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Front Suspension Adjustment

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1. Coolant Coolant Replacement Refer to Safety Precautions on page 19 Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page 136 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 118 NOTICE Improper disposal of drained fluids is harmful to the environment 1 water hoses 4 water pump cover 2 overflow tube 3 water leakage check hole 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
2. Jet needle number Jet needle number standard series 1 2 clip position richer than standard series at 1 8 to 3 4 throttle 6DGY26 62 6DGY27 62 2 620 mm 2 620 mm 6DGY26 63 6DGY27 63 395 g 2 630 mm g 2 630 mm 9 6DGY26 64 6DGY27 64 E 8 2 640 mm 2 640 mm S standard needle o 6DGY26 65 6DGY27 65 2 650 mm 9 2 650 mm 3 5 6DGY26 66 6DGY27 66 S 2 660 mm 2 660 mm 87 6DGY26 67 6DGY27 67 2 670 mm 2 670 mm 6DGY26 68 6DGY27 68 2 680 mm 9 2 680 mm FRAME Remarks FRAME Remarks Driven sprocket Drive chain links Shock spring Higher gearing 48 Teeth Aluminum 114 Standard 291 2 Ibf in 5 2 kgf mm Standard 49 Teeth Aluminum 114 No mark factory products Lower gearing 50 Teeth Aluminum lt 114 gt Handlebar lower or Black holder paint Standard no offset aftermarket parts Optional 3 mm offset Optional 280 0 Ibf in 5 0 kgf mm Front wheel Softer Standard 21 inch White Fork height 0 3 in 7 0 mm er paint align the index groove with the top of the upper clamp Stiffer 302 4 Ibf in 5 4 kgf mm Optional 20 inch Green e wheel assembly OW paint except brake disk e tire tube e tire flap 313 6 Ibf in 5 6 kgf mm rim lock bead stopper a e front tire 90 100 20 er paint Fork height 0 in 0 mm align the top of the fork tube with the top of the upper clamp Fork spring 24 64 Ibf in 0 44 kgf mm Standard No mark Qr factory products TOOLS
3. sees 19 Important Safety Precautions 19 Maintenance Schedule usus 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 Remoyval asceo noce er xe terere 29 Fuel Tank Removal eeeee 30 Subframe Removal seen 32 Contents Service Procedures Fluid amp Filters Fuel System emt tee tree 34 Transmission Qil eee 36 Coolant ensenen aiii aaa 38 Air CIeanetc ue irse et tert erred 40 Engine Throttle eicere ente 42 Clutch Syste on vis neto et rte trente 44 Spark Plug eren terrere ee 48 Cylinder System ue erret emeret 49 RC Valve cte etre emeret cas 55 Reed ValV amp i iorieesc eere eere 58 Chassis SUSp6nSIOD 4 scr ee teer teet eee 60 Brake S ERR 65 Wheels e 69 Tues amp Tubes rte tette 70 Drive Chain eene 12 Expansion Chamber esses 75 Additional Maintenance Procedures 76 Appearance Care eerte teen 78 ADJUSTMENTS FOR COMPETITION 81 Front Suspension Adjustments 82 Rear Suspension Adjustments 95 Suspension Adjustments f
4. 135 Authorized Manuals esee 136 Contacting Honda sene 137 Your Honda Dealer esee 138 The Honda Rider s Club USA only 139 TABLE OF CONTENTS eee 140 INDEX Q 141 QUICK REFERENCE Index A C E ACCESSOLIES indecens bete EESE EES 3 capacity fuel reete ertet eter 35 engine adjustments carburetor flooded 1 err hri n nrbt 13 altitude and temperature 105 adjustment reete ee 104 idle speed eerte 106 exige tirare ie sheen cauievevadeosavecive seers 103 circuit functions sse 103 PUI DOR 25a oerte rer ert 122 CHASSIS P 110 COMPONENTS aee reitera eter nias 103 juu e 48 control freeplay 42 44 65 disassembly assembly 107 rui 13 for competition esee 81 high altitude adjustment 127 Stop button cete tn 14 Po iip 111 idle Speed is cent mto rods 106 dug d 14 high altitude carburetor 127 mainteranc eee treten EYE Eee 107 WON ESTATE 11s ecco de rete eee etri ee r e ae 13 personal fit erret titres 113 minor adjustments seen 106 environment protecting sesers 118 suspension front
5. 136 Consumer Information U IOo O 4A mr du E Ha 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 City State 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 address is different from the Card VISA Discover shipping address shown above Account Number Expiration Date Mo Yr Customer Signature Date 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 original 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 T
6. 2 dust seal 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 0 06 in 1 5 mm 3 3 wear ring 4 outer tube 3 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times Suspension i 7 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 contained 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 99 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 inc
7. eeseseeeeeeee 82 Cate appearance ose eee genes 78 expansion chamber sse 75 SUSPENSION rear 95 CHAIN drive uus eee a 72 suspension track conditions 99 chassis adjustment for track conditions 99 F tire selection sessir entere sees 112 Choke knob e retro 13 after competition maintenance 27 cleaner alf errre p retired c mr cv er vec e 40 filter Af leah E nearer 40 cleaning appearance care esses 78 QUT M ER 40 air pressure clutch system adjustment sss 44 flooded engine starting sess 13 front suspension eseeeeee 82 component locations fork puc m I 70 maintenance esceee iecore eerte inan 28 front suspension adjustment 82 American Honda contacting e 137 Operati ON svisai eie aE PLE EEEE 6 front suspension inspectiOn cece 60 apparel protective 1 ceres 2 competition logbook eese 129 oil recommendation eee 62 eru M 38 consumer information seen 135 front brake lever adjustment 65 appearance cate creto redet erp 78 contacting Honda een ete 137 front suspension maintenance 83 authorized manuals ees
8. 104 Adjustments for Competition All jetting is based on Standard Jetting 32 1 Fuel Oil Ratio Unmodified Engine Including Porting Exhaust and Timing TEMPERATURE CENT 30 17 18 6 7 5 4 16 15 v 27 26 v 38 37 49 ALTITUDE FAHR 21 0 1 20 19 40 39 60 59 80 79 100 199 120 AS 2 2 2 2 1 4 2 1 2 2 1 2 2 1 2 10 000 ft 3 050 m SJ 40 40 37 5 37 5 37 5 35 35 to NC 3 3 3 2 2 2 2 7 500 ft 2 300 m JN 6DGY26 65 6DGY26 65 6DGY26 66 GDGY27 66 6DGY27 67 6DGY26 67 GDGY26 68 MJ 420 410 400 390 390 380 370 AS 13 4 2 2 2 2 1 4 2 1 2 2 1 2 7 499 ft 2 299 m SJ 40 40 40 37 5 37 5 37 5 35 to NC 3 3 3 3 2 2 2 5 000 ft 1 500 m JN 6DGY26 65 6DGY26 65 6EDGY26 65 GDGY26 66 6DGY27 66 6DGY27 67 GDGY26 67 MJ 430 420 410 400 390 390 380 AS 2 13 4 2 2 2 2 1 4 2 1 2 4 999 ft 1 499 m SJ 42 5 40 40 40 37 5 37 5 37 5 to NC 3 3 3 3 3 2 2 2 500 ft 750 m JN 6DGY27 65 6DGY26 65 6DGY26 65 GDGY26 65 6DGY26 66 6DGY27 66 GDGY27 67 Mu 440 430 420 410 400 390 390 AS 13 4 2 13 4 2 2 2 2 1 4 2 499 ft 749 m SJ 42 5 42 5 40 40 40 37 5 37 5 to NC 4 3 3 3 3 3 2 1 000 ft 300 m JN 6DGY26 65 6DGY27 65 6DGY26 65 GDGY26 65 6DGY26 65 6DGY26 66 6DGY27 66 MJ 450 440 430 420 410 400 390 AS 2 13 4 2 134 2 2 2 999 ft 299 m SJ 45 42 5 42 5 4
9. 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 CR250R 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 Y
10. will decrease freeplay and turning it in direction will increase freeplay Tighten the lock nut Return the dust cover to its normal position 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 limit 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 5 rubber cap 6 lock nut 7 adjuster increase decrease 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 Ch
11. Check spoke tension frequently between the first few 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 After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad wear v 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 N aN 1 chain adjuster index marks e Suspend the front wheel above the ground and use the pressure release screws 2 to rele
12. Loosen the lock nut 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 3 8 3 4 in 10 20 mm Tighten the lock nut Check the adjustment Start the engine pull the clutch lever in and shift into gear Make 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 Ww N ns 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 134 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 and washer 2 by removing its pivot bolt 3 1 rear brake pedal 2 washer 3
13. brake hose clamp bolts 21 Clean the surfaces where the axle and axle clamps contact each other Install the left and right side collars into the wheel hub Insert the front axle shaft through the wheel hub from the right side Make sure the front axle shaft is seated firmly onto the left fork leg clamp inner surface Tighten the axle nut 19 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m 19 axle nut Front Suspension Adjustments 22 Align the brake caliper 20 and hose with 23 the left fork leg making sure that the brake hose is not twisted An improperly routed brake hose may rupture and cause a loss of braking efficiency Route the hose carefully Clean the threads of the brake caliper mounting bolts 21 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the slider and tighten the brake caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m Fit the brake caliper over the disc taking care not to damage the brake pads 20 brake caliper 21 brake caliper mounting bolts cont d Adjustments for Competition 93 Front Suspension Adjustments 24 Install the handlebar 22 mounting rubbers 23 washers and handlebar holder nuts 24 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 22 handlebar 23 mounting rubbers 24 washers handlebar holder nuts 25 I
14. driving dirt inside and needed lubrication 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 NOTICE 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 1 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 A
15. longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 5 8 clicks with the punch marks on the adjuster and the shock absorber aligned 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 adjustment 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 1 Support your
16. or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Pro Honda White Lithium Grease Wheel Bearing Grease Silicone Sealer high temperature grease Urea based multi purpose grease with extreme pressure Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape ENGINE CONTROL UNIT ENGINE STOP SWITCH Lal TP SENSOR zs d o i ler TU sag UA x ag Ed o J Sag WPC 8P BI 3 zd iol 35 gt IGNITION PULSE END ALTERNATOR Wiring Diagram SERVO MOTOR e 9 g Bu G i W BI e eo a gt IGNITION COIL REGULATOR RECT IF ER Bless BLACK Br BROWN Y eee YELLOW Q eres ORANGE Busse BLUE Lb LIGHT BLUE Gee GREEN Lgs LIGHT GREEN R v asss WHITE Gree GRAY Technical Information 133 134 Technical Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals eee 136 Contacting Honda eene 137 Your Honda Dealer eee 138 The Honda Rider s Club USA only 139 Consumer Information Consumer Information 135 Authorized Manuals The Service Manual used by your Honda dealer is available from Helm Inc Also available but not necessary to service your m
17. seriously scalding you Always let the engine and radiator cool down before removing the radiator cap 2 Add coolant up to the filler neck if the level is low Inspect 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 16 US qt 1 10 at disassembly 1 02 US qt 0 97 at coolant change 3 Install the radiator cap securely NOTICE 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
18. 39 4 0 3 Carburetor insulator bolt 9 12 1 2 4 Clutch cover bolt 9 12 1 2 1 cylinder head nut 6 RC cover bolt 5 Water pump cover 2 cylinder mounting nut bolt 9 12 1 2 3 carburetor insulator bolt 6 RC cover bolt 3 7 5 0 5 RIGHT SIDE 4 clutch cover bolt 5 water pump 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
19. 7 Ibf ft 1 N m 0 1 kgf m 5 Make sure that the clearance between the reed valve and cage 7 is less than the 0 008 in 0 2 mm 4 reed valve Reed Valve Installation 1 Install the new gasket 1 to the crankcase 2 2 Install the reed valve assembly 3 to the crankcase gasket 3 reed valve assembly C 3 Install the insulator 4 six carburetor insulator mounting bolts 5 and tighten to the specified torque in a crisscross pattern 9 Ibf ft 12 N m 1 2 kgf m After installation check for secondary air leaks around the reed cage and insulator 4 insulator 5 carburetor insulator mounting bolts 4 Install the carburetor page 107 Reed Valve Servicing Your Honda 59 Suspension Refer to Safety Precautions on page 19 Loose worn or damaged suspension components may adversely affect the handling and stability of your CR If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection When your CR is new break it in for approximately one hour to ensure that the suspension has worked in page 15 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 af
20. CR on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension UNLOADED MEASUREMENT on workstand without rider 3 Measure the loaded 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 loaded with rider dimension JAEN LOADED MEASUREMENT on ground with rider EXAMPLE 19 7 in 500 mm EA Race Sag Calculation unloaded 23 6 in 600 mm loaded with rider 19 7 in 500 mm Race Sag 3 9 in 100 mm Rear Suspension Adjustments 4 Calculate the race sag dimension To do this subtract the loaded with rider dimension step 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
21. Drive train Overall length 86 0 in 2 185 mm Type Liquid cooled 2 stroke Final reduction 3 769 Overall width 32 3 in 821 mm Cylinder arrangement Single 9 inclined from Gear animated Left foot operated return Overall height 50 1 in 1 275 mm vertical P system 1 N 2 3 4 5 Wheelbase 58 5 in 1 487 mm Bore and stroke 2 61 x 2 83 in 66 4 x 72 0 mm Electrical Seat height 37 4 in 950 mm Displacement 15 21 cu in 249 3 cm Ignition CDI Foot peg height 16 9 in 429 mm Compression ratio 9 0 1 Starting system Kickstarter i Transmission oil NGK Ground clearance 13 6 in 347 mm capacity Spark plug Standard BROEG N 8 Frame After draining 0 69 US qt 0 65 2 7 0 027 0 031 in Type Twin tube After disassembly 0 74 US qt 0 70 Spark plug gap 0 7 0 8 mm Telescopic fork F suspension travel 11 0 in 280 mm Carburetor stroke 12 4 in 315 mm Type Piston valve Pro link Identification number TMX11A R suspension travel 12 4 in 316 mm Main jet standard 420 F tire size pressure 80 100 21 51M Slow jet standard 40 psi kPa kgf cm 15 100 1 0 Air screw opening 2 turns out R tire size pressure 110 90 19 62M i psi kPa kgf cm 15 100 1 0 vost negn SES 1 a mm Tre ype pias piy tube Clutch type Wet multi plate type F brake swept area Single disc brake 51 8 in 334 5 cm Transmission 5 speed constant mesh Single disc brake Primary reduction 3 000 R brake swept area 60 6 i
