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1. SPARK PLUG mm qum 0030Z KSR 7100 Technical Information 129 130 Technical Information Consumer Information This section contains information about Authorized Manuals eee 132 contacting Honda and how to get an official Contactumg Honda tn 133 Honda service manual Your Honda Dealer t ves 134 The Honda Rider s Club USA only 135 Consumer Information 131 Authorized Manuals The Service Manual used by your authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Publication Item No Description Price Each 61KSR02 2006 CR125R Service Manual 48 00 61CM002 Common Manual 48 00 31KSR620 2006 CR125R Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST OR By c
2. G M R gap Spark plug erogarri eisni 48 maintenance RC Valve 26 eddie metet eed 55 2a30h0l 5 5 itio ree t a OR ro eps 124 additional procedures sess 76 rear suspension maintenance eene 61 gasolime iitr o oer E E neutra da 34 after competitIOB aer rere renta 26 MOCO VAIV C M 58 ATE M a VAE debeat Dico fadi D id SIUS 108 before amp after competition 26 Rider s Club Honda esee 135 guidelines suspension adjustment 97 between motos amp practice sssss 26 riding component locations eere 28 apparel totu 2 H general competition eee 22 basic Operati OT me deo iere epi entre etre 11 ImpOtt tiCe vcro Se RE tees 18 Delote u cn EE t imei ifte obi tei J handlebar inspection eee 76 naf M tes 19 important safety information 2 high altitude carburetor adjustment 123 Schedule iie oer bte eane 20 safety precautions a be aiara 2 Honda manual Service sev ncdceseasaccedaoesdeboretesbebesssavededsess 132 COMACHING iiie puc ot one Ed deiode 133 ImOGdiBCations eicere Ptr Erie ep entes 3 S Rider s Club i e rrt tdt 135 Service Manual 2 5 5 2 nee 132 O safety your dealet etr edt rtt 134 important information eee 2 oil important precauti
3. Torque Item Remarks Ibf t Nm kgfym FRAME 21 Caliper mount bolts 22 30 3 1 NOTE 1 22 Front brake disc nuts 12 16 1 6 NOTE 4 23 Rear brake disc nuts 12 16 1 6 NOTE 4 24 Brake pedal pivot bolt 27 36 3 7 25 Spokes front 2 7 3 68 0 4 rear 2 7 3 7 04 26 Rim locks 9 12 3 2 27 Subframe bolt upper 22 30 3 1 lower 22 30 3 1 28 Fork center bolt 40 54 5 5 29 Fork piston rod lock nut 21 28 2 9 30 Disc cover bolt 10 13 1 3 31 Fork protector bolts 5 2 7 0 7 NOTE 1 32 Expansion chamber mounting bolt front stay 9 12 1 2 33 Sprocket nuts 24 32 3 3 NOTE 4 34 Seat mounting bolts 20 27 2 8 35 Front brake reservoir cap screw 0 7 1 0 1 36 Rear brake reservoir cap bolt 0 7 1 0 1 37 Fork air plug 0 9 1 2 0 1 38 Upper chain roller 9 12 1 2 NOTE 6 39 Lower chain roller 9 12 1 2 NOTE 4 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 122 Technical Information High Altitude Carburetor Adjustment When operating this motorcycle at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory spec
4. esses 120 High Altitude Carburetor Adjustment 123 Oxygenated Fuels ecce 124 Competition Logbook esses 125 Optional Parts List oerte 127 Spare Parts amp Equipment eee 128 Wiring Diagram eere 129 CONSUMER INFORMATION 131 Authorized Manuals sees 132 Contacting Honda cenae 133 Your Honda Dealer mte 134 The Honda Rider s Club USA only 135 TABLE OF CONTENTS eren 136 INDEX Q 137 QUICK REFERENCE Index A C E dCCeSSOFIES 5e E canes 3 Capacity TUEL tr e eR dete 35 engine adjustments carburetor flooded 2 ie E im wetter 13 altitude and temperature 102 adjustment cooceternr tegere ceneo 101 idle Speed tte ene 103 CAL DUTCLOL x eere toti oe RR TERES etta 100 CIFCUIL MINCHONS incre 100 DUM DOR uctor tp cr edades 118 CHASSIS em 107 COMPOMEMIS eco orte coe puto 100 juin 48 control Tree play iu etre 44 disassembly assembly 104 SUATELITID ioter tbi n EDU Etat reads 13 for COMPCUUON uccdesdaee rore ertet re 81 high altitude adjustment 123 StOp DUELO corto eee Perte ses 14 SOAPS Ie E 108 idle spe cden enceinte 103 SLODDIHIg ico te E EER a 14 high altitude car
5. Tires Front 80 100 21 51M Rear 100 90 19 57M Type bias ply tube Tire Pressure Front 15 psi 100 kPa 1 0kgf cm cold Rear 15 psi 100 kPa 1 0kgf cm Spark Plug Standard BR9EG NGK or W27ESR V DENSO Optional BR9EV NGK or W27ESR ZU DENSO Drive Chain DID 520DMA2
6. ore T RE SZ RY 1 X grip 4 Q vi NSA Qn radiator cap fuel fill cap rear suspension spring pre load adjuster kickstarter front suspension rebound damping adjuster SATE PE fuel tank rear suspension high speed compression damping adjuster rear suspension low speed compression damping adjuster air cleaner rear brake fluid reservoir chain slider rear brake front brake drive chain caliper caliper transmission transmission oil oil filler cap check bolt rear suspension rebound rear brake pedal front suspension compression transmission oil drain bolt damping adjuster damping adjuster 28 Servicing Your Honda Seat Removal Refer to Safety Precautions on page 19 Installation 1 Slide the seat front prong 4 onto the seat Removal bracket 5 and the seat rear prong 6 onto 1 Remove the seat bolts 1 and collars 2 the tabs 7 by pushing down and forward on 2 Slide the seat 3 back the seat in each of these areas 2 Install the collars and tighten the seat bolts to the specified torque 20 Ibf ft 27 N m 2 8 kgf m 1 seat bolts 2 collars 4 seat front prong 5 seat bracket 6 seat rear prong 7 tabs Servicing Your Honda 29 Fuel Tank Removal Refer to Safety Precautions on page 19 5 Pull the breather tube 5 out of steering stem 9 Disconnect the fuel line 9 from the fuel nut valve 1 Removal 6 Unhook the air cle
7. 3 Apply a locking agent to the reed valve mounting screw threads 4 Install and tighten the mounting screws to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m 5 Make sure that the clearance between the reed valve and cage 6 is less than the 0 008 in 0 2 mm 6 4 N 4 reed valve Reed Valve 2 Install the new gasket to the crankcase Reed Valve Installation 3 Install the reed valve assembly and insulator 4 to the crankcase 1 Install the reed valve inner 1 into the reed 4 Install the six carburetor insulator mounting valve assembly 2 while aligning the cut outs bolts 5 and tighten to the specified torque in a crisscross pattern 7 Ibf ft 10 N m 1 0 kgf m After installation check for secondary air leaks around the reed cage and insulator 1 reed valve inner 3 cut outs 2 reed valve assembly I 4 insulator 5 carburetor insulator mounting bolts 5 Install the carburetor page 104 Servicing Your Honda 59 Suspension Refer to Safety Precautions on page 19 Loose worn or damaged suspension components may adversely affect the handling and stability of your CR If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection When your CR is new break it in for approximately one hour to ensure that the
8. Be careful not to drop the B clip and collar into the right crankcase 3 bolt 7 B clip 4 screw 8 setting collar 5 right RC cover 9 valve rod 6 grommet 50 Servicing Your Honda 5 Remove the bolts 10 and clamp 11 n 10 bolts 11 clamp 6 Remove the left RC cover 12 and gasket 12 left RC cover 7 Loosen the radiator hose clamp screw 13 and disconnect the radiator hose 14 8 Remove the radiator shrouds 15 on both sides 9 Loosen the upper mounting bolts 16 on both sides 10 Remove the lower mounting bolts 17 then swing the radiator grills 18 forward on both sides 13 screw 14 radiator hose 15 radiator shroud 16 upper mounting bolt 17 lower mounting bolt 18 radiator grill 11 Remove the cylinder 19 by removing the four flange nuts 20 A 19 cylinder 20 flange nuts 12 Remove the gasket 21 and dowel pins 22 ES 21 gasket 22 dowel pins Piston Removal 1 Place the shop towel in the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers Press the piston pin 2 out of the piston 3 and remove the piston 3 Remove the connecting rod small end bearing 4 Under racing conditions the piston and ring should be replaced after 7 5 hours of running Replace the piston pin and connecting rod small end bearing after 22 5 hours of running i 1 fh 1 piston pin
