Home

2005 Honda CR85/85RB EXPERT OWNER`S

1. 100 Storing Your Motorcycle sess 101 You amp the Environment sess 102 Jroubleshootimnp 2 pertinet 103 TECHNICAL INFORMATION 105 Vehicle Identification sess 106 e ee 107 Torque Specifications eese 109 High Altitude Carburetor Adjustment 111 Oxysenated Fuels orent ens 112 Competition Logbook sess 113 Optional Parts List 115 Spare Parts amp Foupment 117 Wiring Diaeramt semi titer eee tentes 118 CONSUMER INFORMATION 119 Authorized Manual 120 Contacting Honda 121 Your Honda Dealer 122 The Honda Rider s Club USA only 123 Table of Contents Table of Contents 125 Index A C E ACCESSOLIES reegen 3 capacity EE 35 engine adjustments carburetor Hooded eaaet ror eser 13 altitude and temperature 111 te ice tee Eres need 91 idle speed ese reca tentaret ote ret eese 91 CATDUTCLOF iei ble deti erre 88 circuit nt e EES 88 Ont dee nei ie ie etes 106 CHASSIS irune oeae er rae EEEE EE touted 95 COMPONENUS c c esce tote Rea etos egen ree haa 88 juri p E 34 control free play sese 42 44 disassembly assembly 92 Statin p 13 TOF competi isere regeert 71 high altitude adjustment 111 SOS DU COM sass
2. compression Fork Oil Level CR85RB Standard 0 28 kgf mm Fork Spring E 1 coil at both ends gt Optional Stiffer 0 30 kgf mm Fork Spring d Standard oil 4 0 in level 102 mm Maximum oil 3 7 in Slightly stiffer as level 95 mm it nears full compression Minimum oil 4 2 in Slightly softer as level 106 mm it nears full compression ta 2 coils at one end EE 1 coil at other end Standard oil 4 1 in level 105 mm Maximum oil 4 0 in Slightly stiffer as level 102 mm it nears full compression Minimum oil 4 3 in Slightly softer as level 110 mm it nears full compression Optional Softer 0 26 kgf mm Fork Spring 2 coils at both ends SS Standard oil 3 8 in level 96 mm Maximum oil 3 6 in Slightly stiffer as level 92 mm it nears full compression Minimum oil 3 9 in Slightly softer as level 100 mm it nears full compression Be sure the oil level is the same in both fork legs Always use the after market syringe while adjusting the oil level If it isn t used air may get into the fork f a syringe is not available first set the oil level somewhat lower than the normal level then add small amounts of oil until the correct level is obtained measuring the level each time oil is added Front Suspension Adjustments 16 Inspect both ends of the fork spring If you fi
3. 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety pistoiaren 19 Important Safety Precautions 19 Maintenance Schedule sess 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 Contents Service Preparations Component Locations ssssessiessetsorssisesisseoiisciinss 28 Seat le TEE 29 Fuel Tank Removal eterne ttes 30 Subframe Removal esee 32 Service Procedures Fluid amp Filters Fettes ENEE 34 Transmission Ol oett EE 36 RT enS 38 Nr Cheater e ete rettet eer eoe cud 40 Engine RR E 42 Clutch Gaeren Eug reegen Ene dd 44 Spark Plug nint 46 Cylinder System retenti 47 Chassis SUSPENSION cs ete i Eesen Ee P eb tese rien de 52 ec 57 Wheels ca eege 61 Tires amp Dubes iere oti oet ced 62 Drive e EE 64 Expansion Chamber 67 Additional Maintenance Procedures 68 Appearance Care enne ated 69 ADJUSTMENTS FOR COMPETITION 71 Front Suspension Adjustments 72 Rear Suspension Adjustments 80 Suspension Adjustments for Track Conditions xit oreet A 84 Suspension Adjustment Guidelines 85 Carburetor Adjustments amp Tuning Tips 88
4. 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 45 Jet needle NFSF Needle clip position 3rd groove from top Main jet 142 Float level 0 75 in 19 0 mm Identification number PWK10A All jetting is based on Standard Jetting 32 1 Fuel Oil Ratio Unmodified Engine Including Porting Exhaust and Timing Carburetor Adjustments amp Tuning Tips TEMPERATURE Cent 30 17 18 6 7 5 4 16 15 27 26 38 37 49 ALTITUDE FAHR 21 0 1 20 19 40 39 60 59 80 79 100 99 120 3050m AS 2 2 2 1 4 2 1 2 2 3 4 3 3 10 000 ft SJ 45 45 45 45 45 45 42 to NC 3 3 2 2 2 2 1 2300m JN NBKF NFSF NBKF NBKG NSFG NSFG NBKG 7 500 ft MJ 142 142 140 138 135 132 130 2299m AS 1 3 4 2 2 2 1 4 2 1 2 2 3 4 3 7 499 ft SJ 45 45 45 45 45 45 45 to NC 3 3 3 2 2 2 2 1500m JN NBKF NBKF NFSF NBKF NBKG NSFG NSFG 5 000 ft MJ 145 142 142 140 138 135 132 1499m AS 2 1 3 4 2 2 2 1 4 2 1 2 2 3 4 4 999 ft SJ 48 45 45 45 45 45 45 to NC 3 3 3 3 2 2 2 750m JN NBKE NBKF NBKF NFSF NBKF NBKG NSFG 2 500 ft MJ 148 145 142 142 140 138 135 749m AS 1 3 4 2 1 3 4 2
5. Your CR does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance NOT RECOMMENDED OK Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10W 40 SAE 10W 30 0 20 40 60 80 100 F 20 10 0 10 20 30 JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard has the following classification on the oil container PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification 1 1 2 Checking amp Adding Oil oil filler cap 2 oil check bolt Run the engine for three minutes then shut it off Wait three minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission Support the CR in an upright position on a level surface Remove the oil filler cap 1 and oil check bolt 2 from the right crankcase cover A small amount of oil should flow out of the check bolt hole Al
6. air screw adjustment P 91 CORRECT 3 Check if air cleaner is overoiled P 40 CORRECT 4 Check if the insulator is leaking INCORRECT INCORRECT LEAKING NOT LEAKING 5 Try spark test GOOD SPARK WEAK OR INTERMITTENT SPARK POSSIBLE CAUSES e Faulty ignition control module e Faulty alternator e Faulty ignition pulse generator e Fuel air mixture too lean Turn the air screw in P 91 e Fuel air mixture too rich Turn the air screw out P 91 Over oiled air clean er e Deteriorated reed valve gasket Loose caburetor Faulty carbon or wet fouled spark plug P 94 Faulty ignition control module Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Poor performance at high speed CHECK 1 Check ignition INCORRECT timing CORRECT 2 Disconnect fuel line at carburetor FUEL FLOW RESTRICTED L and check for clogging P 35 UNRESTRICTED FUEL FLOW 3 Remove air DIRTY cleaner P 40 AIR FILTER NOT DIRTY Y 4 Check carburetor CLOGGED jets for clogging NOT CLOGGED 5 Install a larger carburetor main CONDITION Ce WORSE jet P 89 Troubleshooting POSSIBLE
7. aahi et Se 12 i ee 11 Le E SCH os 9 Ka 9 main jet 14 float 10 jet needle 15 float valve 11 needle jet 16 float bowl 12 air jet 13 nozzle Carburetor Circuit Functions The carburetor has several major circuits each providing the fuel air mixture over a given range of throttle valve opening These major circuits overlap as shown below MAIN JET JET NEEDLE TAPERED SECTION Hi NEEDLE STRAIGHT SECTION E SLOW JET AND AIR SCREW FULLY 1 8 1 4 1 2 3 4 FULLY CLOSED OPENED Main Jet The main jet affects air fuel ratio from half to full throttle The size should be reduced at higher altitudes Honda carburetor jet sizes are numbered in increments of 20r3 When changing the main jet size increase or decrease it gradually until the desired setting is obtained Because your CR s jet size numbers do not correspond with other carburetor manufacturer s jet size numbers use only Honda jets Jet Needle The jet needle controls fuel air mixture over 1 16 to 3 4 throttle The straight section 1 affects throttle response at smaller throttle openings By changing the position of the clip 2 in its groove you can improve acceleration at medium low and medium speed 1st LEANER 2nd eS 2 H 4th 5th T 1 2 clip RICHER 1 straight section Slow Jet and Air Screw Refer to Carburetor Minor Adjustments Page 91
8. hotter than 113 F 45 C 90 Adjustments for Competition Once you ve adjusted the carburetor for temperature and altitude it shouldn t need major readjustment unless race conditions change drastically However there are some unique atmospheric conditions or race day situations that may require additional adjustments They are as follows To prevent engine damage always adjust the main jet before adjusting the jet needle Always choose the next richer jet if there is any doubt so there is a margin for safety Main Jet Go richer on the main jet by one number when the track has a very long straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is hotter than 113 degrees F After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CR If larger jetting changes are necessary check for worn crankshaft seals air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Pre Adjustment Checks Before adjusting carburetor settings check the following air cleaner condition page 40 air leaks ignition timing float level clogged carburetor jets spark plug fouling improper heat range or other cause freshness of fuel and fuel oil ratio If the ab
9. 19 7 2 0 E d Zen 30 Fork protector bolts 5 2 7 0 7 NOTE 1 JET 27 31 Expansion chamber PAF SSIS L7 Ne mounting bolt front E FNY S stay 65 88 0 9 Cs Sy 32 Sprocket nuts es Bu de de 33 ei g riven 32 33 Seat mounting bolts 19 26 2 7 28 34 Fork air plug 10 13 0 1 32 NOTES 1 Apply Honda thread Lock 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 QS 34 7 Alock bolt do dar Q e I I g ge 31 23 30 110 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 111 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 standard
10. Action Rear end kicks up on deep bumps on sand track Test stiffer compression and rebound damping adjustments in 1 4 turn increments until the rear end does not kick up and or the suspension becomes stiff Then test softer compression damping adjustments in 1 4 turn increments Suspension bottoms and rear end kicks up on large bumps on a hard surface track Test stiffer compression and rebound damping adjustments in 1 4 turn increments Rear end gets poor traction accelerating away from a corner Test softer rebound damping adjustments in 1 4 turn increments Test no more than 2 1 2 turns If 1 2 or 3 4 turns don t produce satisfactory results test softer compression damping adjustments in 1 4 turn increments After the above adjustment check if the suspension bottoms after jumping If it does test stiffer compression damping adjustments in 1 4 turn increments Rear end kicks sideways and suspention feels stiff on continuous bumps Test softer rebound damping adjustments in 1 4 turn increments After the above adjustment check if the suspension bottoms after jumping If it does test stiffer compressi on damping adjustments in 1 4 turn increments Adjustments for Competition 87 Carburetor Adjustments amp Tuning Tips Refer to Safety Precautions on page 19 The carburetor on your CR should perform suitably with the standard recommended settings under average lo
11. Compress the fork tube fully then release your hand Use your other hand to secure the fork tube Repeat viscosity weight 5 W this procedure 3 times suggested oil Pro Honda HP Fork Oil or equiva lent Fork Oil Change x 2 een 1 Remove the fork cap and fork spring as described in Oil Level Adjustment dau page 72 2 Pour out the fork oil by pumping the fork tube and piston rod 1 8 10 times with the rod end down as shown 2 fork tube 5 Pour the remaining fork oil into the piston rod until a little oil flows out of the top of the rod Pump the piston rod slowly 8 10 times through a stroke of 10 in 25 cm Gently slide the fork tube down onto the lower end of the slider pipe 3 Wait about 5 minutes 1 piston rod 1 piston rod 3 lower end of the slider 2 fork tube pipe 54 Servicing Your Honda 6 With the fork tube held upright measure the oil level 4 from the top of the tube 4 oil level 7 Adjust the oil level by adding or removing the oil with an after market syringe 5 5 syringe Fork Oil Level CR85R Standard 0 28 kgf mm Fork Spring GE 1 coil at both ends Suspension Optional Stiffer 0 30 kgf mm Fork Spring gt c factory products Standard oil 4 0 in level 101 mm capacity 12 1 US oz liasz cm Maximum oil 3 7 in Slight
12. but not so close that either is depressed when sitting or standing comfortably on your CR Handlebar Position Width amp Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cut off just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide further adjustment to riding position and may better suit your particular body size or riding style Each of the ergonomic dimensions of the machine were determined to suit the greatest possible number of riders based on an average size rider Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 100 Storing Your Motorcwvcle 101 You amp the Environment esss 102 Troubleshooting is re rct 103 Tips Tips 99 Transporting Your Motorcycle If you use a truck or
13. 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 upper lock nut install the rubber 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 can not 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 1 Check that the throttle assembly is positioned properly and the securing bolts are tight 2 Check for smooth rotation of the throttle 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
14. 12 0 US oz compression 363 6 om Optional Softer 0 26 kgf mm Fork Spring SS 2 coils at both ends Standard oil 3 8 in level 96 mm capacity 12 2 US oz 360 4 cm Maximum oil 3 6 in Slightly stiffer as level 92 mm it nears full capacity 12 3 US oz compression 362 8 cm Minimum oil 3 9 in Slightly softer as level 100 mm it nears full capacity 12 1 US oz compression 358 5 cm 56 Servicing Your Honda Optional Stiffer 0 30 kgf mm Fork Spring 2 coils at one end 1 coil at other end Standard oil 4 1 in level 105 mm capacity 12 0 US oz 354 2 cm Maximum oil 4 0 in Slightly stiffer as level 102 mm it nears full capacity 12 1 US oz compression 356 6 cm Minimum oil 4 3 in Slightly softer as level 110 mm it nears full capacity 11 9 US oz compression 351 5 cm Be sure to check the oil level Some oil will be left in the fork tube when the oil is drained and causes the oil level to be raised slightly Be sure the oil level is the same in both fork legs If a syringe is not available first set the oil level somewhat lower than the normal then add small amounts of oil until the correct level is obtained measuring the level each time oil is added 8 Install the fork spring spring seat Refer to Safety Precautions on page 19 Both the front and rear
15. 2 1 connecting and insulator tube clamp screws 2 float bowl plug cont d Adjustments for Competition 91 Carburetor Adjustments amp Tuning Tips 7 Change the jets as required 3 main jet 4 slow jet 8 Reinstall the float bowl and its plug securely 9 Remove the carburetor top throttle valve and throttle cable page 93 and then change the jet needle clip position as required 10 Reinstall the jet needle throttle valve cable holder and carburetor top page 93 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 11 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 92 Adjustments for Competition Carburetor Disassembly Assembly Turn the fuel valve off Disconnect the fuel line 1 from the carburetor 3 Loosen the insulator and connecting tube clamp screws 2 NR 1 fuel line 2 insulator and connecting tube clamp screws 4 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 5 Remove the screws 3 and carburetor top
16. 40 50 in increments of 2 or 3 Standard 45 Jet Needles Standard needle NFSF Straight diameter 92 415 mm MARK CHM jp Jet needle Specific flow Jet needle jer characteristics number Beer Siar at 1 16 to 1 4 standard p throttle series than standard at 1 8 to 3 4 throttle Rich NFSE NBKE 92 405 92 405 standard needle NBKF NFSF 92 415 92 415 NSFG NBKG Lean 92 425 92 425 FRAME REMARKS FRAME REMARKS Drive chain links Shock CR85R 48T Aluminum 116 Springs Cher 49T Aluminum lt 116 gt Standard Driven 50T Aluminum lt 116 gt Softer 4 6 kgf mm amp Brown mark sprocket lt gt Drive chain links 54T Aluminum 124 Red mark REDDE 55T Aluminum 124 Standard 4 8 kgf mm 56T Aluminum lt 124 gt RK420MSZ1 Standard 5 0 kgf mm S White mark Drive Standard 116 Links CR85R 124 Links CR85R chain No mark Optinal RK420MSZ1 130 Links 5 2 kgf mm CG Stiffer 5 4 kgf mm S Black mark Rider Weight 5 0 kgf mm Standard 20 30 40 50 60 68kg e i 00 Se 1o 150 Ibs The maximum load capacity is 150 Ibs Rider weight must not exceed this limit Technical Information 115 Optional Parts List 116 Technical Information FRAME REMARKS FRAME
