS Sosa eeu ceecce cca drszsanaamen ssevoaeoaetees 44 SPa PI ag ssc e sat cocoa dient asetozadaatesadadancetaaceseceencecies 48 Cut Syste ernennen 49 ROI E 55 Recd Nlis esecveser eto aae EE Eia 58 Chassis SE Ms dicot ice TT ET 60 BE e A E 65 IDOE RR 69 Tires amp MDE eE eee 70 Dre sl 1 eE a 72 Expansion CDambeE ssccsscstcaceccssntceosivensetidvessevearecs 75 Additional Maintenance Procedures 76 JADDEJIODCO E MEE eE 78 ADJUSTMENTS FOR COMPETITION 81 Front Suspension Adjustments 82 Rear Suspension Adjustments 92 Suspension Adjustments for Track Conditions 96 Suspension Adjustment Guidelines 97 Carburetor Adjustments amp Turning Tips 100 Chassis XO HSETISPIES oco tosasoasoneuetecnansdesascutateieses 107 O eese coeesbas eite ter ue mq eM EDU MUE 108 Tire Selection for Track Conditions 109 Personal Pit Adjustments asessci coerente 110 TIE qm M 111 Transporting Your Motorcycle 112 Stonne Your Hond 8 oice tessticicecsavessivessacuncseecotes 113 You amp the Environment sscccccsesasstecaisetesoncesaccanes 114 Troubles hoone sesaosan 115 TECHNICAL INFORMATION 117 Vebicle TO TEL HO AION ji ioceet teo poa uEc96 0002505
146. ta tinte 22 PO ro cM RC 18 Sa P 19 OS assesses sacs 20 manual SErVicE osniastae oM det nO PUPPES 132 modic alons seeen d ivaspoacatib E EEES 3 oil TOR EI EE E EE ETETA 62 fans missio seregno ese rE 36 operation component locations 6 operating CODLIRODSU uou ie buie t etes UO EE 5 TELS PUC CONS oaote caste EEE 11 optional lu Ml en 127 SPO EO e 127 oxy PCAC ICIS sericis e ee 124 pads D akee E ES ES enr UE 68 puits Optional suscite tuni iub os socrecsaosenceds 127 personal fit adus Hie nisse ooo eai ode oag dcs 110 Pingine PHP ITO coo2uo010o0 2H UD OM OS EOd EE i 34 DUS EPIK MR 48 pre load rear SUSpension e essssssssseeerssssss 92 DIES MS OCCU OM en trarcservereannteannectrensneevenstontvanes 9 PLOUCCIING apparel aiecncecacrcsossccsanierssduomcnessaicesannste 2 IPRC a E 55 rear suspension maintenance eeseee 61 TUE CI T T 58 Rider s Club Hondarren 135 riding aP l e 2 Dasic OPCTAU ON iesaesentotiocei cus teice aeni 11 De O apr T y important safety information ss 2 safety DRCC AU OUG miescie oin 2 safety important information eeeeeeeeeeee 2 important PrECAULIONG ses essesiaxsasesscsacersivsvcssinctes 2 DEI o 4 JR TILES UELLE CU MR R E 19 riding D COQULIOTIS o occus roasted edet ta teile eiae 12 schedule maintenance eese 20
147. tenance Procedures RIGHT SIDE 1 cylinder head nut 6 right RC cover bolt 2 cylinder mounting nut 7 right RC cover screw 3 carburetor insulator bolt 4 clutch cover bolt 5 water pump cover bolt LEFT SIDE 8 alternator cover bolt 9 left RC cover bolt Servicing Your Honda 77 Appearance Care Refer to Safety Precautions on page 19 Frequent cleaning and polishing will keep your Honda looking newer longer Frequent cleaning also identifies you as an owner who values his motorcycle A clean CR is also easier to inspect and service While you re cleaning be sure to look for damage wear and gasoline or oil leaks General Recommendations To clean your CR you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CR or discolor the seat and decals If your CR is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your CR High pressure washers like those at coin operated car washes can damage certain parts of your CR The force of water under extreme pressure can penetrate the dust seals of the suspension pivot points and steering head bearings driving dirt inside and needed l
148. than the standard rate page 127 82 Adjustments for Competition Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CR 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 pressure The standard air pressure is 0 psi 0 kPa O kgf cm You may relieve accumulated air pressure in the fork legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place an optional workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pressure release screws 1 3 Check that the O ring 2 1s in good condition 4 Install the pressure release screws to the specified torque 0 9 Ibf ft 1 2 N m 0 1 kgf m Front Suspension Damping Compression Damping Compression damping affects how quickly the fork compresses The compression damping adjuster has 20 positions or more Turning the adjuster screw one full turn advances the ad
149. the ground 2 Remove the number plate bolt 1 and number plate 2 1 number plate bolt 2 number plate 84 Adjustments for Competition 3 Remove the handlebar pad Remove the washers handlebar holder nuts 3 mounting rubbers and handlebar 4 Keep the master cylinder upright to prevent air from entering system E Need 3 washers handlebar holder nuts 4 handlebar 4 Loosen the upper pinch bolts 5 before loosening the fork caps to avoid damaging the fork caps 5 Loosen the fork caps 6 but do not remove them yet Using an adjustable wrench to loosen the fork caps may damage them 5 upper pinch bolts 6 fork cap 6 Remove the disc cover 7 by removing the 7 disc cover 8 bolts 7 Remove the axle nut 9 and loosen the axle pinch bolts 10 on both forks 8 Pull the front axle shaft 11 out of the wheel hub and remove the front wheel 9 axle nut 10 axle pinch bolts 11 front axle shaft 9 Remove the fork protector bolts 12 brake hose clamp bolts 13 and fork protectors 14 10 Remove the brake caliper bolts 15 and brake caliper 16 Do not support 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 Ez 5 a amp 12 fork protector bolts 15 brake caliper bolts 13 brake hose clamp bolts 16 brake