9. 3 mounting rubbers and handlebar 4 fork caps 5 Loosen the fork caps 6 but do not remove NOTICE them yet Keep the master cylinder upright to prevent air NOTICE from entering system Using an adjustable wrench to loosen the fork caps may damage them 3 washers handlebar holder nuts 4 handlebar 5 upper pinch bolts 6 fork cap Front Suspension Adjustments 6 Remove the disc cover 7 by removing the 9 Remove the fork protector bolts 12 brake 11 Loosen the fork leg lower pinch bolts 17 two bolts 8 hose clamp bolts 13 and fork protectors then pull the fork legs down and out f 14 N i NI 10 Remove the brake caliper bolts 15 and x M brake caliper 16 NOTICE Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the brake pads 7 disc cover 8 bolts 17 lower pinch bolts 7 Remove the axle nut 9 and loosen the axle pinch bolts 10 on both forks 8 Pull the front axle shaft 11 out of the wheel hub and remove the front wheel 12 Clean the fork assembly especially the sliding surface of the slider pipe 18 and dust seal 19 NOTICE The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid 12 fork protector bolts 15 brake cali
10. INCORRECT INCORRECT LEAKING NOT LEAKING 4 Try spark test WEAK OR INTERMITTENT SPARK GOOD SPARK 5 Check the throttle position sensor CORRECT 6 Check the RC valve system P 55 CORRECT INCORRECT gt INCORRECT POSSIBLE CAUSES e Improper ignition timing Faulty ICM Faulty alternator Fuel air mixture too lean Turn the air screw in P 103 Fuel air mixture too rich Turn the air Screw out P 103 Deteriorated reed valve gasket Loose insulator clamp Faulty insulator Faulty carbon or wet fouled spark plug P 48 Faulty ignition control module Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty throttle position sensor Excessive carbon build up on the RC valve Faulty RC valve POOR PERFORMAN CHECK CE AT HIGH SPEED 1 Check ignition INCORRECT timing CORRECT 2 Disconnect fuel line at carburetor m FUEL FLOW RESTRICTED and check for clogging P 35 UNRESTRICTED FUEL FLOW 3 Remove air DIRTY cleaner P 40 AIR CLEANER NOT DIRTY Y 4 Check carburetor y CLOGGED jets for clogging NOT CLOGGED
11. Turn the carburetor upright and tighten its clamp screws Adjust the air screw opening required Reconnect the fuel line at the carburetor Repeat steps 2 through 12 until the engine gives maximum power with the correct spark plug reading It is always better to jet a little rich than a little lean It is advisable to record the settings course conditions lap times and climatic and barometric conditions for future reference Adjustments for Competition Carburetor Disassembly Assembly 1 Remove the fuel tank Page 30 2 Remove the subframe Page 32 3 Loosen the insulator band screw 1 1 insulator band screw 4 Disconnect the throttle sensor connector 2 and remove the wire band 3 and clamp 4 2 throttle sensor connector 3 wire band 4 clamp 5 Loosen the screws 5 and remove the carburetor top 6 5 screws 6 carburetor top 6 Pull up the throttle position sensor arm 7 then pull out the throttle valve 8 from the carburetor body 7 throttle position sensor arm 8 throttle valve 7 Remove the throttle cable 9 and collar 10 from the cable holder 11 8 Remove the collar and throttle valve spring 12 from the throttle cable 9 Remove the throttle cable holder and jet needle 13 from the throttle valve 14 p 5 d N 9 throttle cable 10 collar 11 cable holder 12 throttle valve spring 13 jet needle 14 throttle valve Carbureto
12. 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 134 Consumer Information Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider s Club of America Your purchase of a new motorcycle scooter ATV or PWC from a participating U S Honda dealer entitles you to a complimentary one year membership in the Club There are hundreds of HRCA Chapter sponsoring dealers across the USA with events and activities almost every weekend Membership benefits include
13. Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling NOTICE Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear 40 Servicing Your Honda Cleaning Remove the seat page 29 2 Loosen the air cleaner retaining bolt 1 3 Remove the air cleaner assembly 2 1 air cleaner retaining bolt 2 air cleaner assembly 4 Remove the air cleaner 3 from the air cleaner holder 4 1 air cleaner retaining bolt 3 air cleaner 4 air cleaner holder mS Wash the air cleaner in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner is made in two pieces inner and outer which can t be separated Clean the inside of the air cleaner housing Allow the air cleaner to dry thoroughly After drying soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil Apply air cleaner oil to the entire surface inner and outer and rub it with both hands to saturate the air cleaner with oil Squeeze out excess oil Air Cleaner 8 Apply a thin coat of Honda White Lithium 10 Insert the pin in the air cleaner housing hole 11 Reinstall the seat page 29 making sure it is Grease or an equivalent to the sealing 7 and install the assembly into the air securely
14. plug The following procedure is recommended You may not get an accurate reading if you simply turn off the engine and pull the plug for inspection Use a new spark plug Inspect the plug before installing it 106 Adjustments for Competition NOTICE Using spark plugs with an improper heat range or incorrect reach can cause engine damage Before removing the spark plug clean the spark plug area thoroughly to prevent dirt from entering the cylinder Ride for 10 15 minutes before taking a plug reading A new plug will not color immediately To obtain an accurate reading of a new spark plug 1 Accelerate at full throttle on a straight 2 Push the engine stop button and pull the clutch lever in to release the clutch 3 Coast to a stop 4 Remove the spark plug 5 Use a magnifying glass to inspect the spark plug The porcelain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain indicate rich jetting NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 1 insulator 2 center electrode 3 side electrode Spark Plug Coloring Guidelines Condit
15. replace 4 brake pads 5 rear brake caliper 6 brake disc Other Inspections Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Wheels Sete E enero Wheel Rims amp Spokes Axles amp Wheel Bearings 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 See the Honda Service Manual for inspection information 1 Check the axle for runout 2 Check the condition of the wheel bearings It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations 1 wheel rim 3 spoke nipple 2 spoke 4 rim lock nut 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spoke nipples 3 and rim lock nuts 4 to the specified torque Front spoke nipple 2 7 Ibf ft 3 68 N m 0 4 kgf m Rear spoke nipple 2 7 Ibf ft 3 7 N m 0 4 kgf m Rim lock nuts 9 Ibf ft 12 N m 1 2 kgf m 3 Ch
16. 14 radiator grill 15 radiator mounting bolts 18 screw 16 radiator shroud 17 radiator hose 13 Install a new gasket 19 onto the left RC valve cover 20 14 Install the left RC valve cover and clamp 21 tighten the bolts 22 to the specified torque 9 Ibf ft 12 N m 1 2 kgf m 19 gasket 20 left RC valve cover 21 clamp 22 bolts cont d Servicing Your Honda 53 Cylinder System 15 16 17 18 23 gasket 24 exhaust pipe joint 54 Install a new gasket 23 as shown Install the exhaust pipe joint 24 with the flat facing 25 down Install and tighten the bolts 26 to the specified torque 6 6 Ibf ft 9 N m 0 9 kgf m Install the expansion chamber and springs page 75 25 flat face 26 bolts Servicing Your Honda 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 n 4 1 dowel pins 2 cylinder head gasket 3 UP mark 4 tab 3 Install the cylinder head 5 and tighten the five cylinder head nuts 6 to the specified torque in a crisscross pattern in 2 or 3 steps 20 Ibf ft 27 N m 2 8 kgf m 5 cylinder head 6 cylinder head nuts 4 Install the clamp 7 hanger plates 8 and tighten the nuts 9 to the specified torque 25 Ibf ft 34 N m 3 5 kgf m 5