17. 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 A lean condition can be caused by air leaks in the insulator tract in the center crankcase joint and leaking ignition side crank seal Insufficient oil on the air cleaner may also cause a lean condition 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 Failure to remove the air cleaner housing cover for dry conditions may also cause a rich condition Pressure vacuum testing your engine on a regular basis to detect air leaks is recommended See your Honda dealer The same simple throttle opening identification system used in the Break in section of this manual can also be used to accurately identify where carburetion problems occur should they arise page 16 Refer to Safety Precautions on page 19 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 3 in 85 mm of sag you can run 3 1 in 80 mm or 3 0 in 75 mm so the rear of the bike will sit a little higher This sh
18. CAUSES Faulty alternator Faulty ignition control module 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 reject in the opposite direction P 89 Tips 103 104 Tips This section contains dimensions capacities and other technical data Vehicle Identification sees 106 SDECILICALIOTS iecore toi trier been elen ze 107 Torque Specifications eese 109 High Altitude Carburetor Adjustment 111 Oxysgenated Fuels ette 112 Competition Logbook sess 113 Optional Parts List ite 115 Spare Parts amp Boupmment sess 117 MWanns Diagram siii e tre Rida 118 Technical Information Technical Information 105 Vehicle Identification 3 The frame number 1 is stamped on the right Serial Numbers side of the steering head The VIN frame and engine serial numbers are RIGHT SIDE 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 the manual 1 frame number The engine number 2 is stamped on the left crankcase LEFT SIDE 2 engine number 106 Technical Information CR85R Sp
19. Chassis Adiustments eene 95 GOAT EE 96 Tire Selection for Track Conditions 97 Personal Fit Adjustments esses 98 TIPS ur osneass 99 Transporting Your Motorcycle 100 Storing Your Honda eese 101 You amp the Environment eese 102 Troubleshooting esirin aen 103 TECHNICAL INFORMATION 105 Vehicle Identifica omesse sinssecsriieiisisesisieist 106 Specifications senesine e a a 107 Torque Specifications esee 109 High Altitude Carburetor Adjustment 111 Oxysenated Euels eire detto 112 Competition Logbook sss 113 Optional Parts List 115 Spare Parts amp Boumment sess 117 Wining Diagram ien eer estet eee 118 CONSUMER INFORMATION 119 Authorized Manual 120 Contacting Honda 121 Your Honda Dealet RR Eee 122 The Honda Rider s Club USA only 123 TABLE OF CONTENTS eeeeeees 124 INDEX Q 126 QUICK REFERENCE Motorcycle Safety This section presents some of the most important Important Safety Information 2 information and recommendations to help you Important Safety Precautions 2 ride your CR safely Please take a few moments Important Message to Parents 2 to read these pages This se
20. General Competition Maintenance Gaskets Spark Plug Always use new gaskets when reassembling components 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 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 47 Spark Plug Cap Install a small plastic tie wrap around the spark plug cap to reduce any possibility of it loosening or of water penetration 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 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
21. 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 2 exhaust port Cylinder Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your Honda dealer for correct Service Limit measurements Connecting Rod Inspection 1 Temporarily remove the shop towel 2 Install the bearing and piston pin 1 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 piston pin 3 Place the shop towel back in the crankcase Cylinder Head Inspection Check the cylinder head 1 for warpage in diagonal directions with a straight edge 2 and a feeler gauge 3 Service Limit 0 004 in 0 10 mm 3 feeler gauge 1 cylinder head 2 straight edge Reed Valve Inspection 1 Check the reed valves 1 for damage or fatigue and replace them if necessary 2 Replace the reed valves with new ones if the seats are cracked or damaged 1 reed valve Reed Valve Disassembly Assembly 1 Remove the reed valve mounting screws 1 stopper 2 and reed valve 3 2 Align the cut outs 4 between the reed valves and stoppers then install them onto the cage 5 3 x
22. However information for wheel removal is provided for emergency situations Wheel Rims amp Spokes Aa SES Seer 2 Zz 2 1 rim lock 2 lock nut 1 Inspect the wheel rims and spokes for damage 2 Tighten any loose spokes and rim locks 1 to the specified torque Spoke 2 8 Ibf ft 3 7 N m 0 4 kgf m Rim Lock 9 Ibf ft 12 4 N m 1 3 kgf m 3 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 61 Tires amp Tubes Refer to Safety Precautions on page 19 To safely operate your CR the tires must be the proper type off road and size in good condition with adequate tread and correctly inflated A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement Air Pressure Properly inflated tires provide the best combination of handling tread life and riding comfort Generally
23. REMARKS Shock CR85RB Shock CR85R Springs springs 2 coils at Softer 4 8 kgf mm 28 Red mark Softer 0 26 kgf mm both ends 5 0 kgf mm 28 White mark 1 coil at Standard 0 28 kgf mm both ends Standard 5 2 kgf mm ES No mark 2 coils at S Stiffer 0 30 kgf m the end 5 4 kgf mm ES Black mark 1 coil at other end Stiffer 5 6 kgf mm S Blue mark CHBSHE 2 coils at Softer 0 26 kgf mm 7 both ends Rider Weight 1 coils at 5 6 kgf mm Stiffer Standard 0 28 kgf mm both ends gt 2 coils at Stiffer 0 30 kgf mm one end 4 8 kgf mm Softer 1 coils at other end 20 30 40 50 60 68 kg I b ibo be he 150 lbs The maximum load capacity is 150 Ibs Rider TOOLS REMARKS weight must not exceed this limit Workstand For maintenance Air gauge For checking tire air pressure Pin spanner To adjust spring preload two spanners required 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 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 l
24. Tires I 61 62 63 Nuts Bolts Fasteners I 68 109 110 Steering Head Bearing I 68 This maintenance schedule is based upon average riding condition Machine subjected to severe use require more frequent servicing NOTE 1 Clean after every moto heat for dusty riding 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 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 in your Owner s Manual page 9 22 Servicing Your Honda Handgrips Always use Honda Hand Grip Cement U S A only or Honda Bond A when replacing handgrips Throttle Grip Align the A mark on the throttle grip with the hole of the throttle cable guide Left handlebar grip Align the top of the wa
25. a 2 2 1 4 2 1 2 2 499 ft SJ 48 48 45 45 SZ Je E 45 45 to NC 4 3 3 3 B8 3 E 2 2 300m JN NFSE NBKE NBKF NBKF NFSF NBKF NBKG 1 000 ft MJ 150 148 145 142 70 dy 140 138 299m AS 1 1 2 1 3 4 2 1 3 4 2 2 2 1 4 999 ft SJ 48 48 48 45 45 45 45 to NC 4 4 3 3 3 3 2 Dm JN NBKE NFSE NBKE NBKF NBKF NFSF NBKF Sea Level MJ 152 150 148 145 142 142 140 Legend AS Air Screw opening from fully seated SJ Slow Jet NC Needle Clip position JN Jet Needle MJ Main Jet Adjustments for Competition 89 Carburetor Adjustments amp Tuning Tips Adjustments for Altitude amp Temperature All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture Condition Mixture will be Adjust to cold temperature lean richer warm temperature rich leaner dry air lean richer high humidity rich leaner high altitude rich leaner 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
26. adjust the rear suspension Make all compression and rebound 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 the rear suspension is too stiff soft adjust it by turning both the compression and rebound damping adjusters in one click increments until the suspension feels approximately right Turning just one adjuster rather than both may cause a loss of balance between compression and rebound damping After adjusting both adjusters simultaneously suspension may be fine tuned by turning either the compression or rebound damping adjuster in one click increments If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Bounce the rear of the motorcycle up and down and check for smooth suspension action 2 Remove the subframe page 32 3 Check for a broken or collapsed spring 4 Check the shock for a bent shaft or oil leaks D e 1 rear shock absorber 5 Push the rear wheel sideways to check for worn or loose swingarm bearings There should be no movement If there is have the bearings replaced by your Honda dealer Suspension Servicing Your Honda 53 Suspension p 3 Pour half of the recommended fork oil into 4 Raise the fork tube 2 and cover the top of Fork Oil Recommended the fork slider and fork tube the tube with your hand
27. 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 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and remove the carburetor drain bolt Drain gasoline into an approved container Reinstall the drain bolt 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 3 Remove the coolant drain bolts 1 at the cylinder 2 and water pump 3 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washers are in good condition and reinstall the drain bolts 1 drain bolts 2 cylinder 3 water pump 4 Lubricate the drive chain 5 Remove the spark plug and pour a tablespoon 0 51 0 68 US oz 15 20 cm of clean engine oil into the cylinder With the spark plug grounded or the engine stop button pressed in operate the kickstarter several times to distribute the oil then reinstall the spark plug NOTICE When turning the engine over the engine stop button should be pressed in and the spark plug placed in its cable cap and grounded to prevent damage to the ignition system 6 Inflate the tires to their recommended pressures 7 Place your CR on the op
28. and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rust inhibiting oil more heavily if the event was particularly wet or muddy Take care to avoid spraying any oil near the disc brakes or the disc rotors Remove the drive chain clean it and lubricate the chain and sprockets Be sure the chain is wiped clean and is dry before applying the chain lube 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 69 Servicing Your Honda 27 Component Locations clutch lever front brake fluid reservoir front brake leve
29. down several times to seat the axle and check front brake operation AY St Lo NA ca P di X H 2 Te 45 Turn the rebound damping adjuster screws back to their original settings 78 Adjustments for Competition Front Suspension Damping Compression Damping Compression damping affects how quickly the fork compresses The compression damping adjuster has 15 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 To adjust to the standard position 1 compression damping adjuster 1 Turn the compression damping adjuster 1 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 9 CR85R 10 CR85RB 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 3 turns or less Always start with the full hard position when adjusting damping To adjust to the standard position 2 rebound damping adjuster 1 Turn the rebound damping adjuster 2 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 1 1 4 turns This is the standard position 3 Make sure both fork legs are adju
30. faster on wet and dirty tracks Inspect the pads at each regular maintenance interval page 21 Front Brake Pads Inspect the pads 1 through the front wheel to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced 2 1 brake pads 2 wear limits 60 Servicing Your Honda Rear Brake Pads Inspect the pads 1 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 V ul 2 1 brake pads 2 wear limits 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 necessary to remove the wheels to perform the recommended service in the Maintenance Schedule
31. 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 1 4 US gal 5 3 Transmission oil Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke engine oil or an equivalent Tires CR85R Front 70 100 17 40M Rear 90 100 14 49M Type bias ply tube CR85RB Front 70 100 19 42M Rear 90 100 16 52M Type bias ply tube Tire Pressure cold Front 15 psi 100 kPa 1 0kgf cm Rear 15 psi 100 kPa 1 0kgf cm Spark Plug Standard BR10EG NGK Drive Chain RK420MSZ1
32. gasket N N Ke lower clutch cable adjuster 2 cylinder mounting nuts 3 cylinder 4 reed valve Cylinder System Reed Valve Removal Drain the radiator coolant page 39 Remove the carburetor page 92 Remove the radiator hose of the cylinder head 4 Loosen the carburetor insulator mounting bolts 1 in a criss cross pattern in 2 or 3 steps 5 Remove the insulator 2 and reed valve 3 from the cylinder by removing the four carburetor insulator mounting bolts and clamp 4 6 Remove the gasket 5 Tus 1 1 carburetor insulator mounting bolts 2 insulator 3 reed valve 4 clamp b gasket Servicing Your Honda 47 Cylinder System Piston Removal Place the shop towel in the crankcase Using a pair of needle nose pliers carefully remove the piston pin clip 1 Avoid letting it fall into the crankcase 3 Support the piston 2 and press the piston pin 3 out of the piston Remove the piston NR Under racing conditions the piston and rings 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 3 piston pin 4 piston ring 4 Spread the piston ring 4 and remove by lifting it up at a point just opposite the gap NOTICE The piston rings may be damaged if their ends are spread too far 48 Servicing Your Honda Cylinder
33. hours of easy break in time Optional front and rear suspension springs are available in both firmer and softer than standard rates in order to tailor your CR specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag setting section of Rear Suspension Adjustments to determine if your combined 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 72 Rear Suspension Adjustments 80 Suspension Adjustments for Track Conditions 84 Suspension Adjustments Guidelines 85 Carburetor Adjustments amp Tuning Tips 88 Chassis Adjustments esee 95 EUR Eeer eege e 96 Tire Selection for Track Conditions 97 Personal Fit Adjustments esses 98 Adjustments for Competition Adjustments for Competition 71 Front Suspension Adjustments Refer to Safety Precautions on page 19 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
34. 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 Handlebar Inspection 1 Check the handlebar for bends or cracks 2 Check that the handlebar has not moved from its proper position by inspecting the punch mark alignment 3 Check the torque of the upper holder bolts Tighten the front bolts first 16 Ibf ft 22 N m 2 2 kgf m 1 handlebar 2 handlebar upper holders 68 Servicing Your Honda 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 Be certain that the throttle cables have no kinks or other damage Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Torque Item Remarks Ibf ft N m kgf m ENGINE 1 Oylinder head 20 27 2 8 2 Right crankcase cover 6 6 9 0 9 3 Carburetor insulator 6 6 9 0 9 4 Oil drain plug 18 25 2 5 5 Drive sprocket 10 13 1 3 6 Alternator cover 5 2 7 0 7 1 cylinder head 3 carburetor insulator 5 drive sprocket carbur 4 oil drain plug 6 alternator cover 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