150. the above adjustment or If initial and middle travel becomes 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 initial travel compression damping is obtained Lower the oil level by 0 2 in 5 mm Entire travel too stiff Test softer compression damping adjustments in one click increments e Stiff suspension on any type of terrain Reduce the rebound damping in one click increments Lower the oil level by 0 2 in 5 mm 98 Adjustments for Competition Rear Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard settings If the suspension is too stiff soft adjust according to the chart below Sand track Suspension Adjustment Guidelines Lower the rear end to improve front wheel stability by increasing Race Sag reduce spring preload Example Turn the compression damping adjuster and especially rebound damping adjuster to a stiffer setting Increase standard Race Sag 40 2 to 0 4 in 5 to 10 mm because mud build up increases your CR s weight Example Adjust the compression and rebound damping adjusters to stiffer settings Install the optional stiff spring Mud track Adjust to a stiffer position Reduce standard Race
151. u ve determined that the main and slow jets must be changed you must remove the float chamber plug Removing the float chamber plug will allow the fuel in the float chamber to drain Do not remove the plug if the engine is hot A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 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 103 Adjustments for Competition Carburetor Adjustments amp Tuning Tips 7 Change the main jet 5 and slow jet 6 as required b main jet 6 slow jet 8 Check the O ring for wear then reinstall the float chamber plug securely 9 Remove the carburetor top throttle valve and cable holder this page and then change the jet needle clip position as required 10 Reinstall the jet needle throttle valve cable holder and carburetor top page 105 11 Turn the carburetor upright and tighten its clamp screws 12 Adjust the air screw opening required Reconnect the fuel line at the carburetor 13 Repeat steps 2 through 12 until the engine gives maximum power with the correct spark plug reading It is always better to jet a little r
152. ubrication out 78 Servicing Your Honda If you use a high pressure washer avoid spraying the following areas wheel hubs expansion chamber outlet area under seat engine stop button brake master cylinders under fuel tank drive chain carburetor steering head bearings suspension pivot 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 both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Washing Your Motorcycle with a Mild Detergent Rinse your CR thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CR with 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 cle
153. uction in traction Check the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim Tires amp Tubes Tube Replacement Tire Replacement If a tube is punctured or damaged you should The tires that came on your CR were designed to replace it as soon as possible A repaired tube provide a good combination of handling braking may not have the same reliability as a new one durability and comfort across a broad range of and it may fail while you are riding riding conditions Use a replacement tube equivalent to the original 80 100 21 51M 1009019 57M bias ply tube Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Servicing Your Honda 71 Drive Chain Refer to Safety Precautions on page 19 The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets When the motorcycle is ridden on unusually dusty or muddy tracks more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and check that your transmission is in neutral Inspection 1 Turn the engine off
154. ue can reduce your ability to perform well and ride safety 2 Motorcycle Safety Don t Drink and Ride Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either Keep Your Honda in Safe Condition Maintaining your CR properly is critical to your safety A loose bolt for example can cause a breakdown in which you can be seriously injured Accessories amp Modifications Installing non Honda accessories removing original equipment or modifying your CR in any way that would change its design or operation could seriously impair your CR s handling stability and braking making it unsafe to ride A WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories Motorcycle Safety 3 Safety Labels 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 IMPORTANT INFORMATION Operator only No passengers This Honda Motorcycle is sold as is without warranty and the entire risk as to quality and performance is with the buyer Read owner s manual This vehicle is designed manufactured and sold for competition use