17. 7 LANT 6 silencer 7 bolt washer 8 Install the right side cover 8 and bolt collar 9 8 right side cover 9 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 128 Use of lower octane gasoline can cause persistent pinging or spark knock a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid getting di
18. Check for signs of oil leakage Damaged or leaking fork seals should be replaced before your CR is ridden 2 dust seal 1 fork protector 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 4 3 0 06 in 1 5 mm 3 wear ring 4 outer tube 3 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times Rear Suspension Inspection The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure The gas pressure in the reservoir is contained within a rubber bladder The shock absorber s spring preload and damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions page 96 Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only When your CR is new break it in for approximately one hour with the standard suspension settings before attempting to adjust the rear suspension Make all compression and rebound damping adjustments in the specified increment or turns described in pages 93 Adjusting two or more increments or turns at a time may cause
19. Condensation Control Changes in temperature combined with humidity allow moisture to form in some confined areas on your CR The most affected area is the alternator ignition cavity in the left side of the crankcases Each time you wash your CR you should remove the alternator cover 1 wipe out any visible moisture and allow the cavity to air dry for at least a couple of hours before installing the cover Replace the gasket with a new one if it is not in good condition before installing the cover Some condensation can form within the transmission cavity as well This is natural and just one more reason you should change the transmission oil often 1 alternator cover After Cleaning Lubrication There are some things you should do just after washing your CR to help prevent rust and corrosion Once your CR is clean and dry you should protect any bare steel from rusting by applying a light coating of a rust inhibitor Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent Be sure the chain is wiped clean and is dry before applying the chain lube Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Appearance Care Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or
20. RC valves 2 valve shaft 3 valve stopper 4 valve rod 5 governor gear 6 governor spring 7 primary drive gear 8 governor rack gear Servicing Your Honda 55 RC Valve Exhaust valve Removal 1 Remove the cylinder page 50 2 Remove the socket bolt 1 and stopper plate 2 3 Remove the nut 3 and washer 4 from the valve shaft assembly 1 socket bolt 3 nut 2 stopper plate 4 washer 4 Remove the valve shaft assembly 5 collar 6 and RC valves 7 from cylinder 5 valve shaft assembly 7 RC valves 6 collar 56 Servicing Your Honda Exhaust Valve Decarbonizing 1 Remove the carbon deposits from the valve shaft assembly 1 and RC valves 2 Decarbonize the valve shaft assembly and RC valves each race 2 Inspect the RC valve valve shaft assembly for wear or damage 1 valve shaft assembly 2 2 RC valves Valve Shaft Oil Seal Inspection Check the valve shaft oil seals 1 for wear or damage Replace the oil seals if necessary AR um a 1 valve shaft oil seals RC Valve 6 Install the washer 6 and nut 7 then tighten Exhaust Valve Installation the nut to the specified torque 6 6 Ibf ft 9 N m 0 9 kgf m 1 Install the RC valves 1 into the slot on the 7 Install the stopper plate 8 and tighten the cylinder socket bolt 9 to the specified torque 2 Position the RC valves fully open 7 Ibf ft 10 N m 1 0 kgf m 3 Install
21. Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean L lubricate R replace 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 Maintenance Schedule Frequency Each race Every 3 races Every 9 races Note or about or about or about Ref page Items 2 5 hours 7 5 hours 22 5 hours Throttle Operation l 42 Air Cleaner Note 1 C 40 Spark Plug l R 48 Radiator Coolant Note 2 l 38 Cooling System I 39 Cylinder Head Decarbonizing C 51 Exhaust Valve Decarbonizing C 56 Piston and Piston Ring R 51 Piston Pin and Connecting Rod Small End Bearing R 51 52 Reed Valve Only R 58 Transmission Oil R 36 Drive Chain LL R 72 Drive Chain Sliders l 72 Drive Chain Rollers l 73 Drive Sprocket l 74 Driven Sprocket l 74 Brake Fluid Note 2 l 66 Brake Pad Wear l 68 Brake System l 65 Clutch System l 44 Control Cables LL 76 Expansion Chamber Silencer l 75 Suspension l 60 61 Swingarm Shock Linkage L 25 61 Fork Oil Note 3 R 62 Nuts Bolts Fasteners l 77 124 Wheels Tires l 69 70 Steering Head Bearing l 76 This maintenance schedule is based upon average riding condition Machin
22. loss of traction and slower lap times 96 Adjustments for Competition Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CR using the methods described on pages 82 96 Remember to make all adjustments in one click increments Test ride after each adjustment Front Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below 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 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 one click increments Middle travel too soft Front end dives when cornering If suspension isn t stiff in initial travel Test stiffer compression damping
23. regular inspection and service is required as shown in the Maintenance Schedule that follows The Maintenance Schedule lists items that can be performed with basic mechanical 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 136 Service intervals in the maintenance schedule are expressed in terms of races and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CR best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability 20 Servicing Your Honda Perform the pre ride inspection page 9 at each scheduled maintenance period Summary of Maintenance Schedule Notes and Procedures Notes 1 Clean after every moto for dusty riding conditions 2
24. upper level mark 2 reservoir cap 5 reservoir cap Remove the screws 1 reservoir cap 2 and Remove the bolts 4 reservoir cap 5 and diaphragm diaphragm 2 Fill the reservoir with DOT 4 brake fluid to 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 3 Do not overfill the upper level mark 6 Do not overfill 3 Reinstall the diaphragm and reservoir cap 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws to the specified torque 4 Tighten the bolts to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m 0 7 Ibf ft 1 N m 0 1 kgf m Servicing Your Honda 67 Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear faster on wet and dirty tracks Inspect the pads at each regular maintenance interval page 21 Front Brake Pads Inspect the pads 1 through the front wheel to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced minimum thickness indicator 1 replace replace 1 1 brake pads 2 front brake caliper 3 brake disc 68 Servicing Your Honda Rear Brake Pads Inspect the pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced minimum thickness indicator 4