35. information or call 1 800 847 HRCA or log on to www hrca honda com The Honda Rider s Club USA only Consumer Information 123 Table of Contents The following presents the contents fo each section of your owner s manual MOTORCYCLE SAFETY eene 1 Important Safety Information 2 Important Safety Precautions 2 Important Message to Parents 2 Safety Label 2 8 ette ora tn eate teresa 4 OPERATING CONTROLS eee 5 Component Locatons eee 6 BEFORE RIDING eee eene ener ntnnn 7 Are You Ready to Rudel 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection eere 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Precautions esses 12 Starting amp Stopping the Engine 13 PrepatatioD eret erede Deer te eres 13 Starting Drocedure sess 13 Elooded Engine ote 13 How to Stop the Engine 14 Shtange Gears eerie etta rea tenenda 15 Break in Gudelmes sss 16 124 Table of Contents SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety esesseeeeeenee 19 Important Safety Precautions 19 Maintenance Schedule sss 20 General Competition
36. lock nut 1 and turn the adjusting bolt 2 in direction to raise the pedal 3 or in direction to lower it 2 Tighten the lock nut at the desired pedal height 1 lock nut 2 adjusting bolt 3 rear brake pedal raise the pedal height lower the pedal height Servicing Your Honda 57 Brakes Fluid Level Inspection Front Brake Fluid Level Check 1 LWR lower level mark With the motorcycle in an upright position check the fluid level It should be above the LWR lower level mark 1 If the level is at or below the LWR level mark check the brake pads for wear page 60 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake level 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 motorcycle dealer for brake bleeding 58 Servicing Your Honda Rear 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 1 level mark If the level is at or below the LOWER level mark check the brake pads for wear page 60 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 1 2 in 30 mm there is probably air in the brake system and it must be bled Refer
37. lt 1 m el ij 1 read value mounting screws 2 stopper 3 reed valve 4 cut out 3 Apply a locking agent to the reed valve mounting screw threads 4 Install and tighten the mounting screws to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m 5 Make sure that the clearance between the reed valve and stopper is less than the 0 008 in 0 2 mm Gs 3 V b cage 3 reed valve Piston Installation Clean the piston ring groove Lubricate the piston ring and piston ring groove with clean 2 stroke oil 3 Install the piston rings on the piston with the marks facing up Locate the piston ring end gaps on the pins in the ring grooves 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 facing the intake side 6 Install new piston pin clips 3 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 NR Cylinder System 1 piston pin 2 IN mark 3 piston pin clip Reed Valve Installation 1 Replace the insulator o ring 1 and reed valve gasket 2 with new ones 1 insulator o ring 2 reed valve gas
38. mental condition Free of alcohol and drugs e Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride 8 Before Riding A WARNING Not wearing a helmet increases the chance of serious injury or death in a 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 hurt 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 e 46 Air cleaner for condition and CODtLatmnatlon rne eii pibe ebore 40 Clutch operation and freeplay 44 Steering head bearings and related
39. 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 Rear Suspension Adjustments Adjustments for Competition 83 Suspension Adjustments for Track Conditions Soft Surface On soft ground sand and especially mud consider increasing compression damping front and rear Sand often requires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average ri
40. requires mechanical skill 3 Replace after the first break in ride Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean L lubricate R replace Maintenance Schedule All items should be checked before each competition event See your Honda dealer unless you are mechanically qualified and have the proper tools Damage from competition use is not covered by the Distributor s Limited Warranty on your Honda 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 Note or about or about or about Ref page Item 2 5 hours 7 5 hours 22 5 hours Throttle Operation I 42 Air Cleaner Note 1 C 40 Spark Plug I R 46 Radiator Coolant Note 2 I 38 Cooling System I 39 Cylinder Head Decarbonizing C 48 Piston and Piston Rings R 48 Piston Pin and Connecting Rod Small End Bearing R 48 Reed Valve R 49 Transmission Oil R 37 Drive Chain ILL R 64 66 Drive Chain Sliders I 64 Drive Chain Rollers I 65 Drive Sprocket I 66 Driven Sprocket I 66 Brake Fluid Note 2 I 58 59 Brake Pad Wear I 60 Brake System I 57 Clutch System I 44 Control Cables LI 68 Expansion Chamber Silencer I 67 Suspension I 52 53 Swingarm Shock Linkage 25 53 Fork Oil Note 3 R 54 Wheels
41. secedies ege 14 e E 96 idle spee ME 91 SLOP PUMPS oisin e E 14 high altitude carburetor 111 MAIMLEN ANCE oce ee eerte ei 92 WOM E SUE icono ect ede tres reso bentes ed 13 personal Tit 5 5 0 0 inmenso cetera 98 minor adjustments sese 91 environment protecting cece eeseeeeeeeeeeees 102 SUSPENSION POM eis cassvss scsseceiansdedencsedscivevessdes 72 care appearance eer ettet etae eh aenea dena onn oo 69 expansion chamber 67 SUSPENSION Tedt 1 ae eerie 80 Ne e 64 suspension track conditions 84 chassis adjustment for track conditions 84 F tire selection iiio ternas 97 choke idle speed knob sess 13 filter after competition maintenance 26 cleanet ap Jue eegen cete e toten Eoo ei 40 zm 42 aime LEAN GR eio ot etude 40 cleaning appearance Care 69 flooded engine starting sese 13 air pressure clutch system adjustment sess 44 fork front SUSPENSION e reme ertet reines 26 consumer pformatton eese 119 front suspension adjustment 72 Duc LP 62 controls OPeratiNg oo cess eeeeceseeeeeeeeeeeeeeneeeaees 5 front suspension inspection 52 American Honda contacting 121 component locations oil recommendation eee 54 app
42. straightened measure the distance between a span of 21 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 RK420MSZ1 Service limit 10 20 in 259 0 mm n3 0 MEASURE A SPAN OF 21 PINS 20 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 security Master links are reusable as long as they remain in excellent condition We recommend installing a new master link retaining clip when the drive chain is reassembled You may find it easier to install a new 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 spring and replace it if it is damaged or stretched 2 Check the flange bolts for tightness 3 Check the expansion c
43. the cylinder since this may cause the piston ring to snag a cylinder port and break E o 4 flange nuts 6 Install the following expansion chamber page 67 carburetor 3 piston ring Before tightening the cylinder nuts make sure that there are no clearance between the cylinder and crankcase mating surface 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 3 UP mark 2 cylinder head gasket 4 tab Cylinder System 3 Install the cylinder head 5 and tighten the 5 Connect the radiator hoses 8 to the cylinder four cylinder head nuts 6 to the specified head torque in a crisscross pattern in 2 or 3 steps Hi 20 Ibf ft 27 N m 2 8 kgf m 5b cylinder head 6 cylinder head nuts 6 Pour the recommended coolant mixture into 4 Install the spark plug and spark plug cap 7 the radiator up to the correct level page 38 7 Start the engine and check for the following compression leaks abnormal engine noise carburetor insulator air leaks coolant leaks Servicing Your Honda 51 Suspension Refer to Safety Precautions on page 19 Loose worn or damaged suspension components may adversely affect the handling and stability of your motorcycle If any suspensi
44. the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables 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 Clutch Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear 44 Servicing Your Honda Cable End Adjustment Minor adjustments are generally made with the cable end adjuster 1 dust cover increase 2 lock nut decrease 3 cable end adjuster 1 2 Pull the dustcover 1 back Loosen the lock nut 2 and turn the cable end adjuster 3 Turning the adjuster in direction will decrease free play and turning in the direction will increase free play After adjustment tighten the lock nut and install the dust cover Check the freeplay again Lower Adjustment The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out near its limit or the correct freeplay cannot be obtained 4 lock nut increase 5 lower clutch cable adjuster decrease 1 Turn the cable
45. to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding Adding Front Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 1 screws 3 diaphragm 2 reservoir cap 4 upper level mark 1 Remove the screws 1 reservoir cap 2 and diaphragm 3 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 4 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws securely 1 reservoir cap 3 UPPER level mark 2 diaphragm 1 Remove the reservoir cap 1 and diaphragm 2 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 bolts securely Other Inspection Brakes Make sure there are not fluid leaks Check for deterioration or cracks in the hoses and fittings Servicing Your Honda 59 Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear
46. who values your CR A clean CR is also easier to inspect and service While you re cleaning be sure to look for damage wear and gasoline or oil leaks General Recommendations To clean your CR you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CR or discolor the seat and decals If your CR is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your CR High pressure washers like those at coin operated car washes can damage certain parts of your CR The force of water under extreme pressure can penetrate the dust seals of the suspension pivot points and steering head bearings driving dirt inside and needed lubrication out If you use a high pressure washer avoid spraying the following areas wheel hubs expansion chamber outlet under seat engine stop button brake master cylinders under fuel tank drive chain carburetor front fork dust seal 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 motorcycle You may use Pro Honda Hondabrite a multi su
47. you are racing on a track with more fast sections than normal As a general recommendation keep the wheel base as short as possible This positions the wheels closer together improves turning response increase 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 Adjustments for Competition 95 Gearing Refer to Safety Precautions on page 19 You can adjust the power delivery of the standard engine to suit track conditions by changing gearing This allows you to utilize a different portion of the engine s power range at a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion of your engine s power range you use can be adjusted by changing the final drive ratio with different sized rear sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There is a choice of both higher and lower final drive ratios with two optional aluminum driven sprockets For muddy or sandy courses there is a more durable steel driven sprocket with the standard number of teeth Like the optional seats and springs these sprockets are listed in the Optional Parts
48. your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule 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 verti cal movement by hand 1 3 4 2 3 16 in 45 55 mm 64 Servicing Your Honda 1 SOIC OE 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 65 if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page 65 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed 5 Check the chain slider 4 for wear If the wear is 0 16 in 4 mm or more repla
49. 0EG NGK Use only the recommended type of spark plugs in the recommended heat range NOTICE Using spark plugs with an improper heat range or incorrect reach can cause engine damage Using a non resistor spark plug may cause ignition problems 46 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 02 0 03 in 0 6 0 7 mm 2 Check the electrode for wear or deposits the gasket 3 for damage and the insulator for cracks 1 plug gap 3 sealing gasket 2 side electrode 3 To obtain accurate spark plug readings accelerate up to speed on a straightaway Push the engine stop button and disengage the clutch by pulling the lever in If you re using a new plug ride for at least ten minutes before taking a plug reading a brand new plug will not color initially 4 Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere page 94 Check the fuel oil mixture carburetor and fuel system and ignition timing 5 Tighten the spark plug If the old plug is good 1 8 turn after it seats f installing a newplug tighten it twi
50. 2005 Honda CR85 85RB EXPERT OWNER S MANUAL amp COMPETITION HANDBOOK Introduction Congratulations on choosing your Honda CR motocross motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your CR is a high 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 motorcycle To do well you must be 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 Introd
51. 4 then pull out the throttle valve 3 screws 4 carburetor top 6 Remove the throttle cable 5 and cable holder 6 from the throttle valve 7 7 Remove the cable holder and throttle valve spring 8 from the throttle cable 8 Remove the throttle cable holder and jet needle 9 from the throttle valve LE 5 fh e VO 5 throttle cable 6 cable holder 7 throttle valve 8 throttle valve spring 9 jet needle 11 float bowl screws 13 float level gauge 14 float level Carburetor Adjustments amp Tuning Tips 9 Remove the float bowl screws 11 and float bowl 12 11 12 float bowl 10 Use a float level gauge 13 to measure the float level 14 with the float tab just contacting the float valve and the carburetor intake 15 facing up The float level should be 0 75 in 19 mm Adjust the float level by bending the float tab carefully 15 carburetor intake 11 To assemble reverse the disassembly procedures 12 To install the carburetor reverse the removal procedures After installing the carburetor check the air vent hoses 16 and overflow hose 17 for kinking or pinching and correct routing as necessary ifj 16 air vent hoses 17 overflow hose Adjustments for Competition 93 Carburetor Adjustments amp Tuning Tips Spark Plug Reading Refer to Spark Plug on page 46 Check any jetting change by reading the spark plug The fo
52. CR set at the standard race sag BIKE LOADED amp without rider Example 22 8 in 580 mm L PSE SH Free Sag Calculation unloaded 23 4 in 595 mm loaded W O rider 22 8 in 580 mm Free Sag 0 6 in 15 mm 6 Calculate the free sag dimension To do this subtract the loaded without rider dimension step 5 from the unloaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CR With the spring pre load set to obtain the proper race sag the rear suspension should sag 0 4 to 1 0 in 10 to 25 mm If the rear of your CR sags more than 1 0 in 25 mm from its own weight the spring is too stiff for your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will not extend as far as it should Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre load consider an aftermarket shock absorber spring A spring that is too soft for your weight forces you to add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebounds The rear end may top out from light braking or kick sideways over lips and square edged terrain It may even top
53. 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 70 Servicing Your Honda After Cleaning Lubrication There are some things you should do just after washing your CR to help prevent rust and corrosion Once your CR is clean and dry you should protect any bare steel from rusting by applying a light coating of a rust inhibitor Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent Be sure the chain is wiped clean 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 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