22. Suspension bottoms at landing 1 Test stiffer high speed compression adjustment after jumping 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after landing 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 Suspension bottoms after end of 1 Test softer rebound dumping adjustment continuous bumps 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 102 Adjustments for Competition 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 airbox 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
23. 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 Fluid Level Inspection Front Brake Fluid Level Check 1 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 1 If the level is at or below the LOWER level mark check the brake pads for wear page 68 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake lever freeplay exceeds 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding 66 Servicing Your Honda Rear Brake Fluid Level Check la 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 68 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake pedal freeplay exceeds 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding Adding Front Brake Fluid The recommended brake fluid is
24. Tips This section contains dimensions capacities and other technical data Vehicle Identification esses 122 Specifications eseeseeeeeeeeen ene 123 Torque Specifications sees 124 High Altitude Carburetor Adjustment 127 Oxygenated Fuels eee 128 Competition Logbook sesses 129 Optional Parts List eeeeeeeeee 131 Spare Parts amp Equipment esses 132 Wiring Diagram eene 133 Technical Information Technical Information 121 Vehicle Identification RIGHT SIDE 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 1 VIN The engine number 2 is stamped on the left crankcase LEFT SIDE 1 VIN 2 engine number 122 Technical Information Specifications Item English Metric Item English Metric Item English Metric Dimension Engine
25. 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 118 Tips NOTICE 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 1 Check ignition timing CORRECT 2 Check carburetor air screw adjustment P 106 CORRECT 3 Check if air is leaking past manifold INCORRECT gt INCORRECT gt LEAKING gt NOT LEAKING 4 Try spark test e WEAK OR INTERMITTENT SPARK GOOD SPARK 5 Check the throttle position sensor CORRECT 6 Check the RC valve system P 55 CORRECT INCORRECT INCORRECT POSSIBLE CAUSES Improper ignition timing Faulty engine control unit Faulty alternator Fuel air mixture too lean Turn the air screw in P 106 Fuel air mixture too rich Turn the air screw out P 106 Deteriorated reed valve gasket Loose insulator clamp Faulty insulator Faulty carbon or wet fouled
26. any possibility of it loosening or of water penetration 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 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 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 Ignition 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 and the flywheel makes the ignition control module compensate to maintain the ignition curve Cleaning dirt from the ignition side main seal helps to prevent premature seal wear Close inspection of this seal can reveal a leakage problem before engine
27. 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 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 Symptom Action Stiff suspension Suspension feels stiff on small 1 Test softer low speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large 1 Test softer high speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 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 Soft suspension Entire travel too soft 1 Test stiffer high and low speed compression adjustments simultaneously 2 If it still feels soft replace the spring with a stiffer spring optional and begin with the standard settings to stiffer setting Rear end sways 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms
28. base gasket 1 and dowel pins 2 on the crankcase 1 cylinder base gasket 2 dowel pin 4 Lubricate the piston and ring with 2 stroke oil Align the ring end gap with the piston ring pin 3 in the ring groove and slip the cylinder 4 over the piston while compressing the piston ring NOTICE 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 is 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 29 Ibf ft 39 N m 4 0 kgf m Be careful not to overtighten the mounting nuts This is the most common cause for leaks here 5 flange nuts Cylinder System 6 Return the radiators 6 to the original positions on both sides 7 Tighten the radiator mounting bolts 7 then install the radiator grills 8 on both sides 8 Connect the radiator hose 9 and tighten hose clamp screw 10 12 Install a new exhaust gasket 15 13 Install the expansion chamber and springs page 75 15 exhaust gasket 6 radiator 9 radiator hose 7 radiator mounting bolts 10 screw 8 radiator grill 9 Install the RC valve cables Adjust if necessary page 57 10 Install a new gasket 11 onto the RC valve cover 12 11 Install t
29. before starting the engine page 37 38 1 fuel valve 2 choke knob Cold Engine Starting AUN Turn the fuel valve 1 ON Shift the transmission into neutral Pull the choke knob 2 up With throttle closed operate the kickstarter Starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion After the engine starts the choke knob should be pushed down as soon as possible to prevent spark plug fouling 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 1 2 3 4 Turn the fuel valve ON Shift the transmission into neutral Push the choke knob down 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 1 Push the choke knob down all the way to OFF 2 Open the throttle fully 3 While pushing the engine stop button crank the engine several times with the kickstarter Release the engine stop button Follow the Warm Engine Starting procedure ns Basic Operating Instructions 13 Starting amp Stopping
30. cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that you do not transport your CR on its side This can damage the motorcycle and leaking gasoline could be a hazard 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 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 Handle fuel only outdoors Wipe up spills immediately 4 Remove the radiator cap and coolant drain bolt 1
31. cleaning in solvent Be sure the chain is wiped clean and 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 NOTICE 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 7447 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 set
32. clicks This is the standard position 3 Make sure both fork legs are adjusted to the same position Fork Springs The fork springs in CR s are about right for riders weighing between 150 and 160 Ibs 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 control 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 0 20z 5 cm in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil level Minimum oil capacity Standard spring Softer spring Stiffer spring 11 2 US oz 331 cm 11 4 US oz 336 cm 11 0 US oz 326 cm 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 1800 p 1600 F Oil capacity 14 5 US oz 430 cm MAX 1400 1200 Oil capacity 13 3 US oz 394 cm STANDARD l 1000 Force N 800 Oil capacity 11 2 US oz 331 cm 600 MIN 40 F 200 0 0 30 60 90 3120 150 180 210 240 270 30 Stroke mm Front Suspension Adjustment Front Suspension Disassembly f your CR is brand new
33. ebbe ek Ein ero EE EV 72 Expansion Chamber sess 75 Additional Maintenance Procedures 76 Appearance Cate nere teret rere 78 ADJUSTMENTS FOR COMPETITION 81 Front Suspension Adjustments 82 Rear Suspension Adjustments 95 Suspension Adjustments for Track Conditions 99 Suspension Adjustment Guidelines 100 Carburetor Adjustments amp Turning Tips 103 Chassis Adjustments esses 110 S DD M 111 Tire Selection for Track Conditions 112 Personal Fit Adjustments sss 113 IEIPS eE AEA E E E 115 Transporting Your Motorcycle 116 Storing Your Honda sese 117 You amp the Environment eesss 118 Troubleshooting 1 rettet tne 119 TECHNICAL INFORMATION 121 Vehicle Identification sess 122 Specification S sissors ente orae nna Poen etes 123 Torque Specifications esses 124 High Altitude Carburetor Adjustment 127 Oxygenated Fuels esee 128 Competition Logbook eessss 129 Optional Parts List eee 131 Spare Parts amp Equipment esses 132 Wiring Diagram cece eerte 133 CONSUMER INFORMATION
34. 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 NOTICE Improper or lack of proper air 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 8 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 Air Cleaner 8 Apply a thin coat of Pro Honda White 10 Insert the pin in the air cleaner housing hole 11 Reinstall the seat page 29 making sure it
35. 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 ethanol 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 5 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 128 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 NOTICE Oxygenated fuels can damage paint and p
36. 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 Wipe up spills immediately 1 fuel valve 1 2 3 Fuel Line P ii 2 fuel line Check the fuel valve 1 and fuel filter for contamination Check for leaks Check the fuel line 2 for cracks deterioration damage or leakage Replace the fuel line if necessary Check for interference between the frame and tank and adjust if necessary Fuel System 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 To service the fuel filter 1 Drain the fuel from the fuel tank into an approved gasoline container Disconnect the fuel line 2 Remove the fuel valve 1 by removing the bolts 2 Wash the fuel filter 3 in high flash point cleaning solvent 1 fuel valve 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 t
37. pivot bolt 3 Remove the six clutch cover bolts 4 and clutch cover 5 4 clutch cover bolts 5 clutch cover 4 Remove the six clutch spring bolts 6 and clutch springs Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps 46 Servicing Your Honda 5 Remove the clutch pressure plate 7 6 clutch spring bolts 7 clutch pressure plate 6 Remove the clutch lifter 8 and clutch lifter rod 9 7 Remove the eight clutch discs and seven clutch plates 10 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 Vim Fe t 8 clutch lifter 10 clutch discs and plates 9 clutch lifter rod Clutch Disc Plate 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 1 clutch disc Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 008 in 0 20 mm Replace the clutch discs and plates as a set 2 clutch plate Clutch Spring Inspection MW 1 1 clutch spring Measure the free length of each sprin
38. 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 the ground 2 Remove the number plate bolt 1 and number plate 2 1 number plate bolt 2 number plate cont d Adjustments for Competition 83 Front Suspension Adjustments 3 Remove the handlebar pad Remove the washers handlebar holder nuts 3 mounting rubbers and handlebar 4 NOTICE Keep the master cylinder upright to prevent air from entering system 3 washers handlebar holder nuts 4 handlebar 4 Loosen the upper pinch bolts 5 5 Loosen the fork damper 6 but do not remove them yet NOTICE Do not use an adjustable wrench to loosen the fork damper it may damage them Loosen the upper pinch bolts before loosening the fork damper to avoid damping the fork cap 5 upper pinch bolts 6 fork damper 84 Adjustments for Competition 6 Remove the disc cover 7 by removing the disc cover bolts 8 7 disc cover 8 disc cover bolts 7 Remove the front axle nut 9 and loosen the front axle pinch bolts 10 on both forks Pull the front axle shaft 11
39. rh EE ERE EORR ea 82 PEAT eere titer ene E RT eR ORE ERES 95 for track conditions seesssss 99 guldelIles cree rettet ete td 100 T transmission oil E E E E E 36 Donnie 103 throttle re play iere ere eres 42 INS PECUOM MEN eves 43 tires AIT DIeSSUTE ripsien eni iai 70 abi rU 70 SCLOCH OM cose cs rire reet Pr RE E eene tene 112 foo 132 torque specifications sssseeeeeeee 124 transporting iees retener reet tere euer teure 116 troubleshooting eee 119 tubes replacing retreat 71 V valve fuel eenen raea E a 35 valve Renee A a A AEE 55 valve teed onneen RR GORGE ERR 58 vehicle identification no VIN 122 W washing your motorcycle sesssss 78 wWheelS 265 nire tenir a eT DER ERES 69 writing diagram 0 0 cee eeeeeeeseecneeeeeeeeeeeeeeaaes 133 Index Index 143 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 di
40. 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 is too firm for your weight will not allow the rear tire to hook up under acceleration and will pass more bumps on to you 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 th
41. should they arise page 15 Adjustments for Competition 109 Chassis Adjustments 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 adjustment page 97 in the 3 5 3 9 in 90 100 mm range 110 Adjustments for Competition 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 1 standard position 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 t
42. 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 ZZ LOADED MEASUREMENT on ground without rider EXAMPLE 21 6 in 550 mm JAN Free Sag Calculation unloaded 23 6 in 600 mm loaded without rider 21 6 in 550 mm Free Sag 2 0 in 50 mm cont d Adjustments for Competition 97 Rear Suspension Adjustments 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 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 98 Adjustments for Competition 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
43. spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 9 9 in 252 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 2 in 259 1 mm Each turn of the adjuster changes spring length and spring pre load One turn equals spring length spring pre load 1 16 in 1 5 mm 17 2 lbs 7 8 kg Rear Suspension Adjustments Pin spanners should be used for turning the lock nut and adjusting nut See page 131 for optional pin spanners Spring preload length Standard spring Standard 10 2 in 258 1 mm Min 9 9 in 252 mm Spring preload length Optional spring Min Softer 5 0 kgf mm 9 7 in 246 mm Min Stiffer 5 4 kgf mm 9 7 in 247 mm Min Stiffer 5 6 kgf mm 9 8 in 249 mm Adjustments for Competition 95 Rear Suspension Adjustments Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjusters 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 Adjust the high speed compression adjuste
44. spring f 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 Stiff on bumps when cornering Front end wanders when cornering Stiff suspension on bumps especially downhill bumps While braking front end dives during initial travel then feels stiff If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on large bumps especially downhill bumps Stiff on large bumps when cornering If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If final travel is still stiff after 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 c
45. to maintain proper suspension performance and minimize component wear Use Honda Moly 60 paste U S A only or molybdenum disulfide 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 ser
46. tube 23 then remove the fork damper 24 from the outer tube using a lock nut wrench 25 Gently slide the outer tube down onto the lower end of the slider 26 25 23 outer tube 24 fork damper 25 lock nut wrench 26 slider lower end 15 Pour the fork oil from the outer tube 23 Pour the fork oil from the oil hole 24 of the fork damper 23 outer tube 24 oil hole Front Suspension Adjustments 16 Temporarily install the fork damper to the outer tube 17 Set the lower end axle holder 25 of the slider in a vise with a piece of wood or soft jaws to avoid damage to it NOTICE Over tightening the vise can damage the axle holder 18 Loosen the fork center bolt 26 25 axle holder 26 fork center bolt 19 Push out the fork center bolt from the axle holder of the slider by pushing the fork damper 20 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as shown if you do not have the special tool Thickness 1 0 mm 55 mm 25 mm R 7 55 7 6 mm Adjustments for Competition 85 30 mm cont d Front Suspension Adjustments 21 Apply pressure to the fork damper and insert a special tool or mechanic s stopper tool 27 between the axle holder 25 and lock nut 28 22 Hold the lock nut and remove the fork center bolt 26 from the fork damper NOTICE Do not remove the lock nut from the for
47. 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 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 15 psi 100 kPa 1 0 kgf cm Rear 15 psi 100 kPa 1 0 kgf cm If you decide to adjust tire pressures for a particular riding condition make changes a little at a time 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 f
48. 0 E 40 9 40 37 5 to NC 4 4 3 3 9 3 F 3 3 Sea Level 0 m JN 6DGY26 64 6DGY26 65 6DGY27 65 EDGY 26 65 6DGY26 65 GDGY26 65 EDGY 26 66 MJ 460 450 440 430 420 410 400 Legend AS Air Screw opening from fully seated SJ Slow Jet NC Needle Clip position JN Jet Needle MJ Main Jet 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 Condition Mixture will be Adjust to Component affected Cold temperature Lean Richen Warm temperature Rich Lean Dry air Lean Richen pom stage High humidity Rich Lean High altitude Rich Lean Special Tuning Conditions 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 are 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 sand mud high humidity next smaller raining hotter than 113 F 45 C Carburetor Adjustments amp Tuning Tips Once you ve adjusted the carburetor for temperature and altitude it shouldn t need major readjustment unless race cond
49. 136 controls operating eese 5 fuel terere Erin a M 38 lin 35 B customer service 138 lil 35 cylinder system eere 49 recommendation eeeseeeeeeee 34 basic operation eeesseeeeeeeeeeeennenn 11 telueling 5a eden roter 35 before riding nanesie inesi 7 D iau 34 between motos amp practice maintenance 26 Oxygenaled 5 teet terrere 128 brakes damping adjustments tank capacity sce ertet eere 35 fid level eret ete 66 lire C zesty 82 D c TEE 35 lever front adjustment sess 65 WOAL 555 96 pad Wet aeneo ener eia 68 dealer your Honda eese 138 pedal height s rtt 65 diagram wiring ceeeeeeeeeenen e 133 break in guidelines ess 15 drive chali iis eee tei tert eere tret vases 72 Index 141 Index G M R gap spark plug ertet 48 maintenance RC valve oet ie ninen 55 PERI E 128 additional procedures ssse 76 RC valve cables ern mre iet 57 PERI M 34 after Competition ertet 27 rear suspension maintenance 61 Pio pM 111 before amp after competition 26 Teed Valve etre ertet etii EE 58 guidelines susp
50. 5 3 Tighten the lock nut 4 lock nut 5 integral cable adjuster increase freeplay decrease freeplay 6 Adjust the cable end adjuster for minor adjustment 44 Servicing Your Honda Clutch Lever Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 3 4 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear Make sure to adjust the clutch lever 1 freeplay after the clutch cable is disconnected 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 3 lock nut 4 integral cable adjuster increase freeplay decrease freeplay 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out 5 turns
51. 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 Symptom Action Soft Initial travel too soft Test stiffer compression damping adjustments in one click increments suspension Steering is too quick Test stiffer rebound damping adjustments in one click increments Front end darts while cornering or riding in a straight line Middle travel too soft If suspension isn t stiff in initial travel 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 compression 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 Bottoms on landings Test stiffer compression damping adjustments in one click increments Bottoms on large bumps especially downhill bumps If initial an
52. Apply a thin coat of molybdenum disulfide oil to the hole of RC valve and valve shaft 3 Apply silicone sealer Three Bond 1207B or equivalent 1 to the mating surface of the cylinder as shown 2 RC valve ila 5 bolts A 6 bolts B 1 silicone sealer 56 Servicing Your Honda 8 Install the stopper plate 7 and tighten the socket bolt 8 to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 7 stopper plate 8 socket bolt 9 Check that the RC valve and valve shaft move smoothly 10 Install the cylinder page 52 RC Valve Cable Rear RC Valve cable 1 outer lock nut 2 adjuster 3 rear RC valve cable 1 Turn the outer lock nut 1 until it seats against the adjuster 2 Connect the rear RC valve cable 3 to the RC valve pulley 4 Turn the RC valve pulley counterclockwise fully Turn the adjuster clockwise until the inner lock nut 5 seats against the cylinder 6 Tighten the outer lock nut securely 4 RC valve pulley 5 inner lock nut 6 cylinder RC Valve Front RC Valve cable 1 1 RC valve pulley 6 2 pin 7 3 inner lock nut 8 4 front RC valve cable 9 Turn the RC valve pulley 1 clockwise fully until the RC valve pulley stops against the pin 2 Loosen the inner lock nut 3 until it reaches the end of the cable threads Connect the front RC valve cable spring seat 4 to the
53. IF cap screw 0 7 1 0 0 1 i Pai A 36 Rear brake reservoir 73 cap bolt 0 7 10 0 1 37 Fork air plug 0 9 1 2 0 1 38 Upper chain roller 9 12 12 NOTE 6 39 Lower chain roller 9 12 1 2 NOTE 4 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 24 126 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 NOTICE Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may cause engine overheating and damage Technical Information 127 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
54. ING You CAN be KILLED or SERIOUSLY HURT if you don t 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 1 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications sss 3 Safety Labels eee ree 4 OPERATING CONTRODLS eee 5 Operation Component Locations 6 BEFORE RIDING eene eren eene tnnn 7 Are You Ready to Ride esesssss 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection etre 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Precautions esses 12 Starting amp Stopping the Engine 13 Preparation ecce reete treten 13 Starting Procedure sssissniniiresenssuriiisss 13 Flooded Engine esses 13 How to Stop the Engine 14 Break in Guidelines sss 15 SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety
55. 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 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 Reinstall the diaphragm and reservoir cap Tighten the bolts to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m RU Brakes Other Inspection Make sure there are no fluid leaks 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 reg
56. RC valve pulley Install the seat 5 to the cable guide 6 while compressing the spring Tighten the adjuster 7 until the inner lock nut seats to the cylinder 8 Tighten the outer lock nut 9 securely cable guide adjuster cylinder outer lock nut Sree am 5 seat Servicing Your Honda 57 Reed Valve Refer to Safety Precautions on page 19 Reed Valve Removal 1 Remove the carburetor page 107 2 Remove the insulator 1 and reed valve 2 from the cylinder by removing the six carburetor insulator mounting bolts 3 3 Remove the gasket 3 carburetor insulator mounting bolts 1 insulator 2 reed valve 58 Servicing Your Honda Reed Valve Inspection Check the reed valves 1 for damage or fatigue and replace them if necessary 2 Replace the reed valve with new ones if the seats are cracked or damaged 1 reed valves Reed Valve Disassembly Assembly Remove the reed valve mounting screws 1 stopper 2 sub reed valve 3 reed valve 4 and the spacer 5 on one side of the reed valve 2 Align the cut outs 6 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 b spacer 6 cut out 3 Apply a locking agent to the reed valve mounting screw threads 4 Install and tighten the mounting screws to the specified torque 0
57. Remarks Pin spanner A To adjust shock spring preload or 3 scribe marks A two spanners required eS aftermarket parts Workstand A For maintenance L3 Optional 23 52 Ibf in 0 42 kgf mm EET Softer Air gauge For checking tire air pressure er 1 scribe mark Stiffer 25 76 Ibf in 0 46 kgf mm der 2 scribe marks The standard fork spring and shock spring 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 Technical Information 131 Spare Parts amp Equipment There are numerous spare parts you can take to an 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 and cotter pins 132 Technical Informatio
58. ab 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 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 4 Tighten the front bolt first 5 Check the torque of the upper holder bolts 2 16 Ibs ft 22 N m 2 2 kgf m ae a 1 handlebar 2 handlebar upper holder bolts 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 Additional Maintenance Procedures LEFT SIDE Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Torque Item Remarks Ibf ft N m kgf m ENGINE 1 Cylinder head nut 20 27 2 8 2 Cylinder mounting nut 29
59. abric 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 reduction 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 Tube Replacement If a tube is punctured or damaged you should replace it as soon as possible A repaired tube may not have the same reliability as a new one and it may fail while you are riding Use a replacement tube equivalent to the original Tire Replacement The tires that came on your CR were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions Front 80 100 21 51M Rear 110 90 19 62M Type 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 Tires amp Tubes 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 wi
60. ace the fork cap as an assembly if it is damaged 2 fork damper 4 fork cap assembly 3 Empty the fork oil from the fork damper 2 by pumping the damper and rod several times 2 2 fork damper 4 Clean the fork cap and fork damper threads 5 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork oil 5 W or equivalent Recommended Amount 6 6 US oz 195 cm 2 fork damper 6 Pump the fork damper piston rod 5 slowly several times to bleed the air from the fork damper 2 2 fork damper 5 piston rod Front Suspension Adjustments 7 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper 2 as shown Oil Level 1 65 1 85 in 42 47 mm 1 65 1 85 in E 42 47 mm 2 fork damper 8 Apply fork oil to the bushing and new O ring on the fork cap assembly 4 Extend the fork damper piston rod to maximum length and while holding it install the fork cap assembly to the fork damper 2 Be careful not to damage the fork cap bushing If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 2 4 fork cap assembly cont d 2 fork damper Adjustments for Competition 87 Front Suspension Adjustments 9 Tighten the fork cap 1 while hol
61. ain 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 The following suggestions may make your ride both more comfortable and more responsive to your control input Control Positioning Position the control levers so that you can use them comfortably when seated and standing Adjust the mounting bolts 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 torqu
62. ain 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 increasing your speed with better traction These gearing recommendations should be evaluated by considering your ability your riding style and the track Adjustments for Competition 111 Tire Selection for Track Conditions 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 f