25. 2 clip Slow Jet and Air Screw Refer to Carburetor Minor Adjustments Page 106 Standard Tuning Recommendations For the following recommendations to be accurate you must use the standard settings as a baseline Also don t change any of the settings until you ve determined what changes are necessary Adjustment Standard settings Air screw opening 1 3 4 turns out Slow jet 55 Jet needle 6DGY28 68 Needle clip position 3rd groove Main jet 430 Float level 0 30 in 7 5 mm Identification number TMX05A 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 309 17 18 6 7 v 5 4 v 16 15 v 27 26 38 37 49 ALTITUDE FAHR 21 0 1 20 19 40 39 60 59 80 79 10099 120 AS 2 2 1 4 2 1 2 2 2 1 4 2 1 2 2 3 4 10 000 ft 3050 m SJ 55 55 55 55 50 50 50 to NC 3 3 2 2 2 2 1 7 500 ft 300 m JN 6DGY28 68 6DGY28 68 6DGY28 69 BDGY29 69 6DGY28 70 GDGY28 71 6DGY29 70 MJ 430 420 410 400 390 380 370 AS 13 4 2 2 1 4 2 1 2 2 2 1 4 2 1 2 7 499 ft 2299 m SJ 55 55 55 55 55 50 50 to NC 3 3 3 2 2 2 2 5 000 ft 1500 m JN 6DGY29 68 6DGY28 68 GDGY28 68 EDGY 28 69 6DGY29 69 GDGY28 70 GDGY28 71 MJ 440 430 420 4
26. 24 hour toll free roadside 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 exciusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Specialty Vehicle Institute 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 motocross events Contact your Honda dealer for more information or call 1 800 847 HRCA or log on to www hrca honda com The Honda Rider s Club USA only Consumer Information 135 Table of Contents The following presents the contents of each section of your owner s manual MOTORCYCLE SAFETY eren 1 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications sss 3 Satety Labels 4 e ue rbi bar isitened 4 OPERATING CONTROLS e 5 Operation Compone
27. 76 Appearance Care ose triente 78 ADJUSTMENTS FOR COMPETITION 81 Front Suspension Adjustments 82 Rear Suspension Adjustments 92 Suspension Adjustments for Track Conditions 96 Suspension Adjustment Guidelines 97 Carburetor Adjustments amp Tuning Tips 100 Chassis Adjustments esee 107 J6atllg isi nde aede diete demde 108 Tire Selection for Track Conditions 109 Personal Fit Adjustments sss 110 LIDS isstcssssnsocsinopecssosvescetssnseossonssessisessssospasoeconss 111 Transporting Your Motorcycle 112 Storing Your Honda eerte 113 You amp the Environment esses 114 Troubleshooting 115 TECHNICAL INFORMATION 117 Vehicle Identification esses 118 SDeCL CatioDis nice Piceno oho eee ee den tiers 119 Torque Specifications eeeses 120 High Altitude Carburetor Adjustment 123 Oxy senated Fuels eint 124 Competition Logbook esssss 125 Optional Parts List eerte 127 Spare Parts amp Equipment eee 128 Witte Did Stam sss ett rete 129 CONSUMER INFORMATION 131 Authorized Manuals eee 132 Contacting Honda see 133 Your Honda Dealer ees 134 Th
28. 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 Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors Wipe up spills immediately Fuel Line 1 fuel valve 2 fuel line 1 Check the fuel valve 1 and fuel filter for contamination 2 Check for leaks 3 Check the fuel line 2 for cracks deterioration damage or leakage Replace the fuel line if necessary 4 Check for interference between the frame and tank and adjust if necessary Fuel Filter The fuel filter is included in the fuel valve mounted on the bottom left side of the fuel tank Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor Fuel System To service the fuel filter 1 Drain the fuel from the fuel tank into an approved gasoline container Disconnect the fuel line 2 Remove the fuel valve 1 by removing the bolts 2 Wash the fuel filter 3 in high flash point cleaning solvent 4 e 1 fuel valve 2 bolt 3 fuel filter 4 O ring 3 Reassemble the fuel valve in the reverse order of removal Make sure the O ring 4 is in place Install the fuel valve in the fuel tank Refill the fuel tank Attach the fuel line and turn the fuel valve to ON check for leaks Servicing Your Honda 35 Transmissi
29. Connect the water hose 10 to the cylinder head 6 Install the spark plug and spark plug cap 11 OOWAL o BX 7 clamp 10 water hose 8 hanger plates 11 spark plug cap 9 nuts 7 Pour the recommended coolant mixture into the radiator up to the correct level page 38 8 Install the following fuel tank and seat page 29 30 9 Start the engine and check for the following compression leaks abnormal engine noise secondary air leaks coolant leaks RC Valve Refer to Safety Precautions on page 19 Operating Inspection The exhaust valves open and close according to the engine speed to ensure sufficient torque throughout the entire engine rpm range The valves should be fully closed at low rpm and fully open at high rpm 1 Remove the B clip 1 and setting collar 2 then remove the tie rod 3 from the valve The exhaust valve system is a precision assembly Before beginning inspection decarbonizing please shaft arm study the following text and illustrations carefully 2 Check that the exhaust valve 4 turns Before attempting complete disassembly we recommend you consult the Honda Service Manual or your smoothly If the exhaust valve turns Honda dealer Mismatching of parts on reassembly can measurably affect fully engine performance unsmoothly remove the exhaust valve and decarbonize the RC valves and valve shaft page 56 1 B clip 3 tie rod 2 collar 4 exhaust valve 1
30. If you do switch to tires designed for special terrain use remember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface 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 representatives and dealers Some general recommendations for specific terrain follow Hard Slick Soil Use tires with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface The rubber compound needs to be softer for hard ground in order to hook up but not so soft that the knobs roll over easily and affect holding a straight line These tires tend to wear more quickly than standard tires because of the combination of soft rubber and hard terrain Muddy Soil Use a more open tread pattern to avoid clogging For these conditions the relatively long knobs will probably be made from a harder rubber compound to reduce any tendency to bend back under acceleration or wear quickly Loose Sandy Soil Use a tire that is similar in construction to those needed
31. an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame NOTICE Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminum frame only Servicing Your Honda 79 80 Servicing Your Honda This section tells you how to fine tune your CR for maximum competition performance Initial suspension adjustments should be performed after a minimum of two hours of easy break in time Optional front and rear suspension springs are available in both firmer and softer than standard rates in order to tailor your CR specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag 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
32. and float valve 15 operate to maintain a constant level of fuel in the float chamber lil Z c ED rH m 3 j Mg u 9 9 main jet 13 baffle plate 10 jet needle 14 float 11 needle jet 15 float valve 12 air jet Carburetor Circuit Functions The carburetor has several major circuits each providing the fuel air mixture over a given portion of throttle valve opening These major circuits overlap as shown below MAIN JET ee JET NEEDLE TAPERED SECTION JET NEEDLE STRAIGHT SECTION SLOW JET AND AIR SCREW FULLY 1 8 1 4 1 2 3 4 FULLY CLOSE OPENED Main Jet The main jet affects fuel air ratio from half 1 2 to full throttle 4 4 The size should be reduced at higher altitudes Your CR s carburetor jet sizes are numbered in increments of 10 When changing the main jet size increase or decrease it gradually until the desired jetting is obtained Because your CR s jet size numbers do not correspond with other carburetor manufacturer s jet size numbers use genuine Honda CR125R jets Jet Needle The jet needle controls fuel air mixture over 1 16 to 3 4 throttle The straight section 1 affects throttle response at smaller throttle openings By changing the position of the clip 2 in its groove you can improve acceleration at medium low and medium speed 1st 8 9 2 LEANER 2nd aN 3rd H 4th 5th N RICHER 1 straight section