54. HE LOCAL GOVERNMENTAL AUTHORITY HAVING JURISDICTION ERST DETERMINE THAT OPERATION IS LEGAL 4 Motorcycle Safety Operating Controls Read this section carefully before you ride It Component Locations eee 6 presents the location of the basic controls on your CR Operating Controls 5 Component Locations clutch lever front brake lever SES aD throttle grip fuel fill cap choke knob fuel valve shift lever kickstarter rear brake pedal 6 Operating Controls Before each ride you need to make sure you and your Honda 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 adjustment for competition see page 71 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 should also 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 71 Whether you re preparing for competition or for practice always make sure you are n good physical and
55. Line and were passed too easily Notes on Strategy used by your competition or by riders in another event that are worth remembering Maintenance Records Regular Maintenance items you ll want to record in your logbook should include Dates and Results of Cylinder Piston and Ring Examinations Patterns for Frequency of Need for Decarbonization With a Particular Oil When you Last Performed Shock Linkage and Swingarm Pivot Bearing Maintenance Transmission Fork and Shock 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 113 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 114 Technical Information These parts and tools may be ordered from your authorized Honda dealer Optional Parts List CARBURETOR Remarks Main jet 130 155 in increments of 2 or 3 Standard 142 11 sizes H Size Slow jet
56. 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 more 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 96 Adjustments for Competition However the engine may not pull the higher gearing the spacing between gears may be too wide engine rpm may be too low Lower Gearing more rear sprocket teeth decrease top speed in each gear increases frequency of shifting narrower gear ratios increases engine rpm at a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However 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 teet
57. Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 Service Preparations Component Locatons sose sosssirsissesissiiisosissiat 28 Seat Removal 5 eio EEEE 29 Fuel Tank Removal ii eer cr teens 30 Subframe Removal eee 32 Service Procedures Fluid amp Filters Biel System better tte reet eges 34 Transmission Ou 36 Coolant PP 38 tel EE 40 Engine Throttle er Rr tea ns 42 Clutch E 44 Spark Plug cite eege i 46 Cylinder Systetn eee etd coiere edd 47 Chassis SUSPENSI OTit m 52 regeert eege 57 bride M 61 tege Tubes eR bete 62 Drive Chan uror ere temet renda 64 Expansion Chamber 67 Additional Maintenance Procedures 68 Appearance Care tbe ete erede 69 ADJUSTMENTS FOR COMPETITION 71 Front Suspension Adjustments 72 Rear Suspension Adjustments 80 Suspension Adjustments for Track Conditions 84 Suspension Adjustment Guidelines 85 Carburetor Adjustments amp Tuning Tips 88 Chassis Adjustments see 95 Ee niere e EEEE EEEE 96 Tire Selection for Track Conditions 97 Personal Fit Adjustments sss 98 LR IN e sevsdnnsostsn 99 Transporting Your Motorcycle
58. Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the following information in your letter name address and telephone number product model year and frame VIN serial number 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 121 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 122 Consumer Information Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll
59. S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Honda White Lithium Grease wheel bearing grease silicone sealer high temperature grease antifreeze Other Products safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light Technical Information 117 Wiring Diagram ENGINE STOP SWITCH rar suck s sow Cv venon o onance Pao ewe t usse n e encen ts uont oneen dh Pa cole mk Cw ware Is COLOR COMB GROUND MARKING IGNITION CONTROL MODULE STOP SW BIW l IGN BI Y EXT HIGH Y EXT LOW Bu GND G EXT W P GND G W PUL Bu Y IGNITION COIL IGNITION PULSE GENERATOR 118 Technical Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals eeeeeeeereeeserenee 120 Contacting Honda 121 Your Honda Dealer 122 The Honda Rider s Club USA ONIY Jancis iieiaeie 123 Consumer Information Consumer Information 119 Authorized Manuals The Service Manual used by your authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the profess
60. ad 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 motorcycle 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 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 3 air passage 2 starter jet 4 orifice 88 Adjustments for Competition Slow Circuit Fuel is metered by the slow jet 5 and is mixed with air that has been metered by the air screw 6 The mixture enters the venturi through the bypass 7 and slow jet circuit outlet 8 5 slow jet 6 air screw 7 bypass 8 slow jet circuit 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 at the nozzle 13 Float Chamber The float 14 and float valve 15 operate to maintain a constant level of fuel in the float bowl 16
61. after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the NOTICE The fork tube can drop on the slider and damage the fork dust seal and guide bushing when the fork cap is removed To avoid damage hold both brake pads the fork tube and slider when removing the fork cap 9 X NO GOOD LI EU II GO dp XLT zm d E NO GOOD N XX 8 11 10 10 fork tube 11 guide bushing 8 slider pipe 9 dust seal 9 Record the rebound damping adjuster position and turn the adjuster screw 12 counterclockwise until it stops 5 fork protectors 6 brake caliper Front Suspension Adjustments 10 Hold the fork tube 10 then remove the fork cap 2 from the fork tube Gently slide the fork tube down onto the lower end of the slider pipe 13 10 2 fork cap 10 fork tube 12 adjuster screw 13 slider pipe lower end NOTICE When removing the fork cap be careful not to damage the damping force adjuster needle rod and the needle on the rod end 11 Remove the fork cap 2 from the piston rod 15 by holding the lock nut 16 12 Remove the fork spring 17 2 fork cap 14 adjuster needle rod 15 piston rod 16 lock nut 17 fork spring cont d 73 Adjustments for Competition Front Suspension Adjustments 13 Pour the re
62. al procedures sess 68 Rider s Club Honda 123 Pct m 34 Chen ee ette efe rebates 27 riding E ien n e tertie 34 before amp after competition 26 hue 2 PCAN p 96 between motos amp practice sess 26 basic Operation donee tite reos 11 guidelines suspension adjustment 85 important safety Drecauton eee 19 IN te Jd general competition seen 22 important safety information 19 H TIN POM ANCE er eee Raid 18 s fety Drecautiobs 5 o ode ets 19 handlebar 1mspectton see 68 Satel E egfeee ge 19 high altitude carburetor adjustment 111 Schedule tei rre teretes 20 S Honda mantal Service sioe beni ertt eta en Tes Eee sess 120 safety e 121 nee rte te Tt eie he HU Reit feeds 2 important DrGCautons 19 Ridet s CTUD iecore totes inerte 123 labe egen 4 Service Manual eene 120 O MAINCENAN enne n e a 19 your AC ANSI xit teeth ot e reb e 122 oil riding precautions erinnern rennen 12 TOR unctione du 54 schedule maintenance essen 20 I TANS misSIOD eec oot bere Rete 36 Serial MUMDETS E 106 identification vehicle neiss 106 operating service idle speed efigime o c tee eee err 91 oio 5 CUSLONIBE koesers deneon atene a eerte eran 119 inspection PLETE eee Es 9 Ee ler le EE 11 ET 120 optional Spare PariS oot opener testes Posee rep Pie
63. arburetor Type Semi double cradle Type Piston valve Telescopic fork Identification number PWK10A F suspension travel 9 6 in 244 mm Main iet standard stroke 10 8 in 275 mm ain jet standard 142 Pro link Slow jet standard 45 R suspension travel 11 5 in 292 mm Air screw opening 2 turns out F tire size pressure 70 100 19 42M Float height 0 75 in 19 mm R tire size pressure 90 100 16 52M Clutch type Wet Iti plate t psi kPa kgf cm 15 100 1 0 E et mui p ate type Single disc brake Transmission 6 speed constant mesh 108 Technical Information F brake swept area 55 5 in 358 1 cm Primary reduction 4 117 Single disc brake Gear ratio 2 267 R brake swept area 40 0 in 257 8 cm Gear ratio II 1 722 Gear ratio III 1 400 Fuel capacity 1 4 US gal 5 3 Gear ratio TV 1174 Caster angle 27 25 Gear ratio V 1 042 Trail length 3 63 in 92 3 mm Gear ratio VI 0 920 Fork oil d per leg level Std 4 0 in 102 mm 8 9 9 8 9 NS 1 X AN d 11 an E pa HJ wei o y NON e p Berea o p E KO S SCH 2 Ve gt eZ 22 m SC ZR e Torque Specifications OO OO JO ol A WN Sch ec 3 O1 0 NS ES oo JO 19 20 Torque Item Remarks Ibf ft N m kgf m FRAME Steering stem nut 94 128 13 1 Top thread nut 44 59 0 6 Fork bridge upper pinch bolts 16 22 2 2 F
64. asic track conditions altitude and temperature carburetion changes suspension settings chassis adjustments tested and selected gearing tire selection 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
65. 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 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 partiicipating 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 roadsiide assistance for your new Honda includes roadside assistance for your transport vehicle as long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundatiion training Separate free training from the Specialty Vehicle Institude of America for ATV owners One full year of the Honda Red Rider magazine or Honda Red Rider ATV for ATV purchasers Discounts from HRCA partners for experienced rider courses Discounted vehicle insurance from the HRCA s insurance partner Racing contingency programs and assistance at selected dual sport off road and motors events Contact your Honda dealer for more
66. brakes are the hydraulic disc type As the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop Frequently inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear 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 60 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 A NU CH EN eo 3 1 lock nut increase 2 adjuster decrease 3 piston NR Loosen the lock nut 1 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 Tighten the lock nut Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay 3 8 13 16 in 10 20 mm Apply grease to the contacting faces of the adjuster and piston 3 Brakes Brake Pedal Height The brake pedal height should be approximately level with the right footpeg 1 Loosen the
67. 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 1 4 turn 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 stiff spring Test softer compression damping adjustments in one click increments If the entire travel feels stiff after the above adjustment Test softer compression damping adjustments in one click increments until the desired initial travel compression damping is obtained Lower the oil level by 0 2 in 5 mm Entire travel too stiff Stiff suspension on any type of terrain Test softer compression
68. ce it 4 chain slider 6 Check the chain guide slider 5 for wear Replace the guide slider if the chain is visible through the wear inspection window 6 5 chain guide slider 6 inspection window 7 Check the drive chain roller 7 for wear Replace if necessary Roller 0 7 in 18 mm 7 drive chain rollers 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 nuts 3 counterclockwise to decrease slack or clockwise to increase slack Align the index marks 4 of the axle plates with the same reference marks 5 on both sides of the axle plates 1 rear axle nut 4 index mark 2 lock nut 5 reference marks 3 adjusting nut 3 Tighten the rear axle nut to the specified torque 65 Ibf ft 88 N m 9 0 kgf m Tighten the lock nut by holding the adjusting nut with a wrench 4 Recheck chain stack and adjust as necessary 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 Drive Chain Removal Cleaning amp Replacement For maximum serv
69. ce 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 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 NAUN ON 1 radiator hoses 2 spark plug cap Drain the radiator coolant page 39 Turn the fuel valve OFF Remove the seat and fuel tank page 29 Remove the radiator hoses 1 Disconnect the spark plug cap 2 and remove the spark plug 3 Remove the four cylinder head nuts 4 using the technique described in the below and remove the cylinder head 5 To avoid warping the cylinder head use a crisscross pattern to loosen each nut about 1 4 then remove the nuts Remove the cylinder head gasket 4 cylinder head nuts 5b cylinder head 3 spark plug ON Un ULP 1 Cylinder Removal Remove the following expansion chamber page 67 exhaust manifold and gasket cylinder head carburetor Disconnect the radiator hoses Loosen the lower clutch cable adjuster 1 Remove the four cylinder mounting nuts 2 Remove the cylinder 3 Do not pry on or strike the cylinder Place a clean shop towel in the crankcase to keep debris out Remove the reed valve 4 from the cylinder and replace the
70. 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 accept able 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 Tire Selection for Track Conditions If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands on the transmission Complete consumer information can be obtained from the various tire manufacturer representa tives and dealers Some general recommendations for specific terrain follow Hard Slick Soil Use tires with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface The rubber compound needs to be softer for hard ground in order to hook up but not so soft that the knobs roll over easily and affect holding a straight line These tires tend to wear more quickly than standard tires because of the combination of soft rubber and hard terrain Muddy Soil Use a more open tread pattern to avoid clogging For these conditions the relatively long knobs will probably be made f
71. chases 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 P O BOX 07280 DETROIT e MI 48207 Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your Honda dealer If he doesn t have the answer right away he will get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only
72. cleaner with oil Squeeze out excess oil on Air Cleaner 9 Apply a thin coat of Honda White Lithium NOTICE Grease or an equivalent to the sealing surface Improper installation of the air cleaner assembly 10 Assemble the air cleaner and holder and put may allow dirt and dust to enter the engine and the air cleaner retaining bolt through the cause rapid wear of the piston rings and cylinder assembly 11 Install the assembly into the air cleaner housing with the tab 5 facing up and tighten 12 Reinstall the seat page 29 making sure it is the bolt securely securely attached 5 tab Servicing Your Honda 41 Throttle Refer to Safety Precautions on page 19 Throttle Freeplay RIGHT SIDE 1 1 throttle freeplay Inspection Check freeplay 1 Freeplay 1 8 1 4 in 3 6 mm If necessary adjust to the specified range Upper Adjustment Minor adjustments are generally made with the upper adjuster 2 rubber dust cover 3 upper lock nut 4 upper adjuster increase decrease 42 Servicing Your Honda 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 will decrease freeplay and turning it in direction will increase freeplay Tighten the upper lock nut Return the rubber dust cover to its normal position After adjustment
73. commended fork oil into the piston rod 15 until a little oil flows out of the top of the piston rod Leave the piston rod for about one minute 14 With the fork held upright measure the oil level 18 from the top of the fork tube to the fork oil 18 15 piston rod 18 oil level 15 Adjust the oil level by adding or removing oil with an aftermarket syringe 19 19 syringe 74 Adjustments for Competition Fork Oil Level CR85R Standard 0 28 kgf mm Fork Spring Ema 1 coil at both ends I i a Optional Stiffer 0 30 kgf mm Fork Spring 2 coils at one end 1 coil at other end gt Standard oil 4 0 in level 101 mm Maximum oil 3 7 in Slightly stiffer as level 95 mm it nears full compression Minimum oil 4 2 in Slightly softer as level 106 mm it nears full compression Standard oil 3 9 in level 99 mm Maximum oil 3 7 in Slightly stiffer as level 93 mm it nears full compression Minimum oil 4 1 in Slightly softer as level 104 mm it nears full compression Optional Softer 0 26 kgf mm Fork Spring C Se 2 coils at both ends Standard oil 3 9 in level 99 mm Maximum oil 3 7 in Slightly stiffer as level 93 mm it nears full compression Minimum oil 4 1 in Slightly softer as level 104 mm it nears full