63. aks coolant leaks Refer to Safety Precautions on page 19 The exhaust valves open and close according to 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 The exhaust valve system is a precision assembly Before beginning inspection decarbonizing please study the following text and illustrations carefully Before attempting complete disassembly we recommend you consult the service manual or your Honda dealer Mismatching of parts on reassembly can measurably affect engine performance Operating Inspection Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Warm up the engine to operating temperature 2 Stop the engine and remove the RC valve cover 3 Connect the tachometer 4 Start the engine and check that the RC valve pulley 1 is in the fully closed position 5 Increase the engine speed until about 8 000 rpm and check that the RC valve pulley turns to the fully open position 1 RC valve pulley 6 Disconnect the cables from the RC valve pulley Check that the exhaust valve turns smoothly If the exhaust valve does not turn smoothly remove the exhaust valve and decarbonize the RC valve 2 and valve shaft assembly 3 2 RC valve 3 valve shaft assembly 1 RC Valve Exhaust Valve Removal Remove the cylinder page 50 2 Remove the so
64. andlebar 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 Adjustments for Competition 113 114 Adjustments for Competition Tips Here s helpful advice on how to transport and Transporting Your Motorcycle 116 store your Honda as well as two troubleshooting Storing Your Honda sese 117 flow charts You amp the Environment eesess 118 Troubleshooting eene 119 Tips 115 Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda we recommend that you follow these guidelines Use a loading ramp Make sure the fuel valve is off e Secure the motorcycle in an upright position using motorcycle tie down straps Avoid using rope which can loosen and allow the motorcycle to fall over 116 Tips To secure your CR brace the front wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach to the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control
65. ase 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 3 feeler gauge 1 cylinder head 2 straight edge 52 Servicing Your Honda Piston Installation 1 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 y 3 hole 4 piston pin clip 1 piston pin 2 IN mark 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 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
66. ase the built up pressure in excess of normal atmospheric pressure 0 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 0 at sea level will increase as elevation increases Check spoke tension and rim lock nut security Check sprocket bolt and nut security 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 2 pressure release screws 26 Servicing Your Honda Be sure the fuel and oil is mixed well by agitating it thoroughly before pouring pre mix into the fuel tank 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 Handle fuel only outdoors 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 r
67. 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 drain bolt and radiator cap i Ned 1 drain bolt 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 2 stroke 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 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 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
68. 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 109 Check the fuel oil mixture carburetor and fuel system and ignition timing 5 Tighten the spark plug 4 If the old plug is good 1 8 turn after is seats f installing a new plug tighten it twice to prevent loosening a First tighten the plug NGK 3 4 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats 4 spark plug 6 Reinstall the sparkplug 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 1 Drain the radiator coolant page 39 2 Remove the seat and fuel tank page 29 30 3 Loosen the water hose clamp and remove the water hose 1 from the cylinder head 4 Disconnect the spark plug cap 2 and remove the spark plug 1 water hose 2 spark plug cap Cylinder System 5 Remove the upper engine hanger plate bolts and nuts 3 then remove the clamp 4 and hanger plates 5 7 Remove the cylinder head gasket 9 and dowel pins 10 3 hanger plate bolts and nuts 4 clamp 5 hanger plates 9 gasket 10 dowel pins 6 Remove the cylinder head nuts A 6 and cylinder head nuts B washers 7 using the techni
69. cket bolt 1 and stopper plate 1 socket bolt 3 4 2 2 stopper plate Remove the valve shaft assembly 3 from the cylinder Remove the cylinder cover 4 by removing bolts A 5 and bolts B 6 Remove the RC valve 7 and O rings 8 3 valve shaft assembly 6 bolts B 4 cylinder cover 7 RC valve 5 bolts A 8 O rings Servicing Your Honda 55 RC Valve 4 For ease of RC valve installation place the Exhaust Valve Cylinder Decarbonizing Valve Shaft Oil Seal Inspection cylinder upside down Set the RC valve 2 onto the cylinder cover 3 and O rings 4 to 1 Remove the carbon deposits from the valve Check the valve shaft oil seal 1 for wear or the cylinder shaft assembly 1 RC valve 2 cylinder port damage and cylinder cover Replace the oil seal if necessary Decarbonize the valve shaft assembly RC valve cylinder port and cylinder cover every 3 races 2 Inspect the RC valve valve shaft assembly for wear or damage 2 RC valve 4 O rings 3 cylinder cover 1 valve shaft oil seal 5 Install the cylinder cover carefully to the cylinder 6 Install the valve shaft assembly Make sure Exhaust Valve Assembly that the valve shaft and RC valve are aligned 7 Tighten the bolts A 5 and bolts B 6 to the 1 valve shaft assembly 1 Clean any gasket material from the mating specified torque surfaces of the cylinder and cylinder cover 9 Ibf ft 12 N m 1 2 kgf m 2
70. col 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 coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE 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 6096 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 is correct when it is at the bottom of the radiator filler neck 1 radiator cap A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out
71. conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride Servicing Your Honda 21 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 handgrip
72. connector 2 and remove the wire band 3 and clamp 4 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 cont d Adjustments for Competition 107 Carburetor Adjustments amp Tuning Tips 7 8 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 9 throttle cable 12 throttle valve spring 13 jet needle 14 throttle valve 108 Adjustments for Competition 10 Remove the carburetor to the left side Be careful not to damage around the throttle sensor Do not assemble or move the carburetor while holding the throttle sensor lead 11 Remove the float chamber screws 15 and float chamber 16 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel and flame away Handle fuel only outdoors Wipe up spills immediately e Stop the engine and keep heat sparks 17 float level gauge 15 15 float chamber screws 16 float chambe
73. d air cleaner case cover breather tube Servicing Your Honda 31 Subframe Removal Refer to Safety Precautions on page 19 4 Loosen the screw 5 on the air cleaner 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 2 Tighten the screw 1 on the connecting tube clamp 2 1 Remove the seat page 29 2 Remove the right side cover 1 by removing the bolt collar 2 im l b screw 6 connecting tube clamp 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 3 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 f
74. d in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between 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 23 Servicing Your Honda General Competition Maintenance Gaskets Always use new gaskets when reassembling components Spark Plug Cap Install a small plastic tie wrap around the spark plug cap to reduce
75. d 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 oz 5 cm Entire travel too soft Install the optional stiff spring Front end shakes Test stiffer compression damping adjustments in one click increments Fork bottoms over any type of terrain Increase rebound damping in one click increments 100 Adjustments for Competition Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff Stiff on small bumps while riding at full throttle in a straight line Stiff on small cornering bumps Front end wanders while riding at full throttle in a straight line Test softer compression damping adjustments in one click increments Reduce the rebound damping adjustments in one click increments Check for dirt in the dust seals Check the fork oil for any contamination f 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
76. damage occurs Engine Mounting Bolts Make sure the engine mounting bolts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Pro Honda Hondalock or an equivalent prior to torquing the nuts 24 Servicing Your Honda Fuel Filter Periodically drain the fuel from the tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 Fuel Contamination Periodically drain the float chamber and inspect the carburetor for contamination from dirt page 35 Inlet Tract Sealing Air leaks around the carburetor insulator and reed valve assembly should be cured by disassembling cleaning 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 Pressure Vacuum Leak Down Test Perform this test at regular intervals to minimize the possibility of engine damage from air leaks 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 4 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
77. ding the cut out of the fork damper 2 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 2 1 fork cap 3 lock nut wrench 2 fork damper 10 Hold the fork damper 2 in an upright position and pump the fork piston rod 5 to 3 9 in 100 mm slowly several times 3 9 in 100 mm 2 fork damper 5 piston rod 88 Adjustments for Competition 11 Screw in the lock nut 6 to the fork damper piston rod 5 fully 5 5 piston rod 6 lock nut Check the fork damper piston rod sliding surface for damage Apply fork oil to the fork damper piston rod sliding surface Cover the fork piston rod end with soft jaws to prevent fork damage NOTICE Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked 12 Drain the extra oil off to the fork damper 2 spring chamber 7 by pumping the fork damper piston rod to full stroke 2 fork damper 7 spring chamber 13 Drain the extra oil from the fork damper spring chamber oil hole By doing this procedure about 17 cm of fork fluid will be drained from the damper spring chamber through the oil hole and cause 178 cm of fork fluid to be left in the chamber 14 Blow out the oil from the fork damper spring chamber 7 using compressed air to the oil hole 8 Wipe the oil completely off the fork damper 7 spring chamber 8 oil hole 15 If y
78. e 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 pde Drive Chain Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda Chain Lube or an equivalent or SAE 80 or 90 gear oil is recommended Saturate each chain joint so that the lubricant penetrates the space between 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 1 retaining clip 2 master link 2 Clean the drive chain in high flash point solvent and allow it to dry 3 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 74 Servicing Your Honda 4 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
79. e is retained Tighten the top bolts first SS SSS 2 E UOY 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 e 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 e 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 3 mm forward or backward using optional handlebar lower holders Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment Personal Fit Adjustments 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 h
80. e lock nut to 11 Measure the length between the axle holder Install the fork center bolt to the fork damper the specified torque and outer tube piston rod aligning the center bolt adjusting 16 Ibf ft 22 N m 2 2 kgf m Standard 12 4 in 315 mm rod to the push rod Tighten the center bolt Compare the length 10 at assembly and at disassembly They should be the same length fully by hand If the length at assembly is longer than at disassembly check the center bolt and lock nut installation 2 lock nut 9 fork center bolt 2 lock nut 7 piston rod 5 stopper tool 8 O ring 6 push rod 9 fork center bolt 10 length 90 Adjustments for Competition Front Suspension Adjustments Fork Oil Capacity Standard 0 44 kgf mm Fork Spring a No mark factory products 12 Pour the recommended fork oil 11 into the outer tube slider 1 Optional Stiffer 0 46 kgf mm Fork Spring ea 2 scribe marks Recommended Oil Pro Honda HP Fork Oil 5W or equivalent 3 scribe marks E sorte ma parts Standard oil 13 2 US oz Standard oil 13 3 US oz capacity 389 cm capacity 394 cm Maximum oil 14 4 US oz Slightly stiffer as it Maximum oil 14 5 US oz Slightly stiffer as it capacity 425 cm nears full capacity 430 cm nears full compression compression Minimum oil 11 0 US oz Slightly softer as it Minimum oil 11 2 US oz Slightly softer as it capacity 826 c
81. e 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 Suspension Adjustments for Track Conditions 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 Adjustments for Competition 99 Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CR using the methods described on pages 82 99 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
82. ear If the wear is 3 16 in 5 mm or more replace 4 chain slider 6 Check the chain guide slider 5 for wear Replace the chain guide slider if it is worn to the bottom of the wear limit groove 6 5 chain guide slider 6 wear limit groove 7 Check the upper drive chain roller 7 and lower drive chain roller 8 for wear or damage Replace if necessary Upper roller 1 0 in 25 mm Lower roller 1 2 in 31 mm 7 upper drive chain roller 8 lower drive chain roller Install the upper and lower drive chain rollers if they were removed Upper and lower rollers 9 Ibf ft 12 N m 1 2 kgf m 8 7 upper drive chain roller 8 lower drive chain roller 8 Check the driven sprocket nut torque values after each race 24 Ibf ft 32 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 sides of the swingarm 6 P N 1 rear axle nut 4 index mark 2 lock nut 5 axle plate 3 adjusting bolt 6 reference marks 3 Tighten the rear axle nut to the specified torque 94 Ibf ft 128 N m 13 1 kgf m Recheck chain slack and adjust as necessary Loosen the adjusting bolt counterclockwise lightly until it touches the axle plat