33. attached surface cleaner housing 8 while aligning the tab 9 9 Assemble the air cleaner and holder on the air cleaner and the reference mark 10 Insert the pin 5 to the hole 6 and the air on the air cleaner housing Tighten the cleaner retaining bolt through the assembly retaining bolt securely Carefully position the sealing flange of the element to prevent dirt intrusion NOTICE Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder 5 pin 6 hole 3 air cleaner 8 air cleaner housing 4 air cleaner holder 9 tab 5 pin 10 reference mark 7 air cleaner housing hole Servicing YourHonda 41 Throttle Refer to Safety Precautions on page 19 Throttle Freeplay RIGHT SIDE 1 1 freeplay Inspection Check freeplay 1 Freeplay 1 8 3 16 in 3 5 mm If necessary adjust to the specified range 42 Servicing Your Honda Upper Adjustment Minor adjustments are generally made with the upper adjuster he md 2 dust cover increase 3 lock nut decrease 4 upper adjuster Pull the rubber dust cover 2 back 2 Loosen the upper lock nut 3 on the throttle cable mechanism 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten the l
34. 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 Adjustments for Competition 95 Suspension Adjustments for Track Conditions Soft Surface On soft ground sand and especially mud consider increasing compression damping front and rear Sand often requires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CR may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and rebound If you run softer rebound damping the wheel will follow the rough ground and small bumps much better and you will hook up better With a lot of rebound damping the wheel returns very slowly and doesn t contact the ground quickly enough after each bump The result is a
35. clip 4 connecting rod small 2 piston pin end bearing 3 piston 5 piston ring 4 Spread each piston ring 4 and remove by lifting it up at a point just opposite the gap NOTICE The piston ring may be damaged if the ends are spread too far Cylinder Head Cylinder Decarbonizing 1 Remove the carbon deposits from the cylinder head 1 and piston dome Take care to avoid scratching the cylinder head piston dome or the head gasket surface 1 cylinder head 2 Clean carbon deposits from the exhaust port 2 area 2 exhaust port Cylinder System Cylinder Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your Honda dealer for correct Service Limit measurements Servicing Your Honda 51 Cylinder System Connecting Rod Inspection 1 Temporarily remove the shop towel 2 Install the small end bearing 1 and piston pin 2 in the connecting rod small end and check for excessive play while holding the connecting rod If it feels loose replace the piston pin and small end bearing 1 small end bearing 2 piston pin 3 Place the shop towel back in the crankcase Cylinder Head Inspection Check the cylinder head 1 for warpage in diagonal directions with a straight edge 2 and a feeler gauge 3 Service Limit 0 002 in 0 05 mm 1 cylinder head 2 straight edge 3 feeler gauge 52 Servicing Your Honda Piston Instal
36. deciding deal maker for a potential buyer Consider using different color pens or pencils to record important information on specific subjects For example record results in black jetting changes in red suspension chassis settings in blue and gearing selections in green Color codes will help you identify the information you want with a glance Tuning amp Adjustment Records Keep track of the settings and adjustments that worked best at a particular location These items include basic track conditions altitude and temperature carburetion changes suspension settings chassis adjustments tested and selected gearing tire 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 repre
37. 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 HIN n incra 1 tire tread depth nspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3 mm or any time you notice a 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
38. is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved forward either 3 mm using optional handlebar lower holders or 6 mm by rotating the standard holders 180 degrees Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment e Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cut off just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide further adjustment to riding position and may better suit your particular body size or riding style Each of the ergonomic dimensions of the machine were determined to suit the greatest possible number of riders based on an average size rider Tips Here s helpful advice on how to transport and Transporting Your Motorcycle 112 store your Honda as well as two troubleshooting Storing Your Honda esse 113 flow charts You amp the Environment sessirnir 114 Troubleshooting eet 115 T
39. normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the top of the most rearward point of the subframe down to the machined edge at the rear of the swingarm as illustrated for three different situations unloaded motorcycle on optional workstand with rear suspension fully extended no rider loaded with rider motorcycle on ground with rider loaded without rider motorcycle on ground without rider 1 Support your CR on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 94 Adjustments for Competition gt UNLOADED MEASUREMENT on workstand without rider EXAMPLE 23 6 in 600 mm 3 Measure the loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CR s seat wearing your riding apparel Ask one helper to steady your CR perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any stiction and settle to a good reference point Ask the other helper to measure the loaded with rider dimension LOADED MEASUREMENT on ground with rider EXAMPLE 19 7 in 500 mm Race Sag Calculation unloaded 23 6 in 600 mm loaded with rider 19 7 in 500 mm Race Sag 3 9 in 100 mm 4
40. nut securely e Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 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 higher altitude remember that fork pressure of 0 at sea level will increase as elevation increases Clean the sides of the drive chain with a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result After adjustment check that the chain adjuster 2 press r relgase screw index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad wear 26 Servicing Your Honda After Competition Maintenance It is important to the long term performance of your CR to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the pa
41. performance SAE 10W 40 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 30 10W 40 30 20 10 0 10 20 30 40 50 C i i i i i J 20 0 20 40 60 80 100 120 F JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification Checking amp Adding Oil 1 oil filler cap 2 oil check bolt 1 2 Run the engine for three minutes then shut it off Wait three minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission Support the CR in an upright position on a level surface Remove the oil filler cap 1 and oil check bolt 2 from the right crankcase cover A small amount of oil should flow out of the check bolt hole Allow any excess oil to flow out of the check bolt hole I 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 fill