74. ction also includes Accessories amp Modifications eeeeeeeeeeereeee 3 information about the location of the safety label Safety Label tbt tectae ud 4 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 Carring a passenger can cause an accident in which you and others can be hurt Wear Protective Gear Whether you re practicing to improve your skills or riding in competition always wear an approved helmet eye protection and proper protective gear Take Time to Get to Know Your CR Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perform well and ride safety Don t Drink and Ride Alcohol and riding don t mix Even one drink can reduce your ability to respond to chang
75. d impress on the junior rider the importance of checking all the items thoroughly before riding Important Safety Information 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 Label Read this label carefully and don t remove it If the label comes off or becomes hard to read contact your Honda dealer for replacement p s IMPORTANT IN ON OPERATOR ONLY NO P ERS THIS HONDA HOTORCYCLE I AS IS WITHOUT WARRANTY AND THE ENTIRE RISK AS TO QUALITY AND PERFORMANCE IS WITH THE BUYER READ OWNER S MANUAL THIS VEHICLE TS DESIGNED AND MANUFACTURED FOR COMPETITION USE ONLY TT DOES NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND OPERATION ON PUBLIC STREETS ROADS OR HIGHWAYS 1S ILLEGAL ADANGER STATE LANS PROHIBIT OPERATION OF THIS VEHICLE EXCEPT IN AN ORGANIZED RACING OR COMPETITIVE EVENT UPON A CLOSED COURSE NEVER OPEN WHEN HOT WHICH TS CONDUCTED UNDER THE AUSPICES OF A RECOGNIZED SANCTIONING Hot coolant will burn you BODY OR BY PERMIT ISSUED BY T
76. d 117 L parts Ist iio eite ea 115 Spark knock iret ead 34 EE EE 4 SPOCK qc Mm 115 spark plug locations component 6 28 oxypenated fuels wis Rete 112 EE 46 logbook competition eee 113 TT Lite Iesteesiieni cer t idee ebd dest o ido 94 P Specifications osnon eet nt deris tundes 107 Pads brake on ru e Treated 60 spring pre load rear suspension 80 parts Optiotial ziii eh deco P RS 115 starting personal fit adjustments esses 98 GE Nc M 13 pinging englne oie sepe ectetuer e paseo 34 troubleshootmg eo tette 103 plug Spark otia ee eege ee eae ege 46 steering stem Inspection 68 pre load rear suspension eese 80 Stopping enge eie e EEE 13 pre ride 1nspection iocus 9 roc 101 SUD EAMG o eite eov com diat dieecias 32 suspension TOM cc otc et RR ERR 52 rM eeege 53 cont d Index 127 Index suspension adjustment TPO i TAAA E E A 72 Eege eege 80 for track conditions ssesssss 84 BuldelitieS iib ee ees 85 T transmission Oll 22 oce rers eee seios eaea e 36 CUMIN S CUPS sitet ope be tite dd pes 88 throttle WIE 42 IB SDECHOH sai Meese tances cedet dila eate iod 43 tires Ce 62 EE 62 T zeiife ens teas E dels atiaden caseserscse 63 lee ee LLL 117 torque specifications esee 109 CHE
77. damping adjustments in one click increments Reduce the rebound damping in 1 4 turn increments Lower the oil level by 0 2 in 5 mm 86 Adjustments for Competition Rear Suspension Adjustment Adjustments for Type of Track Suspension Adjustment Guidelines 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 0 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 Adjustments for Too Soft Stiff Suspention Symptom Action Stiff Entire travel too stiff Test softer compression and rebound damping adjustments in one click increments suspension Install the optional soft spring Soft Suspension bottoms or rear end shakes Test stiffer comression and rebound damping adjustments in one click increments suspension Install the optional stiff spring Adjustments for Too Soft Stiff Suspention Symptom
78. der Your CR may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface On harder ground run less compression damping 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 84 Adjustments for Competition Follow the procedures described below to accurately adjust your CR using the methods described on pages 72 83 Remember to make all adjustments in one click increments Test ride after each adjustment Fork Adjustment Adjustments for Type of Track Suspension Adjustment Guidelines Hard surfaced track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below Install the optional stiff spring Sand track Adjust to a stiffer position Example Turn the compression damping adjuster to a stiffer position Install the optional stiff spring Adjust compression damping to a softer position and rebound damping to a harder position at this time Mud
79. ds of the fork protector bolts and axle holder thoroughly 34 Apply locking agent to the bolt threads 35 Install the fork protectors 5 and tighten the bolts to the specified torque 5 2 Ibf ft 7 N m 0 7 kgf m y 5 fork protectors 36 Clean the surfaces where the front axle shaft and axle clamps contact each other 37 Install the left and right side collars into the wheel hub 38 Insert the front axle shaft through the wheel hub from the right side Make sure the axle shaft is seated firmly onto the left fork leg clamp inner surface 39 Tighten the axle nut 3 to the specified torque 46 Ibf ft 62 N m 6 3 kgf m a 3 axle nut Front Suspension Adjustments 40 Align the brake caliper 6 and hose with the left fork leg making sure that the brake hose is not twisted 41 Clean the threads of the caliper mounting bolts 25 and brake caliper thoroughly 42 Apply locking agent to the bolt threads 43 Install the brake caliper on the fork slider and tighten the caliper bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m An improperly routed brake hose may rupture and cause a loss of braking efficiency Route the hose carefully Fit the brake caliper over the disc taking care not to damage the brake pads 6 caliper 25 caliper mounting bolts cont d Adjustments for Competition 77 Front Suspension Adjustments 44 With the front brake applied pump the fork up and
80. e Piston valve f Telescopic fork Identification number PWK10A F suspension travel 9 6 in 245 mm Main iet standard 142 stroke 10 8 in 275 mm ain jet standard l Pro link Slow jet standard 45 R suspension travel 10 8 in 275 mm Air screw opening 2 turns out F tire size pressure 70 100 17 40M Float height 0 75 in 19 mm psi kPa kgf cm 15 100 1 0 Drive train R tire size pressure 90 100 14 49M Clutch type Wet multi plate type psi kPa kgf cm 15 100 1 0 ale ee Technical Information 107 Specifications CR85RB Item English Metric Item English Metric Item English Metric Engine Drive train Dimension Type Liquid cooled 2 stroke Final reduction 3 667 Overall length 74 1 in 1 881 mm Cylinder arrangement Single 15 inclined from Gear shiit pattern Left foot operated return Overall width 30 3 in 769 mm vertical p system 1 N 2 3 4 5 6 Overall height 46 1 in 1 170 mm Bore and stroke 1 87 x 1 88 in 47 5 x 47 8 mm Electrical Wheelbase 50 7 in 1 289 mm Displacement 5 17 cu in 84 7 cm Ignition ICM Seat height 34 0 in 864 mm Compression ratio 8 45 1 Starting system Kickstarter Foot peg height 164 in 417 mm Transmission oil 18 6 US oz 550 cm Spark plug Standard NGK capacity draining BR10EG Ground clearance 13 9 in 353 mm t disassemibi Dry weight 159 Ibs 72 kg y 20 3US oz 600 cm Frame C
81. e surges lean exiting a corner turn the air screw clockwise to richen the mixture Carburetor Adjustments amp Tuning Tips 1 throttle stop screw increase 2 air screw decrease 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 smallest slow jet is needed If you are under 1 turn out the next larger slow jet is needed Adjustment Procedure 1 Warm up the engine 2 Make two or three laps of a course with the standard setting or corrected jetting page 89 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 46 90 It may take more than two or three 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 90 4 If you ve determined that the main and slow jets must be changed you must remove the float bowl plug Removing the float bowl plug will allow the fuel in the float bowl to drain Do not remove the plug if the engine is hot 5 Turn the fuel valve OFF and disconnect the fuel line from the fuel valve 6 Loosen the connecting and insulator tube clamp screws 1 Rotate the carburetor Remove the float bowl plug
82. e 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 vou 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 Refer to Safety Precautions on page 19 Choosing the correct tire tread pattern and rubber compound can affect your placing in competition The tires on your CR offer a happy medium for the variety of soil conditions the majority of riders are likely to encounter Experienced competitors often switch to tires developed for specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in tires especially the sidewall profile can change the attitude of your CR and its handling Tire variations that raise or lower the rear of your CR have a more signifi cant effect on handling than variations in front tires which generally don t vary as much Often you can see or feel the
83. earance CANE 1 eei erret eorr ine is Een gea n 69 MAIMEM NIU MN 28 frame number aeter iubere ng 106 authorized manuals sese 120 operating controls eere 6 front brake lever adjustment 57 competition Jogbook sees 113 front suspension maintenance ees 52 B contacting Honda sessie srnsisoeiennosores oei 121 fuel Dasic Operati Of E 11 controls Operating ee eee eeseceseeeeeeeeeeeeeeeeeaees 5 neen ssedaetadas 35 pefore Tridino esre re ERE RET ESSERE S 7 COOLANT eres deeg 38 lp 35 between motos amp practice maintenance 26 CUSTOMER SEL VIC credent eoe EI o oc canes 119 recommendation eese 34 Brakes cylinder SyStermuii aire eee te ERR ees 47 retuelme iiti bh peines 35 PUIG level petes 58 irum 34 lever front adiustment s 57 D ONSE niens oo erre ates die 112 pad Wear ectetuer E 60 damping adjustments tank capacity s coe iore eese ege GE 35 pedal heis ht uite erts 57 FROME EET 78 Valve aie siete rk dotes esie eius 35 break in guidelines tette eno 16 rp sen 80 dealer your Honda 122 diagram WINS cere tea cite Lote reiecta 118 Cer imei 64 126 Index G M R gap spark maintenance rear suspension maintenance sees 53 Eltere ege gege 46 addition
84. ecifications Single disc brake Transmission 6 speed constant mesh F brake swept area 55 5 in 358 1 cm Primary reduction 4 117 Single disc brake Gear ratio 2 267 R brake swept area 40 0 in 257 8 cm Gear ratio II 1 722 Gear ratio III 1 400 Fuel capacity 1 4 US gal 5 30 Gear ratio IV 1174 Caster angle 26 51 Gear ratio V 1 042 Trail length 3 02 in 76 7 mm Gear ratio VI 0 920 Fork oil per leg level Std 4 0 in 101 mm Item English Metric Item English Metric Item English Metric Engine Drive train Dimension Type Liquid cooled 2 stroke Final reduction 3 267 Overall length 71 0 in 1 803 mm Cylinder arrangement Single 15 inclined from STE Left foot operated return Overall width 30 3 in 769 mm vertical P system 1 N 2 3 4 5 6 Overall height 443 in 1 126 mm Bore and stroke 1 87 x 1 88 in 47 5 x 47 8 mm Electrical Wheelbase 49 1 in 1 248 mm Displacement 5 17 cu in 84 7 cm Ignition ICM Seat height 324 in 824 mm Compression ratio 8 45 1 Starting system Kickstarter Foot peg height 148 in 376 mm Transmission oil 18 6 US oz 550 cm Spark plug Standard NGK capacity draining BR10EG Ground clearance 12 2 in 311 mm at disass mbi Dry weight 154 Ibs 70kg y 20 3US oz 600 cm Frame Carburetor Type Semi double cradle Typ
85. ed 40 Engine Throttle iecore ete terae tse beeches fees eed edd 42 Clutch System erre ra eer 44 Spark PIUS eegene het et eb gece 46 Cyhnder System menn ira et ined 47 Servicing Your Honda Chassis UE 52 Brak EE 57 WHEELS fem 61 Tires amp TUDES sir rr ER ORDRES 62 Drive CHAI icc ecce scr co e bete tne petere 64 Expansion Chamber 67 Additional Maintenance Procedures 68 Appearance Care ird reb etie dtes 69 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
86. een uoo ois oor aded eee ns 100 troubleshooting irte seta 103 tubes replacmp siento te tet 62 V Valye TUS soe ortos Yea s dene rae ras ceo 34 vehicle dente anon 106 W washing your motorcvcle 69 E 61 Writing diagram seco erra tere etre 118 128 Index Memo 129 Quick Reference The following is a brief but important collection of information you need to know about your Honda You ll also find space to record important notes How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly engine repairs are Transmission oil amp premix oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal Quick Reference Record important information here Frame No Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr Maintenance The maintenance schedule page 19 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 engine oil
87. end adjuster 3 all the way in to provide maximum freeplay 2 Loosen the lock nut 4 3 Turn the lower clutch cable adjuster 5 to obtain the specified freeplay 4 Tighten the lock nut Check the adjustment 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your CR should move smoothly and accelerate gradually If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to pages 121 122 or the official Honda Service Manual 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 System 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 Spark Plug Refer to Safety Precautions on page 19 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions Standard BR1
88. ever brake pedal spokes front amp rear each side sprockets larger amp smaller than standard for gearing changes amp collision damage replace ment assorted nuts bolts washers screws cotter pins Additional Spares front brake master cylinder rear brake assembly front amp rear brake hoses wheels amp tires front amp rear mounted clutch plates amp transmission oil seat ignition components top end complete radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end amp box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CR purchased from your Honda dealer flywheel puller 07733 0010000 Spare Parts amp Equipment Chemical Products Pro Honda HP Trans Oil Pro Honda HP Fork Oil 5W Pro Honda HP2 2 stroke Oil Honda thread Lock Honda Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda Contact Brake Cleaner Honda Dielectric Grease Honda Hand Grip Cement Honda Hondalock Honda Moly 60 Paste U
89. f spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil level in increments of 0 2 in 5 mm Entire travel too soft Front end shakes Fork bottoms over any type of terrain Install the optional stiff spring Test stiffer compression damping adjustments in one click increments Increase rebound damping in 1 4 turn increments Adjustments for Competition 85 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 1 4 turn increments Check for dirt in the dust seals Check the fork oil for any contamination If the front end dives while cornering reduce the rebound damping in 1 4 turn increments If that doesn t solve the problem install the optional stiff spring If the stiff spring makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desire compression damping for initial travel is obtained Middle travel too stiff Stiff on
90. ffle pattern on the grip with the clutch lever as shown in the illustration Refer to the Service Manual for installation instructions For added security you may choose to safety wire the hand grips to the handlebar and throttle 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 grip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the drum and the 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 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 air cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require serv