83. ease screw 1 Check that the O ring 2 is in good condition Install the pressure release screw to the specified torque 0 9 Ibf ft 1 2 N m 0 1 kgf m WN 1 pressure release screws 2 O ring Front Suspension Damping Compression Damping Compression damping affects how quickly the fork compresses The compression damping adjuster has 16 positions or more Turning the adjuster screw one full turn advances the adjuster 4 positions Always start with the full hard position when adjusting damping 1 compression damping adjuster screw To adjust to the standard position 1 Turn the compression damping adjuster screw 1 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster screw counterclockwise 10 clicks This is the standard position 3 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 16 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 AO 7 2 rebound damping adjuster screw To adjust to the standard position 1 Turn the rebound damping adjuster screw 2 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster screw counterclockwise 14
84. ecessary 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 1 wheel rim 2 spoke 1 2 Wheel Rims amp Spokes 3 spoke nipple 4 rim lock nut Inspect the wheel rims 1 and spokes 2 for damage Tighten any loose spoke nipples 3 and rim lock nuts 4 to the specified torque Front spoke nipple 2 7 Ibf ft 3 68 N m 0 4 kgf m Rear spoke nipple 2 7 Ibf ft 3 7 N m 0 4 kgf m Rim lock nuts 9 Ibf ft 12 N m 1 2 kgf m Check wheel rim runout If runout is noticeable see the Honda Service Manual for inspection instructions Axles amp Wheel Bearings See the Honda Service Manual for inspection information 1 Check the axle for runout 2 Check the condition of the wheel bearings Servicing Your Honda 69 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
85. eck 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 kinked or chafed have it replaced 4 Check the cable 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 3 turns Clutch Lever Adjustment Cable end adjuster The distance between the tip of the clutch lever lt and the grip may be adjusted Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable is disconnected 3 cable end adjuster increase freeplay decrease freeplay 5 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
86. eene 20 IDSETUCLIOTS erect ertet 11 serial numbets eerte dense 122 L optional service parts SE uie Pre te e tse Era 131 CUSLOIIET rore tree E Pr EE Pneus 138 labels safety iie Ret ae er REIR ER eld 4 jure cir 131 manuals 12 2 E HERR EIEERURUS 136 locations component oxygenated fuels eee 128 SPpate DaELS cresce there tete Tees 132 maintenance ente ree eee eee 28 Spark knock nee 48 ODeFatlOn 1 eie eerta eee ter vibe ore host d 6 P spark plug logbook competition eee 129 maintenatce srera 48 pads Drake tenorem 68 PCAGUING sorrie Heredes 109 parts optional sessies 131 Specifications sisisi eee ies 123 personal fit adjustments esses 113 spring pre load rear suspension 95 PINGING engine eec eter tton ere 34 starting PLUS SDatk ence Presenter d 48 ursi 13 pre load rear suspension esses 95 troubleshooting eene 119 pre ride INSPECTION eee esee 9 steering stem inspection eseeeeeee 76 protective apparel eese 2 Stopping ehgirie creer tbe eer erre 14 SUOLA GE se EE 117 subtrame er rer eer seessvi se czserecetiseseees 32 142 Index suspension ITOBE 2 on erre rr rer rere eoe rre tact 60 eT 61 suspension adjustment TIO irent cri
87. emicenieaimeci 55 Reed Valve eee rrr rires noon 58 Servicing Your Honda Chassis Suspension eret Energie pre rote naga 60 Brake Saee ERR DERE EO ERE PREIS ERNS 65 WSLS e 69 Tires amp TUDES 5s esiscertirieve tremere pe ober a euo 70 Drive Chalilocen vanitate eme A 72 Expansion Chamber eese 75 Additional Maintenance Procedures 76 Appearance Calerie teet rrr ie enne 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 This section includes instructions on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can a
88. en How to Stop the Engine Break in Guidelines sss SERVICING YOUR HONDA Before You Service Your Honda The Importance of Maintenance Maintenance Safety esses Important Safety Precautions Maintenance Schedule usss General Competition Maintenance Before amp After Competition Maintenance Between Motos amp Practice Maintenance After Competition Maintenance 140 Table of contents 8 49 Service Preparations Maintenance Component Locations 28 Seat Removal ceneni anren 29 Fuel Tank Removal eee 30 Subframe Removal esee 32 Service Procedures Fluids amp Filters Fuel System eere ere 34 Transmission Oll snnne 36 Colatear meN ENS 38 Air Cleaner nene enne 40 Engine Throttle rire ri e Rr REI EE PECES 42 Clute h Syste M e eene tret retenti rper 44 Spark PLUG ss ccssiccedivesceveerssessveek ceostereetevste iisa 48 Cylinder System eese 49 RC ValVei iicet iren aie p e E EIE PERPE CRY 55 Reed Val Ve i ecesiessecens cette eibi Dena tee nena 58 Chassis SUSPENSION E 60 BEAK CS LE 65 WBeels ecce meten E E EE RCREE EI 69 Tires amp TUDES ien cise e rtr ree nnn eoi eene 70 Drive Chal asco tints bebes
89. ension adjustment 100 between motos amp practice sss 26 Rider s Club Honda esses 139 compornent locations eeeeeee 28 riding H general competition eese 22 apparel nuce rette tei e erae 2 IMPONE Asiei ier eiia ian 18 basic Operation iere retinentes 11 handlebar inspection esee 76 cuc 19 aj c 7 high altitude carburetor adjustment 127 schedul rer teret teretes 20 important safety information 2 Honda manual Service eerie ee tees 136 safety precautiorns eerte teorie 2 CODLaCUIg cierres ertet tr eei or Ron a 137 IOdIfICations serie eter ee rerit nione erede npa 3 Rider s Club entes 139 S Service Manual ees 136 O yout dealer 5 terere 138 safety oil important information seeeseeeeene 2 I i qe 62 important precautions 2 transmission e e iere ere tetris 36 labels oie rtt eerte eed 4 identification vehicle sesssss 122 operation compornent locations 6 mainternanc eerte eerte 19 idle speed engine sses 106 operating riding precautions eese 12 inspection pre ride sssrini 9 tone 5 schedule maintenance
90. er s manual This vehicle is designed manufactured and sold for competition use only It does not conform to Federal Motor Vehicle Safety Standards or U S EPA Noise and Emissions Standards Operation on public streets roads highways or for off road recreation is illegal State and Federal laws prohibit operation of this vehicle except in an organized racing or competitive event on a closed course Or by permit issued by the local governmental agency having jurisdiction D NEVER OPEN WHEN HOT Hot coolant will burn you D NE JAMAIS OUVRIR A CHAUD Le liquide risque de vous br ler b BUBIT SS 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 front brake lever throttle grip clutch lever engine stop button choke knob kickstarter T IFS isd PB A D Y A a Ae TSS 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 oo eee eeeesceseceseee
91. erienced 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 If you purchased an off road motorcycle ATV or PWC your benefits do not include roadside assistance or trip interruption protection The Honda Rider s Club USA only Contact your Honda dealer for more information or call 1 800 847 4722 or log on to www hrca honda com Consumer Information 139 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 Safety LabelS ottenere tees OPERATING CONTROLS Operation Component Locations BEFORE RIDING e eeeeee eene ennt Are You Ready to Ride esses Is Your Motorcycle Ready to Ride Pre ride Inspection esesssss BASIC OPERATING INSTRUCTIONS Safe Riding Precautions esses Starting amp Stopping the Engine Preparation enansa etr ete s Starting Procedure seeses Blooded Brgine utente e
92. fter washing rinse your CR thoroughly with plenty of clean 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
93. g Service Limit 1 76 in 44 7 mm 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 Disc Plate Cover Installation 1 Coat the clutch discs 1 and plates 2 with transmission oil 2 Install the eight clutch discs and seven clutch plates five aluminum plates and two steel plates 3 alternately starting with a clutch disc OUT SIDE 1 1 clutch discs 3 clutch steel plates 2 clutch plates 3 Apply grease to the clutch lifter rod 4 4 Insert the clutch lifter rod into the mainshaft 5 Install the clutch lifter 5 onto the rod 4 clutch lifter rod 6 Install the clutch pressure plate 6 7 Install the six clutch springs and bolts 7 8 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 10 N m 1 0 kgf m 7 clutch spring bolts 6 clutch pressure plate Clutch System 9 Install a new O ring 8 in the groove of the clutch cover 9 10 Install the cover by tightening the six cover bolts to the specified torque 9 Ibf ft 12 N m 1 2 kgf m 8 O ring 9 clutch cover 11 Lubricate the rear brake pedal pivot 10 and pivot bolt 11 with Pro Honda White Lithium Grease or an equivalent and install the pivot bolt and washer 12 Tighten the bolt to the specified torque 27 Ibf ft 36 N m 3 7 kgf m Connect the brake pedal return spring 13
94. han conditions warrant Remember that alcohol drugs illness and fatigue 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 own
95. hat 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 866 784 1870 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 product model year and VIN date of purchase dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 137 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 repairs 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 138 Cons
96. he RC valve cover and clamp 13 tighten the bolts 14 to the specified torque 3 7 Ibf ft 5 N m 0 5 kgf m 11 gasket 12 RC valve cover cont d Servicing Your Honda 53 Cylinder System Cylinder Head Installation 1 Clean the cylinder head mating surface and install the dowel pins 1 2 Install the new cylinder head gasket 2 with its UP mark 3 facing up and locating tab 4 facing rearward 1 dowel pins 2 cylinder head gasket 3 UP mark 4 tab 3 Install the cylinder head 5 and tighten the cylinder head nuts A 6 and cylinder head nuts B washers 7 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 7 cylinder head nuts B 6 cylinder head nuts A washers 54 Servicing Your Honda 6 Install the clamp 8 hanger plates 9 and tighten the nuts 10 to the specified torque Engine side 40 Ibf ft B4 N m 5 5 kgf m Frame side 25 Ibf ft 34 N m 3 5 kgf m Connect the water hose 11 to the cylinder head Install the spark plug and spark plug cap 12 8 clamp 11 water hose 9 hanger plates 12 spark plug cap 10 nuts 7 Pour the recommended coolant mixture into 8 the radiator up to the correct level page 38 Install the fuel tank and seat page 29 30 9 Start the engine and check for the following compression leaks abnormal engine noise secondary air le
97. he 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 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 you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits I I 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 yo
98. ide the outer tube down onto the lower end of the slider 4 1 outer tube 6 guide bushing 5 dust seal 7 slider 3 Pour the fork oil from the outer tube 1 Pour the fork oil from the oil hole 8 of the fork damper 1 outer tube 2 fork damper 3 lock nut wrench 4 slider lower end 1 outer tube 8 oil hole 62 Servicing Your Honda 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cm of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube Amount of fork oil left in the fork within damper and spring minute unit cm 5 10 20 35 55 85 145 Ch F 30 86 27 15 3 10 6 94 83 79 7 9 20 68 29 4 16 5 11 8 106 9 4 82 82 10 50 28 2 21 2 16 5 15 3 12 9 11 8 11 8 0 32 30 6 22 4 18 8 16 5 16 5 15 3 14 1 SS eee We ee ee ee a rn 0 20 40 60 80 100 120 140 160 Inverted time minutes 5 Pour the recommended fork oil into the outer tube 1 1 outer tube Suspension Fork Oil Capacity Standard 0 44 kgf mm Fork Spring No mark factory products d 3 scribe marks aftermarket parts Optional Stiffer 0 46 kgf mm Fork Spring 2 scribe marks Optional Softer 0 42 kgf mm F
99. if it was removed 10 brake pedal pivot 12 washer 11 pivot bolt 13 return spring 12 Add the transmission oil page 37 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 Standard BR9EG N 8 NGK Use only the recommended type of spark plug in the recommended heat range NOTICE 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 0 027 0 031 in 0 7 0 8 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
100. 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 NOTICE 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 3 3 side electrode 1 insulator 2 center electrode Spark Plug Coloring Guidelines Condition Spark Plug Appearance Mixture Normal Dark brown to light tan correct color with dry electrode Overheating Lean Light gray or white color lean Wet Wet or sooty rich Rich Remember that in addition to improper jetting e A lean condition can be caused by air leaks in the inlet tract in the center crankcase joint and leaking ignition side crank seal e 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
101. ion high speed compression damping adjuster rear suspension low speed compression damping adjuster A AY rear suspension spring DA front suspension _ AD pre load adjuster or compression damping KS air cleaner adjuster ZSA A Hl A i ST ya i 7 22 rear brake SS ie l fluid reservoir SN lt S drive chain NV F a rear brake RA caliper Z N EN A KEY front brake caliper transmission Tansmission oil check bolt oil filler cap A ume a carburetor front suspension rebound front Suspension Tm i rebound damping adjuster transmission oil drain bolt rear suspension rebound damping adjuster rear brake pedal damping adjuster 28 Servicing Your Honda Refer to Safety Precautions on page 19 Installation 1 Slide the seat front prong 4 onto the seat Removal bracket 5 and the seat rear prong 6 onto 1 Remove the seat bolts 1 and collars 2 the tabs 7 by pushing down and forward on 2 Slide the seat 3 back 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 1 seat bolts 3 seat 2 collars 4 5 6 7 seat front prong seat bracket seat rear prong tabs eer No a A 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 va