155. ulator mounting bolts 3 Remove the gasket mounting bolts Reed Valve Inspection 1 Check the reed valves 1 for damage or fatigue and replace them if necessary 2 Replace the reed valves with new ones if the seats are cracked 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 stoppers then install them onto the cage 1 reed valve mounting screws 2 stopper 3 sub reed valve 4 reed valve 5 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 Ibf ft 1 N m 0 1 kgf m 5 Make sure that the clearance between the reed valve and cage 6 is less than the 0 008 in 0 2 mm 6 4 reed valve 6 cage Reed Valve 2 Install the new gasket to the crankcase Reed Valve Installation 3 Install the reed valve assembly and insulator 4 to the crankcase 1 Install the reed valve inner 1 into the reed 4 Install the six carburetor insulator mounting valve assembly 2 while aligning the cut outs bolts 5 and tighten to the specified torque in 3 a crisscross pattern 7 Ibf ft 10 N m 1 0 kgf m After installation check for secondary air leaks around the reed cage and insulator 1 reed valve inner 3 cut outs 2
156. usters The high speed damping adjuster 1 is effective when damping adjustment is desired for high speed operation The low speed damping adjuster 2 should be used when damping adjustment is desired at relatively low speeds Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise e Adjust the high speed compression adjuster in 1 12 turn increments 1 high speed damping adjuster 2 low speed damping adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed compression damping adjuster has 2 turns or more To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 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 low speed compression adjuster has 18 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4 positions To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 8 12 clicks and the punch marks are aligned Rear Suspension Adjustments Rebound Damping
157. ut Slow jet 30 in Carburetor Adjustments amp Tuning Tips All jetting is based on e Standard Jetting e 32 1 Fuel Oil Ratio Unmodified Engine Including Porting Exhaust and Timing TEMPERATURE CENT 30 17 18 v 6 7 5 4 v 16 15 27 26 38 ALTITUDE FAHR 19 40 39 60 59 80 79 100 10 000 ft 3 050 m to 7 500 ft 2 300 m 6DGY28 70 390 7 499 ft 2 299 m 55 to 2 5 000 ft 1 500 m 6DGY29 69 4 999 ft 1 499 m to 2 500 ft 750 m 6DGY28 69 410 2 499 ft 749 m 55 to 3 1 000 ft 300 m 6DGY28 68 420 1 3 4 999 ft 299 m 55 to Z 3 Sea Level 0 m 6DGY28 68 Legend AS Air Screw opening from fully seated SJ Slow Jet NC Needle Clip position JN Jet Needle MJ Main Jet Adjustments for Competition 101 Carburetor Adjustments amp Tuning Tips Adjustments for Altitude amp Temperature All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture Mixture will be Component affected Uryalr Em stage Special Tuning Conditions Condition Cold temperature Warm temperature High humidity High altitude There are some unique atmospheric conditions or situations that may require additional adjustments It should not be necessary to go more than one jet size richer or leaner to fine tune your CR If larger jetting changes a
158. ve HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for succossful completion of a Motorcycle Safety Foundation training course Separate complimentary training from the Specialty Vehicle Institute of America for purchasers of new ATVs One full year of the Honda Red Rider magazine six issues Discounts from HRCA partners for experienced rider courses Discounted vehicle insurance from the HRCA s insurance partner Racing contingency programs and assistance at selected dual sport off road and motocross events for off road motorcycles and selected ATVs The Honda Rider s Club USA only If you purchased an off road motorcycle ATV or PWC your benefits do not include roadside assistance or trip interruption protection Contact your Honda dealer for more information or call 1 800 847 4722 or log on to www hrca honda com Consumer Information 135 Table of Contents The following presents the contents of each section of your owner s manual MOTORCYCLE SAFETY Important Safety Information Important Safety Precautions Accessories amp Modifications SaEety Labe 8o eim drrtee tes raS re Ies e OMNIS OPERATING CONTROLS Operation Component Locations BEFORE
159. viding the fuel air mixture over a given portion of throttle valve opening These major circuits overlap as shown below MAIN JET JET NEEDLE TAPERED SECTION JET NEEDLE gt STRAIGHT SECTION SLOW JET AND AIR SCREW FULLY 1 8 1 4 1 2 3 4 FULLY CLOSE OPENED 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 s jet size numbers do not correspond with other carburetor manufacturer s jet size numbers use genuine Honda CR125R jets Jet Needle The jet needle controls fuel air mixture over 1 16 to 3 4 throttle The straight section 1 affects throttle response at smaller throttle openings By changing the position of the clip 2 in its groove you can improve acceleration at medium low and medium speed 1st S LEANER 2nd 3rd 2 Ath 5th N RICHER g 1 straight section 2 clip Slow Jet and Air Screw Refer to Carburetor Minor Adjustments Page 106 Standard Tuning Recommendations For the following recommendations to be accurate you must use the standard settings as a baseline Also don t change any of the settings until you ve determined what changes are necessary Adjustment Standard settings Air screw opening 1 3 4 turns o

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