91. ge 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 plastic Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events The best way to organize the many bits of information is to record them in a logbook Your logbook can include such information as suspension adjustments carburetor adjustments gearing and tire selection This detailed information along with your comments 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 sub jects For example record results in black jet ting 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 b
92. h 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 For tight tracks consider lower gearing to avoid having to slip the clutch frequently Repeated fanning or pulling of the clutch lever in a turn to raise engine rpm may eventually damage the clutch system A gearing change may help for riding in sand where you want to keep the front end light so it can float from the peak of one sand whoop to the next Generally with higher gearing it is easier to maintain that perfect attitude maximum rear wheel traction and a light front end because you remain in the powerband longer in each gear The higher gearing allows you to steer more efficiently with throttle control and body English If you are riding a track with sections where you choose to over rev the engine temporarily rather than shifting up higher gearing might help Sometimes you have to sacrifice performance on one section of the track to gain a better overall time Your goal is the fastest overall lap time even if the cost is some sections wher
93. hamber for cracks or deformation A damaged chamber may decrease engine performance Expansion Chamber Removal 1 Remove the expansion chamber by removing the expansion chamber spring 1 and mounting bolts 2 2 Remove carbon deposits from the head pipe of the expansion chamber 2 mounting bolts 1 spring Expansion Chamber Expansion Chamber Installation 1 Inspect the O rings 1 Replace the O rings if it has damaged or otherwise appears unserviceable 2 Install the O rings and washer 2 as shown If necessary apply the grease to the washer and must be installed the washer and O rings 3 Install the expansion chamber 3 expansion chamber spring 4 and mounting bolts 5 Tighten the front and rear mounting bolts to the specified torque 6 5 Ibf ft 8 8 N m 0 9 kgf m 1 O rings 4 expansion chamber 2 washer spring 3 expansion chamber 5 mounting bolts Servicing Your Honda 67 Additional Maintenance Procedures Refer to Safety Precautions on page 19 Steering Stem Inspection 1 With your CR on a box or workstand front wheel elevated turn the handlebar to the right and left to check for roughness in the steering head bearings 2 Stand in front of your CR grab the fork at the axle look at the steering head and push the fork in and out toward the engine to check for play in the steering head bearings If any roughness or play is felt but you do not see any movement
94. hazard that can arise 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
95. hroud and boss 10 of the fuel tank 9 Tighten the shroud bolts 11 8 right side shroud 9 grommet 10 boss 11 shroud bolts Fuel Tank Removal Servicing Your Honda 31 Subframe Removal Refer to Safety Precautions on page 19 Removal 1 Remove the seat page 29 2 Remove the right side cover 1 by removing the bolt collar 2 1 right side cover 2 bolt collar 3 Remove the bolt washer 3 and muffler 4 E 3 bolt washer 4 muffler 32 Servicing Your Honda 4 Loosen the screw 5 on the air cleaner connecting tube clamp 6 5 screw 6 connecting tube clamp 5 Remove the lower subframe mounting bolts 7 and upper subframe mounting bolt 8 6 Remove the subframe 9 by pulling it straight backward 7 lower subframe mounting bolts 8 upper subframe mounting bolt 9 subframe Installation 1 Loosely attach the upper and lower ends of the subframe to the mainframe while connecting the air cleaner connecting tube to the carburetor 2 Tighten the screw 1 on the connecting tube clamp 2 1 screw 2 connecting tube clamp 3 Align the subframe 3 with the rear wheel and install the upper subframe mounting bolt 4 and lower subframe mounting bolts 5 4 Tighten the upper subframe mounting bolt to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 5 Tighten the lower subframe mounting bolts to the specified torque 16 Ibf ft 22 N
96. ice 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 or tight fitting links or otherwise appears unserviceable Replacement chain RK420MSZ1 cont d Servicing Your Honda 65 Drive Chain 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 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 66 Servicing Your Honda 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
97. icing 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 Honda White Lithium Base 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 is not of equivalent quality may cause Air Cleaner Housing Sealing Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with silicone sealer if there is any doubt to its sealing integrity Use Honda Thread Lock or an equivalent on the attaching studs Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent oil changes will also assure consistent performance of both shifting and clutch action page 36 Servicing YourHonda 23
98. 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 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 Honda Thread Lock 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 bowl 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 Inspect the mating surfaces for warpage due to over torquing 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 or
99. ing conditions and your reaction time gets worse 2 Motorcycle Safety 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 Important Message to Parents Your child s safely is very important to Honda That s why we urge you to read this message before you let any young person ride this motorcycle Competitive riding can be fun But bad judgement can result in injury and we don t want that to happen As a parent you can help prevent accidents by making good decisions about when and how your youngster rides this motorcycle Remember this CR is designed only for competition use by experienced junior riders It is an operator only model and the maximum load capacity is 150 lbs Rider weight must not exceed this limit The junior rider must be fall enough to hold the motorcycle up while straddling it with both feet on the ground He or she must also be strong enough to pick up the motorcycle if it is on its side The parent and junior rider must be fully familiar with the motorcycle the motorcycle controls and control functions Both must also Fully understand everything in this manual before riding begins For your child s safely be sure to make pre practice and pre race inspections an
100. ional 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 61GBF10 2005 CR85R RB Service Manual 38 00 61CM002 Common Manual 48 00 31GBF720 2005 CR85R RB EXPERT 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 Publication D m Q Price Total Item No tem Description ty Each Price Sub Total Prices are subject to change without notice and Purchaser s Sales Tax without incurring obligation Mich Add 6 Calif Add 8 25 Orders are mailed within 10 days Please allow ade Handling 5 00 quate time for delivery Charge Grand Total 120 Consumer Information O Jm0 e E OO m Dm e P Oo 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 pur
101. ket cont d Servicing Your Honda 49 Cylinder System 2 Install the gasket to the crankcase 3 Install the reed valve assembly insulator and clamp to the crankcase 4 Install the four carburetor insulator mounting bolts 3 and tighten to the specified torque in a crisscross pattern 6 6 Ibf ft 9 N m 0 9 kgf m After installation check for secondary air leaks around the reed cage and insulator 3 carburetor insulator mounting bolts 5 Install the radiator hose 6 Install the carburetor page 92 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 cylinder base gasket 1 and dowel pins 2 on the crankcase 50 Servicing Your Honda 5 Install the four flange nuts 4 and tighten to the specified torque in a crisscross pattern in 2 or 3 step 20 Ibf ft 27 N m 2 8 kgf m Be careful not to overtighten the mounting nuts this is the most common cause for leaks here 1 cylinder base gasket 2 dowel pin 4 Lubricate the piston and ring with 2 stroke oil Align the ring end gap with the piston ring pin 3 in the ring land and slip the cylinder over the piston while compressing the piston ring NOTICE Do not rotate
102. l maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CR in good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good An ICM Ignition Control Module system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to the Honda Service Manual page 122 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety nte oe rated 19 Important Safety Precautions 19 Maintenance Schedule ssinsiornnisrinsimeninass 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 Service Preparations Component Locations ssessroisssirsiiiseiissiicssse 28 Seat Remoyal ronen rE EEE 29 Fuel Tank Removal ee 30 Subframe Remowval see 32 Service Procedures Fluids amp Filters Fuel System tec ee bee eege 34 Transmission OU 36 COOL AINE EE 38 Aur C leanet 25 eerte Eegen E
103. l 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 1 fork protector leaking fork seals should be replaced before your CR is ridden 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 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times Rear Suspension Inspection The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure The shock absorber s spring preload and damp ing adjustments compression and rebound should be adjusted for the rider s weight and track conditions page 84 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 When your CR is new break it in for approximately one hour with the standard suspension settings before attempting to
104. le Warming the engine is important to prevent cold seizures Warm Engine Starting 1 Turn the fuel valve ON 2 Shift the transmission into neutral 3 Push the choke knob down 4 Open the throttle 1 8 1 4 and operate the kickstarter Starting amp Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine 1 Shift the transmission into neutral 2 Push the choke knob down all the way to OFF 3 Open the throttle fully 4 While pushing the engine stop button crank the engine several times with the kickstarter 5 Release the engine stop button 6 Follow the Warm Engine Starting procedure Basic Operating Instructions 13 Starting amp Stopping the Engine How to Stop the Engine 1 throttle 2 engine stop button Normal Engine Stop 1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle 1 2 3 times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow fill the 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 1 2 After the engine has been warmed up the motorcycle is ready for ridi
105. level is correct when it is at the bottom of the radiator filler neck 2 1 radiator cap 2 filler neck A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap 2 Add coolant up to the filler neck 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 overflow tube is normal If coolant loss is more than this inspect the cooling system Capacity 0 45 US qt 0 43 at disassembly 0 45 US qt 0 43 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 Coolant Cooling System Inspection Coolant Replacement 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 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 Ho
106. level are only felt during the final 3 9 in 100 mm of fork travel Compression damping Turning the compression damping screw adjusts how quickly the fork compresses Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends Fork springs Optional springs are available in softer and stiffer types than the standard rate page 116 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 O 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 72 Adjustments for Competition The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pressure release screw 1 of each front suspension 3 Check that
107. line is highly flammable and 1 Turn the fuel valve OFF 7 Unhook and remove the fuel tank band 7 explosive You can be burned or seriously 2 Remove the right side shroud bolts 1 8 Disconnect the fuel line 8 from the fuel injured when handling fuel 3 Slide the right side shroud 2 forward valve 9 Remove the right and left side fuel tank e Stop the engine and keep heat sparks bolts washers 9 and fuel tank and flame away Handle fuel only outdoors Wipe up spills immediately 1 right side shroud bolts 2 right side shroud 6 breather tube 4 Remove the left side shroud bolts 3 collar 7 fuel tank band 4 and left side shroud 5 8 fuel line 9 right and left side fuel tank bolts washers 3 left side shroud bolts 4 collar 5 left side shroud 30 Servicing Your Honda Installation 1 2 1 2 3 4 Install the fuel tank on the frame Tighten the right and left side fuel tank bolts washers 1 3 Connect the fuel line 2 to the fuel valve 4 5 Put the breather tube 4 in the steering stem Hook the fuel tank band 3 nut right and left side fuel tank bolts washers fuel line fuel tank band breather tube 6 Install the seat page 29 7 Install the left side shroud 5 collar 6 and left side shroud bolts 7 5 left side shroud 6 collar 7 left side shroud bolts 8 Slide the right side shroud 8 aligning the grommet 9 of the s
108. llowing 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 enter ing the cylinder Ride for 10 15 minutes before taking a plug reading A new plug will not color immediately 94 Adjustments for Competition To obtain an accurate reading of a new spark plug 1 Accelerate at full throttle on a straight 2 Push the engine stop button and pull the clutch lever in to release the clutch 3 Coast to a stop 4 Remove the spark plug 5 Use a magnifying glass to inspect the spark plug The porcelain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain indicate rich jetting NOTICE Improperly tightened spark plugs can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 1 insulator 2 center electrode 3 side electrode Spark Plug Coloring Guidelines Condition Spark Plug
109. loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 1 16 in 1 5 1 lock nut 2 adjuster nut 3 pin spanners 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 8 7 in 221 TED oos CR85R 8 9 im 225 EE CR85RB 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 9 4 in 238 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 Pin spanners should be used for turning the lock nut and adjusting nut See page 115 for optional pin spanners CR85R Spring preload length Standard spring Standard 9 3 in 237 mm Min 8 7 in 221 mm Spring preload length Optional spring Min Softer 4 6 kgf mm 8 6 in 218 mm Min Softer 4 8 kgf mm 8 7 in 222 mm Min Stiffer 5 2 kgf mm 8 9 in 225 mm Min Stiffer 5 4 kgf mm 8 7 in 220 mm CR85RB Spring preload length Standard spring Standard 9 0 in 229 0 mm Min 8 9 in 225 mm Spring preload length Optional spring Min Softer 4 8 kgf mm 8 7 in 222 mm Min Softer 5 0 kgf mm 8 7 in 221 mm Min Stiffer 5 4 kgf
110. low any excess oil to flow out of the check bolt hole If no oil flows out of the check bolt hole add oil slowly through the oil filler hole until oil starts to flow out of the check bolt hole Install the oil check bolt and filler cap Repeat steps 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 6 6 Ibf ft 9 N m 0 9 kgf m Transmission Oil Replacing Transmission Oil Run the engine for three minutes then shut it off Support the CR in an upright position on a level surface Remove the oil filler cap from the right crankcase cover Place an oil drain pan under the engine to catch the oil Then remove the drain bolt 1 Pour the drained oil into a suitable container and dispose of it in an approved manner page 102 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 18 Ibf ft 25 N m 2 5 kgf m Add the recommended oil 0 58 US qt 0 55 at oil change Check the oil level by following the steps in Checking amp Adding Oil 1 oil drain bolt Servicing Your Honda 37 Coolant Your CR s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coola