102. is Lithium Grease or an equivalent to the 7 and install the assembly into the air securely attached sealing surface cleaner housing 8 while aligning the tab 9 9 Assemble the air cleaner and holder on the air cleaner and the reference mark 10 Insert the pin 5 to the hole 6 and the air on the air cleaner housing Tighten the cleaner retaining bolt through the assembly retaining bolt securely Carefully position the sealing flange of the element to prevent dirt intrusion NOTICE 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 5 pin 6 hole 4 3 air cleaner 8 air cleaner housing 4 air cleaner holder 9 tab 5 pin 10 reference mark 7 air cleaner housing hole Servicing YourHonda 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 3 lock nut increase decrease 4 upper adjuster 2 3 Pull the rubber dust cover 2 back Loosen the upper lock nut 3 on the throttle cable mechanism Turn the upper adjuster 4 Turning the adjuster in direction
103. ition 89 Front Suspension Adjustments 4 Set the lower end axle holder of the slider in 8 Make sure that there is clearance between the 10 Apply fork oil to the fork center bolt 9 O a vise with a piece of wood or soft jaws to lock nut 2 and center bolt 9 ring avoid to damage Clearance 0 06 0 08 in 1 5 2 0 mm Remove the special tool or mechanic s stopper tool while applying pressure to the NOTICE If the clearance is out of specification check the fork damper lock nut and center bolt installation Install the center bolt to the axle holder and Do not overtighten the axle holder tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 5 Temporarily install the fork damper to the 2 fork PE ai Push out the fork damper piston rod from the axle holder of the slider by pushing the fork 0 06 0 08 in damper 1 5 2 0 mm Apply pressure to the fork damper and insert the special tool or mechanic s stopper tool 5 9 between the axle holder and lock nut 2 Measure the thread length again Standard 0 43 0 51 in 11 13 mm 6 Install the push rod 6 into the piston rod 7 until it stops Check the push rod installation 2 lock nut 9 center bolt by turning the push rod right and left 9 fork center bolt 7 Install the new O ring 8 to the fork center 9 Tighten the lock nut 2 to the fork center bolt bolt 9 9 closely by hand Tighten th
104. itions 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 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 spar
105. 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 choke knob 2 starter jet 3 air passage 4 orifice Carburetor Adjustments amp Tuning Tips 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 providing 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 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 fue
106. k damper piston rod If the lock nut is removed the piston rod will fall in the fork damper and you cannot reassemble the fork damper 25 O 53 aii De 25 axle holder 26 fork center bolt 27 stopper tool 28 lock nut 23 Remove the push rod 29 from the fork damper 24 Remove the special tool or mechanic s stopper tool between the axle holder 25 and lock nut 28 while applying pressure to the fork cap NOTICE Be careful not to damage the lock nut and fork center bolt hole 86 Adjustments for Competition 25 axle holder 28 lock nut 27 stopper tool 29 push rod 25 Remove the fork damper assembly 30 from the fork assembly 31 Remove the fork from the vise Remove the fork spring 32 from the fork damper d ws 30 fork damper assembly 31 fork assembly 32 fork spring Damper Oil Change 1 fork cap 3 lock nut wrench 2 fork damper NOTICE Check the lock nut installation If the lock nut is removed the piston rod will fall in the fork damper and you cannot reassemble the fork damper 1 Loosen the fork cap 1 by turning the fork damper 2 using the lock nut wrench 3 Make sure the compression damping adjuster is set the softest position 2 Remove the fork cap assembly 4 from the fork damper 2 Be careful not to damage the fork cap bushing Do not disassemble the fork cap assembly Repl
107. k plug are highly indicative of the engine condition Refer to the list on page 131 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 Adjustments for Competition 105 Carburetor Adjustments amp Tuning Tips Carburetor Minor Adjustments e 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 104 and 105 Confirm your settings are correct before proceeding Minor Adjustments 1 Adjust the carburetor setting using the turning information on page 104 and 105 2 When the engine is warm enough to run without the choke push the choke knob down to its off position 3 Loosen the lock nut 1 and turn the throttle stop screw 2 to obtain the smoothest idle To decrease idle speed turn the screw counterclockwise To increase idle speed turn the screw clockwise 4 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 5 Adjust the air screw 3 to obtain the best off idle performance If the engine blubbers rich exiting a co
108. l 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 CR250R jets cont d Adjustments for Competition 103 Carburetor Adjustments amp Tuning Tips Jet Needle The jet needle controls fuel air mixture from fully closed 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 as LEANER 2nd 3rd 2 4th a x RICHER 0 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 2 turns out Slow jet 40 Jet needle 6DGY26 65 Needle clip position 3rd groove Main jet 420 Float level 0 30 in 7 5 mm Identification number TMX11A
109. l also find important safety precautions information on oils and tips for keeping your CR looking good An ECU Engine Control Unit 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 136 An optional tool kit may be avaiable Check with your Honda dealer s parts department Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety sess 19 Important Safety Precautions 19 Maintenance Schedule ssss 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 ence ree e EAE ERI 29 Fuel Tank Removal eeeeee 30 Subframe Removal sene 32 Service Procedures Fluids amp Filters Fuel System ertet eterne 34 Transmission Oil seee 36 Coolant ctr erra reri TER 38 Aut Cleaner uenerat rr ir oy Er eaa 40 Engine Throttlez ceo veh T ERE 42 Clutch System iie estet ener eint 44 Spark Plug reete serves 48 Cylinder System eee 49 RC ValVeiscciiosetuenecameant
110. l check bolt and filler cap Repeat steps 1 4 After inspecting the oil level or adding oil tighten the oil check bolt and filler cap securely and oil check bolt to the specified torque 7 Ibf ft 10 N m 1 0 kgf m Transmission Oil Replacing Transmission Oil 1 Run the engine for three minutes then shut it off 2 Support the CR in an upright position on a level surface 3 Remove the oil filler cap from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the drain bolt 1 5 Pour the drained oil into a suitable container and dispose of it in an approved manner page 118 NOTICE 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 7 Add the recommended oil 0 69 US qt 0 65 at oil change 8 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 gly
111. lastic 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 can 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 suspension settings chassis adjustments tested and selected gearing tire se
112. le in softer and stiffer types than the standard rate page 131 The inverted fork on your CR features sealed damper cartridges with dual separate air and oil chambers to prevent aeration The design also isolates the oil in each fork tube slider which may contain air bubbles and or metal particles from the sealed cartridge to provide more consistent damping 1 compression damping adjuster 2 rebound damping adjuster 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 0 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 Remove the pressure rel
113. lection air pressure Competition Records your placings thoughts to improve performance next time both yours and your CR s strategy notes Maintenance Records regular interval maintenance repairs 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 running 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 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 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 main
114. ll 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 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 2 1 drive chain slack 2 drive sprocket 3 driven 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 NOTICE 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 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 w
115. lve 1 Removal 6 Unhook the air cleaner case cover 6 10 Remove the fuel tank 1 Turn the fuel valve 1 OFF 7 Unhook and remove the fuel tank band 7 8 Remove the fuel tank bolt 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 m 5 breather tube 2 Remove the seat page 29 6 air cleaner case cover 3 Remove the shroud A bolts collars 2 7 fuel tank band 4 Remove the shroud B bolts collars 3 and 8 fuel tank bolt shrouds 4 4 oS 3 1 fuel valve 9 fuel line S YE 2 2 shroud A bolts collars 3 shroud B bolts collars 4 shroud 30 Servicing Your Honda Fuel Tank Removal Installation 7 Install the shrouds 7 and shroud B bolts 1 Install the fuel tank on the frame collars 8 2 Connect the fuel line 1 to the fuel valve 2 8 Install the shroud A bolts collars 9 YW for aS WW PC 9 1 fuel line 7 shroud 2 fuel valve 8 shroud B bolts collars 9 shroud A bolts collars Install the fuel tank bolt 3 Hook the fuel tank band 4 9 Install the seat page 29 Hook the air cleaner case cover 5 Put the breather tube 6 in the steering stem nut QN UA RR CS 8 4 5 6 fuel tank bolt fuel tank ban
116. m nears full capacity 331 cm nears full compression compression Be sure the oil capacity is the same in both fork Optional Softer 0 42 kgf mm Fork Spring legs 1 outer tube slider 11 fork oil 13 Install the fork damper as described in Damper Oil Change page 86 88 93 1 scribe mark S Standard oil 13 5 US oz capacity 399 cm Maximum oil 14 7 US oz Slightly stiffer as it capacity 435 cm nears full compression Minimum oil 11 4 US oz Slightly softer as it capacity 336 cm nears full compression Adjustments for Competition cont d 91 Front Suspension Adjustments 14 Check that the O ring 12 on the fork damper assembly 4 is in good condition Apply the recommended fork oil to the O ring 4 12 Qe 1 outer tube slider 4 fork damper assembly 12 O ring 92 Adjustments for Competition 15 Temporarily thread the fork damper 4 into the outer tube 1 Insert both fork legs into the fork clamps Align the groove in the outer tube with the top surface of the upper fork clamp If installing the optional 20 inch wheel align the top of the outer tube not the top of the fork cap with the top surface of the upper fork clamp 16 Temporarily tighten the fork lower pinch bolts 13 and then tighten the fork damper 4 to the specified torque using the lock nut wrench Actual 25 Ibf ft 34 N m 3 5 kgf m Torq
117. mixture page 38 slowly into the radiator filler hole up to the filler neck Capacity 1 16 US qt 1 102 at disassembly 1 02 US qt 0 97 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 117 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 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
118. n Additional Spares brake master cylinders front amp rear brake assemblies front amp rear wheels amp tires front amp rear mounted clutch plates amp transmission oil seat ignition components top end complete radiator hoses radiator shrouds left amp right 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 type hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment U S A 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 50 mm O7WMA KZ30100 piston base 07958 2500001 fork rod stopper O7AMB KZ3A100 U S A only Chemical Products Pro Honda HP Trans Oil or Pro Honda GN4 4 stroke oil Pro Honda HP Fork Oil 5W Pro Honda HP2 2 stroke Oil Pro Honda HP Coolant Pro Honda DOT 4 Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda brite Cleaner Honda Contact Cleaner Honda Dielectric Compound Pro Honda Handgrip Cement Pro Honda Hondalock Honda Moly 60 Paste U S A only
119. n 391 1 cm Gear ratio 1 800 Fuel capacity 2 0 US gal 7 7 liter seat Lar Caster angle 27 08 Gear ratio IV 1 000 Trail length 4 4 in 111 7 mm Gear ratio V 0 869 Fork oil capacity except fork damper 13 3 US oz 394 cm per leg Technical Information 123 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts fasteners before every outing Engine LEFT SIDE 124 Technical Information Torque Item Remarks Ibf ft N m kgf m ENGINE Cylinder head nut 20 27 2 8 Cylinder mounting nut 29 39 4 0 Carburetor insulator bolt 9 12 1 2 Clutch cover bolt 9 12 12 Water pump cover bolt 9 12 12 RC cover bolt 3 7 5 05 Frame Torque Specifications Torque Item Remarks Ibf ft Nem kgf m FRAME 1 Steering stem nut 80 108 11 0 2 Fork bridge upper pinch bolts 16 22 2 2 3 Fork bridge lower pinch bolts 15 20 2 0 4 Handlebar upper holders 16 22 2 2 5 Handlebar lower holder nut 32 44 4 5 6 Front axle nut 65 88 9 0 7 Front axle pinch bolts 15 20 2 0 8 Rear axle nut 94 128 13 1 NOTE 4 9 Chain adjuster lock nut 20 27 2 8 NOTE5 10 Engine mounting bolts 40 54 5 5 11 Engine hanger plate bolt Engine side 40 54 5 5 12 Engine hanger plate bolts Flame side 25 34 3 5 13 Shock abso
120. nd on good traction surfaces However 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 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 power This may require an extra upshift on certain sections or perhaps you can just rev it out a bit longer Gearing 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 maint