42. procedures Preparation for Storage 1 Completely clean all parts of your CR If your CR has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Replace the transmission oil page 37 3 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and remove the carburetor drain plug Drain gasoline into an approved container Reinstall the drain plug A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 1 35 6 10 11 Remove the radiator cap and coolant drain bolt 1 at the water pump 2 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washer is in good condition and reinstall the drain bolt and radiator cap drain bolt 2 water pump Lubricate the drive chain Remove the spark plug and pour a tablespoon 0 51 0 68 US oz 15 20 cm of clean engine oil into the cylinder With the spark plug grounded or the engine stop button pressed in crank the engine several times to distribute the oil then reinstall the spark plug Inflate the tires to their recommended pressures Place your CR on the optional workstand or equivalent to raise both tires off the ground Stuff a rag into
43. replaced at the same time Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap To properly dispose of drained coolant refer to You amp the Environment page 114 NOTICE Improper disposal of drained fluids is harmful to the environment 1 water hoses 3 water pump cover 2 overflow tube 4 water leakage check hole Servicing Your Honda 39 Air Cleaner Refer to Safety Precautions on page 19 The air cleaner uses polyurethane inner and outer pieces which can t be separated A dirty air cleaner will reduce engine power Proper air cleaner maintenance is very important for off road vehicles A dirty water soaked worn out or defective air cleaner will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your CR s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality
44. ring NOTICE Do not rotate the cylinder since this may cause the piston ring to snag a cylinder port and break Cylinder System 3 piston ring pin 4 cylinder Before tightening the cylinder nuts make sure that there is no clearance between the cylinder and crankcase mating surface 5 Install the four flange nuts 5 and tighten to the specified torque in a crisscross pattern in 2 or 3 steps 20 Ibf ft 27 N m 2 8 kgf m Be careful not to overtighten the mounting nuts This is the most common cause for leaks here 5 flange nuts 6 Install the RC valve rod 6 setting collar 7 and B clip 8 7 Install a new gasket 9 onto the right RC valve cover 10 8 Install the grommet 11 onto the brim of the right crankcase cover 6 RC valve rod 9 gasket 7 setting collar 10 right RC valve cover 8 B clip 11 grommet 9 Install the right RC valve cover 10 tighten the bolts 12 and screw 13 to the specified torque Right RC valve cover bolt 9 Ibf ft 12 N m 1 2 kgf m Right RC valve cover screw 1 5 Ibf ft 2 N m 0 2 kgf m A i 10 right RC valve cover 13 screw 12 bolts 10 Return the radiator grills 14 to the original positions on both sides 11 Tighten the radiator mounting bolts 15 then install the radiator shrouds 16 on both sides 12 Connect the radiator hose 17 and tighten hose clamp screw 18
45. suspension has worked in page 15 After break in test run your CR with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CR for 3 hours See page 85 for fork disassembly Replace the fork oil every 3 races or 7 5 hours of running See page 62 for oil level adjustment after changing the fork oil Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CR s front suspension Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination 60 Servicing Your Honda Refer to Suspension adjustment Guidelines page 100 Make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems 1 Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt 2
46. the adjuster counterclockwise 6 clicks This is the standard position 4 Make sure that both fork legs are adjusted to the same position Rebound Damping Rebound damping effects how quickly the fork rebounds The rebound damping adjuster has 18 positions or more Turning the adjuster screw one full turn clockwise advances the adjuster 4 positions Always start with the full hard position when adjusting damping E I rx 2 rebound damping adjuster To adjust to the standard position 1 Turn the rebound damping adjuster 2 clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 15 clicks This is the standard position 3 Make sure both fork legs are adjusted to the same position Front Suspension Adjustment Fork Springs The fork springs in CR s are about right for riders weighing between 150 and 160 Ibs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn and lower the oil level in increments of 5 cm 0 2 oz in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil level Minimum oil level
47. will be left in the fork tube when the oil is drained 14 Install the spring guide 3 as shown and causes the oil level to be raised slightly Loosely install the lock nut 2 Besure the oil level is the same in both fork legs 2 e Always use the after market syringe while L adjusting the oil level If it isn t used air may get into the fork e Ifa syringe is not available first set the oil Pe 3 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 2 lock nut 3 spring guide 15 Install the fork spring spring seat and fork cap as described in Front Suspension Oil Level Adjustment page 84 91 64 Servicing Your Honda Refer to Safety Precautions on page 19 Both the front and rear brakes are the hydraulic disc type As the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop Frequently inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the 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 68 there is probably air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system Front Brake Lever Adju
48. 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 changing conditions and your reaction time gets worse with every additional drink So don t drink and 2 Motorcycle Safety ride and don t let your friends drink and ride either Keep Your Honda in Safe Condition Maintaining your CR properly is critical to your safety A loose bolt for example can cause a breakdown in which you can be seriously injured Accessories amp Modifications Installing non Honda accessories removing original equipment or modifying your CR in any way that would change its design or operation could seriously impair your CR s handling stability and braking making it unsafe to ride A WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories Motorcycle Safety 3 Safety Labels Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Ho
49. 10 400 390 380 AS 11 2 13 4 2 2 1 4 2 1 2 2 2 1 4 4 999 ft 1499 m SJ 55 55 55 55 55 55 50 to NC 3 3 3 3 2 2 2 2 500 ft 750 m JN 6DGY29 67 6DGY29 68 GDGY28 68 EDGY 28 68 6DGY28 69 6EDGY29 69 GDGY28 70 MJ 450 440 430 420 410 400 390 AS 11 4 11 2 13 4 2 21 4 21 2 2 2 499 ft 749 m SJ 60 55 55 55 55 55 55 to NC 4 3 3 3 3 2 2 1 000 ft 300 m JN 6DGY29 67 6DGY29 67 GDGY29 68 EDGY 28 68 6DGY28 68 GDGY28 69 GDGY29 69 MJ 460 450 440 430 420 410 400 AS 13 4 11 4 11 2 1834 134 e 214 2 1 2 999 ft 299 m SJ 60 60 55 55 g 55 55 55 to NC 4 4 3 3 8 3 5 3 2 Sea Level 0 m JN 6DGY29 66 GDGY29 67 GDGY29 67 6DGY29 68 6DGY28 68 3 GDGY28 68 6DGY28 69 MJ 470 460 450 440 430 lt 420 410 Legend AS Air Screw opening from fully seated SJ Slow Jet NC Needle Clip position JN Jet Needle MJ Main Jet Adjustments for Competition 101 Carburetor Adjustments amp Tuning Tips Adjustments for Altitude amp Temperature All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture Condition Mixture will be Adjust to Component affected Cold temperature Lean Richen Warm temperature Rich Lean Dry air Lean Richen lat needle stage High humidity Rich Lean High altitude Rich Lean Special Tuning Conditions There are some unique atmospheric con