111. ly stiffer as level 95 mm it nears full capacity 12 2 US oz compression 361 cm Minimum oil 4 2 in Slightly softer as level 106 mm it nears full capacity 12 0 US oz compression Lea cm E EC 2 coils at one end E 1 coil at other end Standard oil 3 9 in level 99 mm capacity 12 1 US oz 358 cm Maximum oil 3 7 in Slightly stiffer as level 93 mm it nears full capacity 12 2 US oz compression 362 cm Minimum oil 4 1 in Slightly softer as level 104 mm it nears full capacity 12 0 US oz compression 355 cm Optional Softer 0 26 kgf mm Fork Spring Ea 2 coils at both ends SS SS Standard oil 3 9 in level 99 mm capacity 12 1 US oz 358 cm Maximum oil 3 7 in Slightly stiffer as level 93 mm it nears full capacity 12 2 US 0z compression 362 cm Minimum oil 4 1 in Slightly softer as level 104 mm it nears full capacity 12 0 US oz compression 355 cm cont d Servicing Your Honda 55 Suspension Fork Oil Level CR85RB Standard 0 28 kgf mm Fork Spring 1 coil at both ends Ss factory products Standard oil 4 0 in level 102 mm capacity 12 0 US oz 856 cm Maximum oil 3 7 in Slightly stiffer as level 95 mm it nears full capacity 12 2 US oz compression 361 A es Minimum oil 4 2 in Slightly softer as level 106 mm it nears full capacity
112. m 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 70 100 17 40M CR85R Rear 90 100 14 49M Tire type bias ply tube Front 70 100 19 42M CR85RB Rear 90 100 16 52M Tire 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 63 Drive Chain Refer to Safety Precautions on page 19 The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets When the motorcycle is ridden on unusually dusty or muddy tracks more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF and check that
113. m 2 2 kgf m T 3 subframe 4 upper subframe mounting bolt 5 lower subframe mounting bolts 6 Connect the silencer 6 to the expansion chamber with the sealing rubber Install the rubber seal 7 with its FR mark 8 facing foward 7 Install and tighten the muffler bolt washer 9 6 silencer 8 FR mark 7 rubber seal 9 muffler bolt washer 8 Install the right side cover 10 and bolt collar 11 10 right side cover 11 bolt collar 9 Install the seat page 29 Subframe Removal 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 112 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 pi
114. mm 8 7 in 220 mm Min Stiffer 5 6 kgf mm 8 9 in 225 mm Rear Suspension Damping Compression Damping Compression damping can be adjusted with the adjuster located on the rear shock absorber s reservoir To increase damping turn the adjuster screw clockwise To decrease damping turn the screw counterclockwise Rear Suspension Adjustments 1 adjuster 3 reference mark 2 punch mark To adjust to the standard position 1 Turn the adjuster 1 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise approximately 1 3 4 CR85R 3 4 CR85RB turns so that the punch mark 2 on the adjuster aligns with the reference mark 3 on the shock absorber Rebound Damping The rebound damping adjuster 4 is located at the lower end of the shock absorber To increase damping turn the adjuster screw clockwise To decrease damping turn the adjuster screw counterclockwise 4 rebound damping adjuster 6 reference mark 5 punch mark To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seat This is the full hard position 2 Turn the adjuster counterclockwise approximately 1 1 4 CR85R 1 2 CR85RB turns so that the punch mark 5 on the adjuster aligns with the reference mark 6 on the shock absorber Adjustments for Competition 81 Rear Suspension Adjustments Rear S
115. molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Suspension Linkage Lubrication Disassemble clean inspect and lubricate all pivot bearings after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear Use Honda Moly 60 paste U S A only or molybdenum 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 in your Owner s Manual page 60 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 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 m
116. motorcycle trailer to transport your Honda we recommend that you follow these guidelines Use a loading ramp Make sure the fuel valve is off 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 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 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 100 Tips If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CR running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean
117. nd any roughness or burred edge on the end of either spring smooth the roughness with a file and some emery cloth contd Adjustments for Competition 75 Front Suspension Adjustments 17 Clean the spring and spring seat thoroughly with a high flash point solvent to remove all metal particles and dirt 18 Dry the spring and spring seat with air pressure rather than a shop towel Using a shop towel allows lint to stick to the springs Lint or any particles that stick in the damping passages can cause inconsistent damping 19 Check that the O rings 20 on the fork cap and needle rod are in good condition Apply the recommended fork oil to the O rings 20 20 O rings 20 Loosen the lock nut 16 slightly 21 Attach a two foot length of mechanic s wire 21 to the threaded portion on the lock nut Wrap the wire securely around the threads 21 16 lock nut 21 mechanic s wire 76 Adjustments for Competition 22 Install the fork spring 17 as follows With the fork spring held upright on its marked end feed the mechanic s wire up through the spring Angle the fork spring and slowly slide it down into the fork using a gentle rocking motion 23 Reaching through the two adjacent coils near the oil lock valve hold the spring guide 22 with your finger Remove the mechanic s wire and hand tighten the lock nut 16 16 22 17 16 lock nut 17 fork sp
118. nda Service Manual A WARNING Check the water leakage check hole 3 below Removing the radiator cap while the the water pump for leakage Make sure the 1 water hoses 3 water leakage check engine is hot can allow the coolant to hole remains open If water leaks through the 2 ove imiow tube bole spray out seriously scalding you check hole the water pump seal is damaged If oil leaks through the check hole the Always let the engine and radiator cool transmission oil seal is damaged See the down before removing the radiator cap Honda Service Manual or consult your Honda dealer for replacing the water pump seal or the transmission oil seal Both seals should To properly dispose of drained coolant refer to be replaced at the same time You amp the Environment page 102 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
119. ng While the engine is idling pull in the clutch lever and depress the shift lever to shift into Ist low gear Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throttle Coordination of the throttle and clutch lever will assure a smooth positive start NOTICE When moving off from a standing start be careful not to use too much throttle The motorcycle may wheelie over backwards 4 When the motorcycle attains a moderate speed close the throttle pull in the clutch lever and shift to 2nd gear by raising the shift lever This sequence is repeated to progressively shift to 3rd 4th 5th and 6th top gear Raise the shift lever to shift to a higher gear and depress it to downshift Each stroke of the shift lever engages the next gear is sequence The shift lever automatically returns to the horizontal position when released Shifting Gears Basic Operating Instructions 15 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 rings are replaced cylinder is replaced crankshaft or crankshaft bearings are replaced 16 Basic Operating Instructions Keeping your CR wel
120. nging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank 34 Servicing Your Honda 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 78 4 0 118 1 5 5 67 6 0 177 2 0 7 57 8 0 237 2 5 9 46 10 0 296 3 0 11 35 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 Fuel System To service the fuel filter 1 Drain the fuel from the fuel tank into an appro
121. nt will allow the cooling system to work properly and prevent freezing overheating and corrosion Coolant Recommendation Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze container label Use only distilled water as a part of the 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 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 19 1 With the engine cold remove the radiator cap 1 and check coolant level The coolant
122. on 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 52 When your CR is new break it in for approximately one hour to ensure that the suspension has worked in page 16 After break in test run your CR with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CR for three hours See page 72 for fork disassembly Replace the fork oil every three races or 7 5 hours of running See page 72 for oil level adjustment after changing the fork oil Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CR s front suspension Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension adjustment information page 78 for 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 Servicing Your Honda If you become confused about adjustment settings return to the standard position and start over If the fork is stil
123. orce kgf 0 3 9 79 11 8 100 200 300 Stroke in mm Front Suspension Adjustments Adjustments for Competition 79 Rear Suspension Adjustments Refer to Safety Precautions on page 19 The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only Puncture or exposure to flame may also result in an explosion causing serious injury Service or disposal should only be done by your authorized Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the official Honda Service Manual If your CR is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Remove the subframe See page 32 80 Adjustments for Competition 3 Check that the spring preload is adjusted to the standard length Adjust as necessary by
124. ords DANGER WARNING or CAUTION These signal words mean A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions A WARNING You CAN be KILLED or SERIOUSLY HURT if you don t 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 eere 1 Important Safety Information 2 Important Safety Precautions 2 Important Message to Parents 2 Accessories amp Modifications eeeeeeeeeeee 3 Safety Label etate rete eter eroe 4 OPERATING CONTROLS e 5 Component Locations 0 0 0 eee eeseeeseeeeeeereeeeeenees 6 BEFORE RIDING eere eese ener ntnnn 7 Are You Ready to Rudel 8 Is Your Motorcycle Ready to Ride 9 Pre nde Inspection eere 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Drecautons 12 Starting amp Stopping the Engine 13 Preparation odes S 13 Starting Procedure sese 13 Flooded Engrne 4u ttes 13 How to Stop the Engine 14 Shitana EE 15 Break in Gudelmes sss 16 SERVICING YOUR HONDA
125. ore frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service life of brake fluid Water Pump Inspection Hole After every race check the inspection hole located just below the water pump 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 r Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Fork Oil Performance Disassemble clean and inspect the fork and replace the 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 Periodicall
126. ork bridge lower pinch bolts 16 22 2 2 Handlebar upper holders 16 22 2 2 Throttle holder 7 10 1 0 Brake lever pivot 44 59 0 6 Clutch lever pivot 0 7 1 0 1 Clutch lever pivot nut 44 59 0 6 Front brake master cylinder holder 9 12 1 2 Brake hose guide bolt 38 5 2 0 5 Front axle nut 46 62 6 3 NOTE 4 Rear axle nut 65 88 9 0 NOTE 4 Engine hanger bolts 24 32 3 3 Shock absorber upper 33 44 4 5 NOTE4 lower 33 44 4 5 Swingarm pivot nut 58 78 8 0 Fork cap 25 34 3 5 Rear shock arm swingarm side 44 59 6 0 NOTE 4 shock link side 44 59 6 0 NOTE 4 Rear shock link nuts Frame side 44 59 6 0 NOTE 4 Shock spring lock nut 65 88 9 0 NOTES 1 Apply Honda Thread Lock or an equivalent to the threads Apply oil to the threads and flange surface Stake U nut UBS nut SH bolt Alock bolt Am mb at Technical Information 109 Torque Specifications Torque Item Remarks Ibf ft Nem kgf m VA FRAME 4 IN 28 33 21 Caliper mount bolts Z Front 22 30 3 1 Rear 11 15 1 5 dee 22 Front brake disc nuts 15 20 2 0 NOTE 4 a 23 Rear brake disc nuts 15 20 20 NOTEA p S T 24 Brake pedal pivot bolt 24 32 3 3 ES 2 25 Shift lever 12 16 1 6 ANN 26 Spokes 2 8 3 7 0 4 DA m 27 Rim locks 9 124 13 P lt RUN Y 26 28 Subframe bolt upper 16 22 22 Ek lower 16 22 22 Jz pA 29 Fork piston rod lock nut 15
127. ould 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 trans ferred toward the firmer end of wheel travel Keep the race sag adjustment page 82 in the 3 3 4 1 in 85 105 mm range Fork Height Angle The position of the fork tubes in the clamps is adjustable Before making any chassis adjustments or measuring wheel base make sure the fork tubes are set to their proper position Standard Position Align the groove 1 in the outer tube with the top surface of the upper fork clamp 2 1 NL 1 groove 2 upper fork clamp Chassis Adjustments Wheelbase Adjusting your CR s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to re check race sag and adjust if necessary In the past a general rule was lengthen the wheelbase to add straight line stability shorten the wheelbase to improve turning However we suggest you do not lengthen the wheelbase of your CR unless
128. ove check out then adjust the carburetor for your specific racing conditions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition Refer to the list on page 115 for the optional carburetor parts To prevent engine damage always adjust the main jet before adjusting the jet needle If there is any doubt always choose the next richer jet so there is a margin for safety Carburetor Minor Adjustments The standard carburetor settings are ideal for the following conditions 32 to 1 premix ratio using Pro Honda HP2 2 stroke oil or its equivalent sea level altitude and 20 C 68 F air temperature If your conditions are different you may need to adjust the carburetor settings using the tuning information on pages 88 90 Confirm your settings are correct before proceeding Minor Adjustments 1 2 Adjust the carburetor setting using the turning information on pages 88 90 When the engine is warm enough to run without the choke push the choke knob down to its off position Turn the throttle stop screw 1 to obtain the smoothest idle o decrease idle speed turn the screw counterclockwise To increase idle speed turn the screw clockwise Adjust the air screw 2 to obtain the best off idle performance If the engine blubbers rich exiting a corner turn the air screw counter clockwise to lean the mixture If the engin
129. parts TOT Condities eea 68 Carburetor throttle operation 42 Tires for damage or improper inflation IR 62 Spokes for looseness esee 61 Rim locks for Iooseness 61 Front and rear suspension for proper OPCTANOM soc ite or EER 52 53 Front and rear brakes check operation 54 Drive chain for correct slack and adequate lubrication irem eterne 64 Drive chain guide sliders and guide rollers for damage or wear 64 Expansion chamber springs for damage or lack of tension ote eterne 67 Every possible part for looseness such as cylinder head nuts carburetor insulator bolts engine mounting bolts axle nuts drive chain adjusters drive chain guide handlebar holder bolts kickstarter mounting bolts and wire harness connectors 68 109 110 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 Drecaunons esses 12 Starting amp Stopping the Engine 13 Preparation mireu E cei 13 Starting Procedure rite 13 Plooded Engine 1 ir tectis 13 How to Stop the Engine eee 14 Shiftitig Geats net ctae ree tede 15 Break in Gudelmes sess 16 Basic Operating Instructions Basic Operating Instructions 11 Basic Operating Instructions Safe Riding Precautions Before riding your CR for the first time please review the Impor