121. neeeees 8 Is 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 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 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 the following items page numbers are at the right A WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously h
122. nical skill 3 Replace after the first break in ride Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary clean lubricate replace Ara Maintenance Schedule Perform the Pre ride Inspection at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace Frequency Each race Every 3 races Every 9 races or about or about or about Ref page Items 2 5 hours 7 5 hours 22 5 hours Throttle Operation l 42 Air Cleaner C 40 48 38 39 Cylinder Head Decarbonizing 51 Spark Plug Radiator Coolant Cooling System Exhaust Valve and Linkage Decarbonizing 56 Piston and Piston Ring 51 Piston Pin and Connecting Rod Small End Bearing Reed Valve Only 58 Transmission Oil 36 Drive Chain 72 Drive Chain Sliders 72 Drive Chain Rollers 73 Drive Sprocket 74 Driven Sprocket 74 Brake Fluid 66 Brake Pad Wear 68 Brake System 65 Clutch System 44 Control Cables 76 Expansion Chamber Silencer 75 Suspension Swingarm Shock Linkage Fork Tube Slider Damper Fork Oil Nuts Bolts Fasteners Wheels Tires Steering Head Bearing This maintenance schedule is based upon average riding condition Machines subjected to severe use require more frequent servicing NOTE 1 Clean after every moto for dusty riding
123. nstall the number plate 25 by aligning its hole 26 with the tab 27 on the steering stem 25 number plate 26 hole 27 tab 94 Adjustments for Competition 26 Install and tighten the number plate bolt 28 Install the handlebar pad 29 A 28 number plate bolt 29 handlebar pad 27 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 28 First tighten the left axle pinch bolts 30 alternately While keeping the forks parallel alternately tighten the right axle pinch bolts to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 30 axle pinch bolts NOTICE To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 29 Clean the threads of the disc cover bolts and axle holder thoroughly 30 Apply locking agent to the disc cover bolt threads 31 Install the disc cover 31 and tighten the disc cover bolts 32 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m 31 disc cover 32 Turn the compression and rebound damping adjusters back to their original settings 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 at
124. odel 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 61KSK52 2007 CR250R Service Manual 48 00 61CM002 Common Manual 48 00 31KSK630 2007 CR250R 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 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 Price Total Each Price Publication Item No Item Description Qty Prices are subject to change without notice and Sub Total Purchaser s Sales Tax Mich Add 6 Calif Add 8 25 without incurring obligation Handli Orders are mailed within 10 days Please allow Cages 5 00 adequate time for delivery Grand Total
125. ompression damping adjustments in one click increments until the desired initial travel compression damping is obtained Lower the oil level by 0 2 oz 5 cm Entire travel too stiff Stiff suspension on any type of terrain Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Lower the oil level by 0 2 oz 5 cm Adjustments for Competition 101 Suspension Adjustment Guidelines 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 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 Mud track Adjust to a stiffer position 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 Reduce standard Race Sag 0 2 to 0 4 in 5 to 10 mm Symptoms and Adjustment Always begin with the standard settings Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 6 turn increments
126. on 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 4 connecting rod small end bearing 5 piston ring 4 Spread the piston ring 5 and remove by lifting it up at a point just opposite the gap NOTICE The piston ring may be damaged if the ends are spread too far 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 replace the piston pin and small end bearing 1 small end bearing 2 piston pin 3 Place the shop towel back in the crankc
127. onda dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank 34 Servicing Your Honda NOTICE Too much 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 Fuel Oil 32 1 Gallons Liters Ounces cm 0 5 1 89 2 0 59 1 0 3 79 4 0 118 1 5 5 68 6 0 177 2 0 7 57 8 0 237 2 5 9 46 10 0 296 3 0 11 36 12 0 355 3 5 13 24 14 0 414 4 0 15 14 16 0 473 4 5 17 03 18 0 532 5 0 18 92 20 0 591 5 5 20 81 22 0 651 6 0 22 71 24 0 710 Refueling Procedure Fuel Tank Capacity 2 0 US gal 7 7 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
128. or Track Conditions 99 Suspension Adjustment Guidelines 100 Carburetor Adjustments amp Tuning Tips 103 Chassis Adjustments eee 110 SD sestes 111 Tire Selection for Track Conditions 112 Personal Fit Adjustments sss 113 d Uu eT MN 115 Transporting Your Motorcycle 116 Storing Your Honda esee 117 You amp the Environment esses 118 Troubleshooting eee 119 TECHNICAL INFORMATION 121 Vehicle Identification sess 122 Specifications eet ette iseng 123 Torque Specifications ssesesss 124 High Altitude Carburetor Adjustment 127 Oxygenated Fuels esee 128 Competition Logbook esses 129 Optional Parts List eee 131 Spare Parts amp Equipment ssss 132 Wiring Dia Stain sis eee rennen nass 133 CONSUMER INFORMATION 135 Authorized Manuals esee 136 Contacting Honda seen 137 Your Honda Dealer sess 138 The Honda Rider s Club USA only 139 TABLE OF CONTENTS eee 140 INDEX Q 141 QUICK REFERENCE Motorcycle Safety This section presents some of the most impor
129. or 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 112 Adjustments for Competition 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 terr
130. ork Spring E 1 scribe mark Standard oil 13 5 US oz capacity 399 cm Maximum oil 14 7 US oz Slightly stiffer as it capacity 435 cm nears full compression Minimum oil 11 4 US oz Slightly softer as it capacity 336 cm nears full compression Standard oil 13 2 US oz Standard oil 13 3 US oz capacity 389 cm capacity 394 cm Maximum oil 14 4 US oz Slightly stiffer as it Maximum oil 14 5 US oz Slightly stiffer as it capacity 425 cm nears full capacity 430 cm nears full compression compression Minimum oil 11 0 US oz Slightly softer as it Minimum oil 11 2 US oz Slightly softer as it capacity 326 cm nears full capacity 331 cm nears full compression compression Be sure the oil capacity is the same in both fork legs cont d Servicing Your Honda 63 Suspension 6 Check that the O ring 9 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring 2 fork damper 9 o ring 7 Tighten the fork damper using the special tool to the specified torque 25 Ib ft 34 N m 3 5 kgf m 64 Servicing Your Honda 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 b
131. ou can not use compressed air remove the pressure release screw 9 on the fork cap 10 Turn the fork damper upside down for 10 minutes and drain the oil from the fork damper spring chamber 9 pressure release screw 10 fork cap Front Suspension Adjustments Amount of fork oil left in the fork 2 Tighten the lock nut 2 fully by hand and Fork Assembly without damper and spring unit cm measure the thread length minute Standard 0 43 0 51 in 11 13 mm 1 Drain the fork oil from the outer tube slider SCPE d E sd Abd DD a 1 by placing it upside down 3086 7 1 59 4 7 42 35 35 3 5 Wipe the oil completely off the fork damper About 7 cm of fork oil will be left in the 20 68 10 6 82 7 1 59 56 47 47 outer tube slider when it is left inverted for 1050 11 8 83 72 62 58 49 48 about 20 minutes at 20 C 68 F 0 32 12 9 10 6 9 4 82 7 9 7 1 5 9 o 3 2 2 16 0 C 32 F 2 14 10 C 50 F 30 C 86 F 0 43 0 51 in Amount of fork oil j 11 13 mm 2 2 lock nut 0 A LLL 1 M A aie S ER POR 3 Wipe the oil completely off the fork spring 7 Uy o Install the fork spring to the fork damper 1 outer tube slider Install the fork damper 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 fork spring cont d Adjustments for Compet
132. our CR is a high performance 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 NOTICE 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 adj
133. out of the wheel hub and remove the front wheel 11 b Nx 9 axle nut 10 axle pinch bolts 11 front axle shaft 8 Remove the fork protector bolts 12 brake hose clamp bolts 13 and fork protectors 14 9 Remove the brake caliper bolts 15 and brake caliper 16 NOTICE 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 12 fork protector bolts 15 brake caliper bolts 13 brake hose clamp bolts 16 brake caliper 14 fork protectors 10 Loosen the fork leg lower pinch bolts 17 then pull the fork legs down and out 17 lower pinch bolts 11 Clean the fork assembly especially the sliding surface of the slider 18 and dust seal 19 NOTICE 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 NO GOOD 20 18 slider 19 dust seal 20 outer tube 21 guide bushing 12 Record the compression and rebound damping adjuster positions and turn the adjusters counterclockwise until they stop 13 Measure the length 22 between the axle holder and outer tube and record it before disassembling the fork 22 length 14 Hold the outer
134. que described below and remove the cylinder head 8 To avoid warping the cylinder head use a crisscross pattern to loosen each nut about 1 4 then remove the nuts 8 cylinder head 6 cylinder head nuts A 7 cylinder head nuts B washers Servicing Your Honda 49 Cylinder System 3 4 Loosen the lock nuts 6 and disconnect the 9 Remove the cylinder 15 by removing the Cylinder Removal RC valve control cables 7 from the RC four flange nuts 16 valve pulley 8 Remove the expansion chamber page 75 2 Remove the exhaust gasket 1 S 6 lock nuts 8 RC valve pulley 15 cylinder 16 flange nuts 1 exhaust gasket 7 control cables 3 Remove the bolts 2 clamp 3 RC cover 4 10 Remove the gasket 17 and dowel pins 18 and gasket 5 5 Loosen the radiator hose clamp screw 9 and uu z 1 disconnect the radiator hose 10 6 Remove the radiator grills 11 on both sides 7 Loosen the upper mounting bolts 12 on both sides 8 Remove the lower mounting bolts 13 then swing the radiators 14 forward on both sides 2 bolts 3 clamp 17 gasket 18 dowel pins 9 screw 12 upper mounting bolt 10 radiator hose 13 lower mounting bolt 11 radiator grill 14 radiator 50 Servicing Your Honda Piston Removal 1 Place the shop 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 pist
135. r 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 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 20 air vent hoses 21 overflow hose Carburetor Adjustments amp Tuning Tips 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 simply turn off the engine and pull the plug for inspection Use a new spark plug Inspect the plug before installing it NOTICE 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
136. r in 1 12 turn increments 1 high speed damping adjuster 2 low speed damping adjuster 96 Adjustments for Competition 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 3 1 2 turns or more To adjust to the standard position Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 2 5 12 2 11 12 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 13 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4 positions To adjust to the standard position Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 7 clicks and the punch marks are aligned Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 17 positions or more Turning the adjuster one full turn advances the adjuster 4 positions Rebound damping can be increased by turning the adjuster clockwise 3 rebound damping adjuster To adjust to the standard position Turn the adjuster clockwise until it will no
137. rake pads for wear 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 is 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 LESS THAN 0 8 in 20 mm 1 lock nut 2 adjuster 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 If the brake lever freeplay exceeds 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding 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
138. rber upper 32 44 4 5 NOTE 4 lower 32 44 4 5 NOTE 4 14 Swingarm pivot nut 65 88 9 0 NOTE 4 15 Fork fork damper 25 34 3 5 fork cap 22 30 3 1 16 Rear shock arm swingarm side 39 53 5 4 NOTE2 4 shock link side 39 53 5 4 NOTE 2 4 17 Rear shock link nuts Frame side 39 53 5 4 NOTE 2 4 18 Shock spring lock nut 32 44 4 5 19 Kickstarter arm bolt 28 38 3 9 20 Front brake master cylinder holder 7 3 9 9 1 0 21 Brake hose bolts 25 34 3 5 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 125 Torque Specifications Frame Torque Item Remarks Ibf ft N m kgf m FRAME 22 Caliper mount bolts 22 30 3 1 NOTE 1 23 Front brake disc nuts 12 16 1 6 NOTE 4 24 Rear brake disc nuts 12 16 1 6 NOTE 4 25 Brake pedal pivot bolt 27 36 37 26 Spokes front 2 7 3 68 0 4 rear 2 7 3 7 04 27 Rim locks 9 12 1 2 28 Subframe bolt upper 22 30 3 1 lower 22 30 3 1 29 Fork center bolt 51 69 7 0 30 Fork center lock nut 16 22 2 2 31 Disc cover bolt 10 13 1 3 32 Fork protector bolts 5 2 7 0 7 NOTE 1 33 Sprocket nuts 24 32 3 3 NOTE 4 d RY 34 Seat mounting bolts 20 27 2 8 7 f Wo a ANA 35 Front brake reservoir A US tos Gop S
139. rement or turns described in pages 96 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 96 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 If you have a problem finding an acceptable should be no movement If there is have the adjustment return to the standard position and bearings replaced by your Honda dealer begin again Servicing Your Honda 61 Suspension NOTICE Recommended Fork Oil 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 viscosity weight 5 W suggested oil Pro Honda HP Fork Oil or equivalent Fork Oil Change Refer to Suspension Removal on page 83 1 Clean the fork assembly especially the sliding surface of the slider and dust seal 2 Hold the outer tube 1 then remove the fork damper 2 from the outer tube using a lock nut wrench 3 Gently sl
140. riple clamp bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt 124 Before Riding 9 10 Before Riding This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions sessss 12 Starting amp Stopping the Engine 13 Preparation reete ennt 13 Starting Procedure sess 13 Flooded Eng nmt 13 How to Stop the Engine 14 Break in Guidelines sss 15 Basic Operating Instructions Basic Operating Instructions 11 Safe Riding Precautions Before riding your CR for the first time please review the Important 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
141. rise in performing maintenance Only you can decide whether or not you should perform a given task A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this owner s manual Important Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the 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 Maintenance Safety Servicing Your Honda 19 Maintenance Schedule To maintain the safety and reliability of your CR regular inspection and service is required as shown in
142. rner 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 106 Adjustments for Competition 1 lock nut increase 2 throttle stop screw decrease 3 air screw The minimum to maximum range of air screw adjustments is 1 to 3 turns out from the lightly seated position If you exceed 3 turns out the next smaller slow jet is needed If you are under turn out the next larger slow jet is needed Adjustment Procedure 1 Warm up the engine 2 Make 2 3 laps of a course with the standard setting or corrected jetting page 104 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 48 109 It may take more than 2 3 laps to get a good spark plug reading with a new spark plug 3 Change carburetor settings or select suitable carburetor jets taking into consideration the engine conditions and factors for temperature and altitude page 104 4 If you 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
143. rty leaking because of improper installation poor seal Quick Reference Record important information here VIN Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr Maintenance The maintenance schedule page 20 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 Pre ride Inspection 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 expansion chamber Fuel Capacity 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 Transmission oil Pro Honda HP Trans oil Pro Honda GN4 4 stroke oil or an equivalent Tires Front 80 100 21 51M Rear 110 90 19 62M Type bias ply tube Tire Pressure Front 15 psi 100 kPa 1 0kgf cm cold Rear 15 psi 100 kPa 1 0kgf cm Spark Plug Standard BR9EG N 8 NGK Drive Chain DID 520DMA2
144. s to the handlebar and throttle pipe with safety wire to prevent the possibility of them loosening Position the twisted wire ends 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 ri 4 4 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 seale
145. spark plug P 48 Faulty engine control unit Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty throttle position sensor Faulty RC valve cables Excessive carbon build up on the RC valve Faulty RC valve POOR PERFORMAN CHECK CE AT HIGH SPEED 1 Check ignition INCORRECT gt timing CORRECT 2 Disconnect fuel line at carburetor L FUEL FLOW RESTRICTED and check for clogging P 35 UNRESTRICTED FUEL FLOW 3 Remove air DIRTY cleaner P 40 AIR CLEANER NOT DIRTY Y 4 Check carburetor CLOGGED jets for clogging NOT CLOGGED 5 Install a larger carburetor main CONDITION gt WORSE jet P 106 CORRECT 6 Check the RC INCORRECT valve system P 55 CORRECT Troubleshooting POSSIBLE CAUSES Faulty alternator Faulty engine control unit Faulty ignition pulse generator Lack of fuel in tank P 35 Clogged fuel line P 35 Clogged fuel fill cap breather tube P 35 Clogged fuel valve P 35 Clogged fuel filter P 35 Not cleaned frequently enough P 40 Contaminants in the fuel Jet size wrong rejet in the opposite direction P 106 Faulty RC valve cables Faulty RC valve Tips 119 120
146. t 30 N m 3 1 kgf m 6 silencer 7 bolt washer 8 Install the right side cover 8 and bolt collar 9 3 subframe 4 upper subframe mounting bolt 5 lower subframe mounting bolts xX 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 Type unleaded Pump Octane Number 91 or higher 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 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 128 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 H
147. tant Important Safety Information 2 information and recommendations to help you Important Safety Precautions 2 ride your CR safely Please take a few moments Accessories amp Modifications sss 3 to read these pages This section also includes satety Labels eerte eterne 4 information about the location of safety labels on your CR 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 t
148. teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth GOOD NOTICE 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 17 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 520DMA2 Service limit 10 20 in 259 0 mm 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 The master link is the most critical element of drive chain securit
149. tempt 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 rear subframe s three mounting bolts then remove the subframe See page 32 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 adjusting nut changes the spring length by 1 16 in 1 5 mm 1 lock nut 2 adjusting nut 3 pin spanner 4 spring length To increase spring pre load Loosen the lock nut with the optional pin
150. tenance 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 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 129 Competition Logbook Date Running Time Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use 130 Technical Information These parts and tools may be ordered from your Honda dealer Optional Parts List CARBURETOR Remarks Main jet Standard 420 360 480 in increments of 10 420 Slow jet Standard 40 32 5 45 in increments of 2 5 50 55 Jet Needles Standard needle 6DGY26 65 Straight diameter 92 650 mm Jet needle number vee
151. ter riding your CR for 3 hours See page 83 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 Replace the damper fork oil every 9 races or 22 5 hours of running See page 86 for damper fork oil replacement 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 Check the dust seals for dust dirt and foreign materials Check the oil for any contamination 60 Servicing Your Honda 1 fork protector Refer to Suspension Adjustment Guidelines page 100 Make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems 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 replaced before your CR is ridden
152. the Engine How to Stop the Engine 2 a 1 throttle grip 2 engine stop 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 piston ring is replaced cylinder is replaced 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 l
153. the Maintenance Schedule that follows The Maintenance Schedule lists items that can be performed with basic mechanical skills 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 136 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 mecha
154. ting section of Rear Suspension Adjustments to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or 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 95 Suspension Adjustments for Track Conditions 99 Suspension Adjustments Guidelines 100 Carburetor Adjustments amp Tuning Tips 103 Chassis Adjustments eee 110 GO ATID G Am 111 Tire Selection for Track Conditions 112 Personal Fit Adjustments ss 113 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 availab
155. ue wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using 20 in 50 cm long torque wrench When using the lock nut wrench use a 20 inches long deflecting beam type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper For ease of releasing air pressure after the forks are installed loosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adjusters 17 Tighten the fork lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 18 Tighten the fork upper pinch bolts 14 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m Tighten the bolts alternately in 2 or 3 steps NOTICE Over tightening the pinch bolts can deform the outer tubes Deformed outer tubes must be replaced 4 folk damper 13 lower pinch bolts 14 upper pinch bolts 19 Position the wear ring 15 with its end gap facing rearward 15 wear ring 16 fork protector bolts 17 fork protectors 20 Clean the threads of the fork protector bolts 16 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protectors 17 fork protector bolts and brake hose clamp bolts 18 Tighten the fork protector bolts to the specified torque 5 2 Ibf ft 7 N m 0 7 kgf m 16 16 18
156. ular 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 indicator replace 7 wear indicator rooves j9 0 04 in 1 mm a aae Ta 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 4 replace 6 brake disc 4 brake pads 5 rear brake caliper 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 Wheels 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 n
157. umer 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 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 exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for successful 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 Honda Red Rider magazine six issues Discounts from HRCA partners for exp
158. ur 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 engine rpm at a given throttle setting or ground speed which may allow better rear wheel traction on slippery or loose terrain 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 grou
159. urn 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 checking 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 MA standard 4 stroke engine oil only others without friction modifiers as molybdenum additives Pro Honda HP Trans oil Pro Honda GN4 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 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 e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They ma
160. urt or killed Always perform a pre ride inspection before every ride and correct any problems Is Your Motorcycle Ready to Ride Pre ride Inspection Check the following before each ride Transmission oil level 37 Coolant for proper level 38 Cooling system and hoses for condition 39 Spark plug for proper heat range carbon fouling and high tension cord terminal for looseness ei eterne nien reden 48 Air cleaner for condition and COMLAMMIMA MON is 2 eene eco eene tereti 40 Clutch lever adjustment and freeplay 44 Steering head bearings and related parts HOT COnDGILOhn errore Fee tret 76 Carburetor throttle operation 42 Tires for damage or improper inflation jui PM M 70 Spokes for looseness esses 69 Rim locks for looseness 69 Front and rear suspension for proper oir ino E 60 61 Front and rear brakes check operation 65 Drive chain for correct slack and adequate lubrication eerta tetto E ee rene 72 Drive chain guide sliders and guide rollers for damage or wear sese 72 Expansion chamber springs for damage or lack of tension eee 75 Every possible part for looseness such as cylinder head nuts carburetor insulator bolts engine mounting bolts axle nuts handlebar holder bolts fork t
161. ust inhibiting oil more heavily if the event was particularly wet or muddy Take 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 clutch lever front brake fluid reservoir x l D A f throttle grip radiator cap fuel fill cap front suspension compression damping adjuster spark plug rear suspens
162. ustment procedures discussed in this manual The official Honda Service Manual for your CR is available page 136 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 canser 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 WARN
163. vice life of brake fluid Water Pump Inspection Hole After every race check the inspection hole located just below the water pump cover 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 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
164. when handling fuel e Stop the engine and keep heat sparks and flame away Handle fuel only outdoors 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 7 Change the main jet 5 and slow jet 6 as required 5 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 108 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 rich than a little lean It is advisable to record the settings course conditions lap times and climatic and barometric conditions for future reference Carburetor Adjustments amp Tuning Tips 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
165. y 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 chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets Refer to Safety Precautions on page 19 Expansion Chamber Inspection 1 Check the expansion chamber springs and replace them if they are damaged or stretched 2 Check the mounting bolts for tightness 3 Check the expansion chamber for cracks or deformation A damaged chamber may decrease engine performance Expansion Chamber Removal 1 Remove the expansion chamber by removing the expansion chamber springs 1 and mounting bolts 2 2 Remove the exhaust gasket 1 springs 2 bolts 3 Remove carbon deposits from the head pipe of the expansion chamber Check the O rings 3 on the head pipe for wear 3 O rings Expansion Chamber Expansion Chamber Installation Install the expansion chamber in the reverse order of removal 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 gr
166. y affect lubrication and clutch performance Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range NOT RECOMMENDED 10W 30 10W 40 30 20 10 0 10 20 30 40 50 C L li li 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 Checking amp Adding Oil 1 oil filler cap 2 oil check bolt 1 2 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 oi

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