130. r A F j Do LE 7 I NC S 5 ae dr 2t l IN 4 A LS X engine stop button O O S S u y throttle grip steering head b i rear brake fluid reservoir front brake hose N fuel tank fuel fill cap fuel valve air cleaner seat left side cover choke knob shift lever chain roller front brake caliper chain guide slider rear axle shaft chain adjuster 28 Servicing Your Honda kickstarter rear suspension p No LLL resi right side cover pu s S SLT yl e d QN EX transmission oil V rear check bolt WAN e brake caliper rear brake pedal oil filler cap ff age AG rim lock front axle shaft Refer to Safety Precautions on page 19 Removal 1 Remove the seat bolts 1 2 Slide the seat 2 back 1 seat bolts 2 seat Installation 1 Slide the seat front prong 1 onto the seat bracket 2 and the seat rear prong 3 onto the tab 4 by pushing down and forward on the seat in each of these areas 2 Install the seat bolts 5 and tighten them to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 1 seat front prong 2 seat bracket 3 seat rear prong 4 tab 5 seat bolts Seat Removal Servicing Your Honda 29 Fuel Tank Removal Refer to Safety Precautions on page 19 5 Remove the seat page 29 A amp A WARNING 6 Pull the breather tube 6 out of steering stem A_WARNING Removal nut Gaso
131. required as shown in 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 dealer page 121 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
132. requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling NOTICE Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear 40 Servicing Your Honda A 4 Remove the air cleaner 3 from the air Cleaning cleaner holder 4 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 3 air cleaner 4 air cleaner holder 1 5 Wash the air cleaner in clean non flammable high flash point cleaning solvent such as 1 air cleaner retaining bolt kerosene not gasoline Then wash it in hot 2 air cleaner assembly 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 6 Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged 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 of the air cleaner and rub it with both hands to saturate the air
133. reserve 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 a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and to get instructions on how to dispose of nonrecyclable wastes 102 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 INCORRECT
134. rface 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 horse at full pressure Stubborn deposits may require a quick wipe with a sponge 1 2 Appearance Care Washing Your Motorcycle with a Mild Detergent Rinse your CR thoroughly with cool water to remove loose dirt 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 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 asit could damage or discolor the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stain on the non coated aluminum frame only After washing rinse your CR thoroughly with plenty of clean water to remove any residue Dry your CR with a chamois or a soft towel Lubricate the drive chain to prevent rusting Start the engine and let it idle for several minutes The engine heat will help dry moist areas 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 Servicing Your Honda 69 Appearance Care
135. ring 22 spring guide 24 Install the fork cap assembly into piston rod NOTICE When installing the fork cap be careful not to damage the damping force adjuster needle rod and the needle or the rod end 25 Screw the fork cap 2 on the piston rod Hold the lock nut 16 and tighten the fork cap to the specified torque 15 Ibf ft 19 7 N m 2 0 kgf m ue 2 fork cap 16 lock nut 26 Temporarily thread the fork cap into the fork tube 27 Insert both fork legs into the fork clamps 28 Align the groove 23 in the fork tube 10 with the top surface of the upper fork clamps 24 29 Temporarily tighten the fork lower pinch bolts 7 and then tighten the fork cap 2 to the specified torque 25 Ibf ft 34 N m 3 5 kgf m 30 For ease of releasing air pressure after the forks are installed loosen the lower pinch bolts and position the fork outer tubes so that the pressure release screws are in front of the rebound damping adjusters 31 Tighten the fork lower pinch bolts to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 32 Tighten the fork upper pinch bolts 1 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m NOTICE Over tightening the pinch bolts can deform the fork tubes Deformed fork tubes must be replaced 10 d 1 24 1 upper pinch bolts 2 fork cap 7 lower pinch bolts 10 fork tube 23 groove 24 upper fork clamp 33 Clean the threa
136. rom a harder rubber compound to reduce any tendency to bend back under acceleration or wear quickly Loose Sandy Soil Use a tire that is similar in construction to those needed for tacky soil and mud but with a few more knobs Adjustments for Competition 97 Personal Fit Adjustments Refer to Safety Precautions on page 19 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 control lever mounting bolt torque of the clutch and brake lever assemblies so that they can rotate on the handlebar in a fall If an assembly does not rotate it may bend or break a control lever Make sure that the bolts are torqued securely enough to prevent slippage during normal operation Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first 1 control lever mounting bolts 98 Adjustments for Competition 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 Position the shift lever and brake pedal so that they are close to your boot for rapid access
137. s some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by Volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing 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 5 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 112 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 dama
138. sted to the same position Fork Springs The fork springs in CR s are about right for riders weighting 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 one click and lower the oil level in increments of 0 2 in 5 mm in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil level Minimum oil level CR85R Standard Spring 4 2 in 106 mm Softer Spring 4 1 in 104 mm Stiffer Spring 4 1 in 104 mm Minimum oil level CR85RB Standard Spring 4 2 in 106 mm Softer Spring 3 9 in 100 mm Stiffer Spring 4 3 in 110 mm When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork Fork Travel Characteristics CR85R Oil level 3 7 in 95 mm MAX Oil level 4 0 in 101 mm Oil level 4 2 in 106 mm MIN Force kgf 0 3 9 79 11 8 100 200 300 Stroke in mm MW CR85RB Oil level 3 7 in 95 mm MAX Oil level 4 0 in 102 mm mme Oil level 4 2 in 106 mm MIN F
139. tant 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 Always follow the proper starting procedure described below 1 fuel valve 2 choke knob Check the transmission oil and coolant levels before starting the engine page 37 38 Cold Engine Starting 1 Turn the fuel valve 1 ON 2 Shift the transmission into neutral 3 Pull the choke knob 2 up 4 With closed throttle operate the kickstarter Starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion 5 After the engine starts the choke knob should be pushed down as soon as possible to prevent spark plug fouling 6 Allow the engine to warm up for at least 2 minutes before riding off preferably until the side of the cylinder is very warm to the touch through your riding glove Slowly increase rpm and don t blip the thrott
140. th 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 situation and settle to a good reference point Ask the other helper to measure the loaded with rider dimension with rider Example 20 1 in 510 mm Race Sag Calculation unloaded 23 4 in 595 mm loaded with rider 20 1 in 510 mm Race Sag 3 3 in 85 mm 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 3 in 85 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 3 9 in 100 mm may improve stability on faster terrain with less turns but will reduce turning performance slightly and may upset the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range 5 Measure the loaded without rider dimension Do this with your
141. the O ring 2 is in good condition 4 Install the pressure release screw to the specified torque 1 0 Ibf ft 1 3 N m 0 1 kgf m 1 pressure release screw Front Suspension Oil Level If your CR is brand new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in For optimum performance and extended fork life the fork should be completely disassembled and cleaned after the first three hours of riding See the Service Manual or your Honda dealer for this service 1 Place your CR on the optional workstand or equivalent support with the front wheel off the ground 2 Loosen the upper pinch bolts 1 before loosening the fork caps to avoid damaging the fork caps 3 Loosen the fork caps 2 but do not remove them yet NOTICE Using an adjustable wrench to loosen the fork caps may damage them 2 1 B Bess 1 upper pinch bolts 2 fork cap 4 Remove the axle nut 3 5 Pull the front axle shaft 4 out of the wheel hub and remove the front wheel 7 Loosen the fork leg lower pinch bolts 7 then pull the fork legs down and out 7 lower pinch bolts 3 axle nut 4 front axle shaft 8 Clean the fork assembly especially the sliding 6 Remove the fork protectors 5 and brake surface of the slider pipe 8 and dust seal 9 caliper 6 Do not support the brake caliper by the brake hose Do not operate the brake lever
142. tional workstand or equivalent to raise both tires off the ground Storing Your Motorcycle 8 Stuff a rag into the silencer outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 9 Store your CR in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 10 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 Removal from Storage 1 Uncover and clean your CR Change the transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with pre mixed fuel page 34 4 Pour a fresh recommended coolant mixture page 38 slowly into the radiator filler hole up to the filler neck Capacity 0 45 US qt 0 43 at disassembly 0 45 US qt 0 43 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 101 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 p
143. 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 Adjustments for Too Soft Stiff Damping Symptom Action Soft suspension Initial travel too soft Steering is too quick Front end darts while cornering or riding in a straight line Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in 1 4 turn increments Middle travel too soft Front end dives when cornering If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in 1 4 turn 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 Bottoms on landings Bottoms on large bumps especially downhill bumps If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments If initial and middle travel are stiff Install the optional stiff spring If initial travel is stiff after installing the optional stiff spring Test soft compression damping adjustments in one click increments If initial travel is still soft after installing the optional stif
144. uction 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 Honda other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in this manual The official Honda Service Manual for your CR is available page 120 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 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 w
145. ult 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 26 Servicing Your Honda alignment will also extend brake pad wear Isi Z 1 1 chain adjuster index marks e Suspend the front wheel above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 2 pressure release screws Be sure the fuel and oil is mixed well by agitating it thoroughly before pouring pre mix into the fuel tank A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away 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
146. 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 motorcycle ride more harshly are more prone to damage from surface hazards and wear uneven ly Make sure the valve stem caps are secure If necessary install a new cap 62 Servicing Your Honda 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 fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3 m
147. uspension Race Sag Setting the proper race sag ride height is very important for competition use Race sag refers to the amount of rear wheel trav el 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 center of the seat mounting bolt to the edge of the last chain adjuster mark as illustrated for three different situations unloaded motorcycle on 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 CR on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 82 Adjustments for Competition UNLOADED MEASUREMENT without rider Example 23 4 in 595 mm 3 Measure the loaded wi
148. ved gasoline container Disconnect the fuel line 2 Remove the fuel valve 1 by removing the bolt 2 Wash the fuel filter 3 in high flash point cleaning solvent Fuel Line Refueling Procedure Fuel Tank Capacity 1 4 US gal 5 3 1 fuel valve 2 fuel line 2 1 fuel fill cap 3 steering stem nut 1 Check the fuel valve 1 and fuel filter for 2 breather tube contamination 2 Check for leaks 1 fuel valve 3 fuel filter 1 To open the fuel fill cap 1 pull the breather 3 Check the fuel line 2 for cracks 2 bolt 4 O ring tube 2 out of the steering stem nut 3 Turn deterioration damage or leakage Replace the the fuel fill cap counterclockwise and remove fuel line if necessary it 4 Check for interference between the frame and 2 Add fuel until the level reaches the bottom of tank and adjust if necessary 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 the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube to the steering stem nut A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel 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 flo
149. w of the fuel to the carburetor e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors Wipe up spills immediately Refill the fuel tank Attach the fuel line and turn the fuel valve to ON check for leaks Servicing Your Honda 35 Transmission Oil Refer to Safety Precautions on page 19 Using the proper oil and regularly 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 4 stroke engine oil only SG or higher except oils labeled as energy conserving on the circular API service label Viscosity SAE 80W 85W weight transmission oil SAE 10W 40 4 stroke engine oil JASO T903 MA standard 4 stroke engine oil only others without friction modifiers as molybdenum additives suggested oil Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke engine oil or an equivalent Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label
150. y inspect the frame closely for possible cracking or other damage It makes good racing sense Spokes 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 61 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 Honda Thread Lock or an equivalent and tighten to the specified torque Servicing Your Honda 25 Before amp After Competition Maintenance Between Motos amp Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments Clean accumulated dirt from under the fenders and off the wheels suspension components hand grips controls and footpegs A stiff nylon parts cleaning brush works well Check tire air pressure Check spoke tension and rim lock nut security 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 res

2005 Honda CR85/85RB EXPERT OWNER`S

Contents

Download Pdf Manuals

Related Search

Related Contents