50. 12 0 in 305 mm Type Piston valve Pro link Identification number TMX05A po o R suspension travel 12 6 in 320 mm Main jet standard 430 F tire size pressure 80 100 21 51M Slow jet standard 55 Spark phigigap 506mm pe kPa kgf cm ma EA Air screw opening 1 3 4 turns out tire size pr n i i psi kPa kgflom 15 100 1 0 ae SD Tam Tire WBE DIIS Ube Clutch type Wet multi plate type F brake swept area Single disc brake 51 8 in 334 5 cm Transmission 5 speed constant mesh Single disc brake Primary reduction 3 150 R brake swept area 60 6 in 391 1 cm Gear ratio 2 308 Fuel capacity 2 0 US gal 7 7 liter Sear a Vs Caster angle 25 45 Gear ratio IV 1 294 Trail length 3 9 in 100 mm Gear ratio V 1 130 Fork oil f eer leg Level Std 2 8 in 71 mm Technical Information 119 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts fasteners before every outing Engine RIGHT SIDE 120 Technical Information Torque Item Remarks Ibf ft N m kgf m ENGINE 1 Cylinder head nut 20 27 2 8 2 Cylinder mounting nut 20 27 2 8 3 Carburetor insulator bolt 7 10 1 0 4 Clutch cover bolt 7 10 1 0 5 Water pump cover bolt 9 12 1 2 6 Right RC cover bolt 9 12 1 2 7 Right RC cover screw 1 5 2 0 2 8 Alternator cover bolt
51. 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 silencer 4 PT 1 n M Y 3 bolt washer 4 silencer 32 Servicing Your Honda 4 Loosen the screw 5 on the air cleaner connecting tube clamp 6 NM 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 22 Ibf ft 30 N m 3 1 kgf m 5 Tighten the lower subframe mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 3 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 7 Install and tighten the bolt washer
52. 2 Check the electrode for wear or deposits the a First tighten the plug satisfactory for most racing conditions gasket 3 for damage and the insulator for NGK 3 4 turn after it seats cracks DENSO 1 2 turn after it seats b Then loosen the plug nap E AN DENCO 2 c Next tighten the plug again 1 8 turn after it seats Optional BR9EV NGK or W27ESR ZU DENSO 3 Use only the recommended type of spark plugs in the recommended heat range NOTICE Using a spark plug with an improper heat range or incorrect reach can cause engine damage Using a non resistor spark plug may cause 1 plug gap 3 sealing gasket ignition problems 2 side electrode 3 To obtain accurate spark plug readings 4 spark plug accelerate up to speed on a straightaway Push the engine stop button and disengage the clutch by pulling the lever in If you re using a new plug ride for at least ten minutes before taking a plug reading a brand new plug will not color initially 4 Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere page 106 Check the fuel oil mixture carburetor and fuel system and ignition timing 48 Servicing Your Honda Refer
53. 2006 Honda CR125R OWNER S MANUAL amp COMPETITION HANDBOOK Introduction Congratulations on choosing your Honda CR motocross motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your CR is a high performance racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned closed course events by experienced riders only Be aware that motocross is a physically demanding sport that requires more than just a fine CR To do well you must be in excellent physical condition and be a skillful rider For the best results work diligently on your physical conditioning and practice frequently Before riding take time to get acquainted with your CR and how it works To protect your investment we urge you to take responsibility for keeping your CR well maintained Scheduled service is a must of course But it s just as important to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual You should also read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book Introduction As yo
54. 5 Install a larger carburetor main CONDITION gt WORSE jet P 103 CORRECT 6 Check the RC INCORRECT valve system P 55 CORRECT Troubleshooting POSSIBLE 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 rejet in the opposite direction P 103 Faulty RC valve Tips 115 116 Tips Technical Information This section contains dimensions capacities and other technical data Vehicle Identification sessss 118 SPECICATION uii ete 119 Torque Specifications eese 120 High Altitude Carburetor Adjustment 123 Oxysenated Euels aote 124 Competition Logbook esses 125 Optional Parts List eeeeee 127 Spare Parts amp Equipment esssss 128 Winrng Diagram etes 129 Technical Information 117 Vehicle Identification The frame number 2 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 whe
55. 7 10 1 0 9 Left RC cover bolt 9 12 1 2 Frame Torque Specifications n 7 L Torque Item Remarks Ibf ft Nem kgf m FRAME 1 Steering stem nut 80 108 11 0 2 Fork bridge upper pinch bolts 16 22 2 2 3 Fork bridge lower pinch bolts 15 20 2 0 4 Handlebar upper holders 16 22 2 2 5 Handlebar lower holder nut 32 44 4 5 6 Front axle nut 65 88 9 0 7 Front axle pinch bolts 15 20 2 0 8 Rearaxle nut 94 128 13 1 NOTE 4 9 Chain adjuster lock nut 20 27 2 8 NOTE 5 10 Engine mounting bolts 40 54 5 5 11 Engine hanger plate bolts 25 34 3 5 12 Shock absorber upper 32 44 45 NOTE 4 lower 32 44 4 5 NOTE 4 13 Swingarm pivot nut 65 88 9 0 NOTE 4 14 Fork cap 22 30 3 1 15 Rear shock arm swingarm side 39 53 5 4 NOTE 2 4 shock link side 39 53 5 4 NOTE 2 4 16 Rear shock link nuts Frame side 39 53 5 4 NOTE 2 4 17 Shock spring lock nut 21 29 3 0 18 Kickstarter arm bolt 28 38 3 9 19 Front brake master cylinder holder 7 3 9 9 1 0 20 Brake hose bolts 25 34 3 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 Technical Information 121 Torque Specifications Frame
56. 82 Rear Suspension Adjustments 92 Suspension Adjustments for Track Conditions 96 Suspension Adjustments Guidelines 97 Carburetor Adjustments amp Tuning Tips 100 Chassis Adjustments sese 107 SEAUITIg 1 eec enne tet cet Dod ee o Dope etea 108 Tire Selection for Track Conditions 109 Personal Fit Adjustments sss 110 Adjustments for Competition Adjustments for Competition 81 Front Suspension Adjustments The front suspension can be adjusted for the rider s weight and riding conditions by using one or more of the following methods Oil volume The effects of higher or lower fork oil level are only felt during the final 3 9 in 100 mm of fork travel Compression damping Turning the compression damping screw adjusts how quickly the fork compresses Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends Fork springs Optional springs are available in softer and stiffer types than the standard rate page 127 82 Adjustments for Competition Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CR will get stiffer during a race For this reason release built up air pres
57. Calculate the race sag dimension To do this subtract the loaded with rider dimension step 3 from the unloaded dimension step 2 Standard Race Sag 3 9 in 100 mm Adjust spring pre load as necessary to obtain the desired handling results Decreasing the race sag dimension example 3 5 in 90 mm improves turning ability for tight terrain at the cost of slightly reduced straight line stability Increasing the race sag dimension example 4 3 in 110 mm may improve stability on faster terrain with less turns but will reduce turning performance slightly and may upset the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range 5 Measure the loaded without rider dimension Do this with your CR set at the standard race sag Rs XZ LOADED MEASUREMENT A on ground without rider p EXAMPLE 23 0 in 583 mm m Free Sag Calculation unloaded 23 6 in 600 mm loaded without rider 23 0 in 583 mm Free Sag 0 6 in 17 mm Rear Suspension Adjustments 6 Calculate the free sag dimension To do this subtract the loaded without rider dimension step 5 from the unloaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CR With the spring pre load set to obtain the proper race sag the rear s
58. Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing 1 Remove the master link retaining clip 1 with pliers Do not bend or twist the clip Remove the master link 2 Remove the drive chain 1 retaining clip 2 master link 2 Clean the drive chain in high flash point solvent and allow it to dry 3 Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceable Replacement chain DID 520DMA2 74 Servicing Your Honda 4 Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Damaged Sprocket Worn sprocket Teeth teeth REPLACE REPLACE Normal Sprocket Teeth GOOD NOTICE Use of a new chain with worn sprockets will cause rapid chain wear 5 Measure a section of the drive chain to determine whether the chain is worn beyond its service limit Put the transmission in gear and then turn the rear wheel forward until the lower section of the chain is pulled taut With the chain held taut and any kinked joints straightened
59. Clutch System iiie tercio onte did 44 Spark Plug beret e repe d 48 Cylinder System eerte 49 RO Val 6 nessieira a e ters ciego 55 Reed Valve iicatotu eau i 58 Servicing Your Honda Chassis NUUS 60 Brakes ertet etes its dades de i 65 WCE Sis tcd iS 69 Tires amp T beS certo yet loses eise rai onn 70 Drive Calli correpta er deni detienen enn esit 72 Expansion Chamber eese 75 Additional Maintenance Procedures 76 Appearance Cate x eot eter 78 Servicing Your Honda 17 The Importance of Maintenance Keeping your CR well maintained is absolutely essential to your safety It s also a good way to get maximum performance during each moto Careful pre ride inspections and good maintenance are especially important because your CR is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CR before each ride and follow the Maintenance Schedule in this section A WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual 18 Servicing Your Honda This section includes instructions on how to perform some important maintenance tasks Some of the most important safety precautions follow However we
60. 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 21 lists service frequencies for each race or about 2 5 hours every 3 races or about 7 5 hours and every 9 races or about 22 5 hours Pre ride Inspection Check the items listed on the Pre Ride inspection checklist each time before you ride page 9 tires spokes amp rims leaks transmission oil fuel drive chain drive chain guide amp sliders amp guide rollers cables nuts amp bolts spark plug and cap throttle brakes clutch lever expansion chamber Fuel Capacity unleaded gasoline pump octane number of 91 or higher Premix Pro Honda HP2 2 stroke oil 32 1 Tank 2 0 US gal 7 7 Transmission oil Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or an equivalent
61. Oil Level Suspension Standard 0 44 kgf mm Fork Spring C 44 No mark A factory products Standard oil 2 8 in level 71 mm capacity 15 6 US oz 462 cm Maximum oil 1 5 in Slightly stiffer as level 37 mm it nears full capacity 16 9 US oz compression 450 cm Minimum oil 4 4 in Slightly softer as level 113 mm it nears full capacity 14 2 US oz compression 40 cm Optional Softer 0 42 kgf mm Fork Spring 8 1 scribe mark Standard oil 2 6 in level 67 mm capacity 15 8 US oz 466 cm Maximum oil 1 3 in Slightly stiffer as level 33 mm it nears full capacity 17 1 US oz compression 505 cm Minimum oil 4 3 in Slightly softer as level 108 mm it nears full capacity 14 4 US oz compression 425 cm cont d Servicing Your Honda Suspension Optional Stiffer 0 46 kgf mm Fork Spring 13 Remove the lock nut and spring guide 2 scribe marks together Install the partition plate 6 Standard oil 3 0 in level 75 mm capacity 15 5 US oz 458 cm Maximum oil 1 6 in Slightly stiffer as level 41 mm it nears full capacity 16 7 US oz compression 493 cm Minimum oil 4 6 in Slightly softer as level 117 mm it nears full capacity 14 1 US oz compression 416 cm 6 partition plate Be sure to check the oil level Some oil
62. Standard Spring 4 45 in 113 mm Softer Spring 4 25 in 108 mm Stiffer Spring 4 61 in 117 mm When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork Fork Travel Characteristics 2500 2000 Oil level 1 46 in 37 mm MAX j o 1500 F Oil level 2 80 in 71 mm S STANDARD Ta 1000 Oil level 4 45 in 118 mm S MIN 500r S j M Li 1 Lope Spe 0 Sf SM Oo O OO 6 POPP ESE LES Stroke in mm Adjustments for Competition Front Suspension Adjustments Front Suspension Oil Level Adjustment 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 Remove the number plate bolt 1 and number plate 2 i 1 number plate bolt 2 number plate 84 Adjustments for Competition 3 Remove the handlebar pad 4 Remove the washers handlebar holder nuts Loosen the upper pinch bolts 5 before loosening the fork caps to avoid damaging the
63. adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring Final travel too soft 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 stiff spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil level in increments of 0 2 in 5 mm Entire travel too soft 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 one click increments Adjustments for Competition 97 Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff e Stiff on
64. after the change to get an accurate appraisal of the change Seat of the pants feelings can t be trusted Eliminating wheelspin with a gearing change can make you feel like you re going slower when in reality you ve decreased your time by increasing your speed with better traction These gearing recommendations should be evaluated by considering your ability your riding style and the track Choosing the correct tire tread pattern and rubber compound can affect your placing in competition The tires on your CR offer a happy medium for the variety of soil conditions the majority of riders are likely to encounter Experienced competitors often switch to tires developed for specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in tires especially the sidewall profile can change the attitude of your CR and its handling Tire variations that raise or lower the rear of your CR have a more significant effect on handling than variations in front tires which generally don t vary as much Often you can see or feel the change in tire size Another way to check is to measure the rolling circumference of the old and new tires A higher profile tire will have a larger rolling circumference
65. age numbers are at the Check the following before each ride right Transmission oll level ssss 37 e Coolant for proper level 38 e Cooling system and hoses for condition 39 A WARNING Spark plug for proper heat range carbon Improperly maintaining this motorcycle or fouling and high tension cord terminal for failing to correct a problem before riding lO0SeHeSss tope tern made teee ivit end 48 can cause a crash in which you can be Air cleaner for condition and seriously hurt or killed contamination seseeseeeeeeeeetrenenn 40 e Clutch lever adjustment and freeplay 44 Always perform a pre ride inspection Steering head bearings and related parts before every ride and correct any for COndiH ON srini nEn 76 problems Carburetor throttle operation 42 Tires for damage or improper inflation jore s 70 Spokes for looseness sees 69 Rim locks for looseness sss 69 Front and rear suspension for proper ODGFatlOT eite ent eet orate tbe tilted 60 61 e Front and rear brakes check operation 65 Drive chain for correct slack and adequate TubEICatlOn orninn en E 72 Drive chain guide sliders and guide rollers for damage or wear sese 72 Expansion chamber springs for damage or lack of tens1Ons zitat tte edt 75 Every possible part for looseness such as cylinder h
66. and brake hose clamp bolts 13 Tighten the fork protector bolts to the specified torque 5 2 Ibf ft 7 N m alas id 14 nv 13 NOTICE Over tightening the pinch bolts can deform the fork tubes Deformed fork tubes must be replaced 12 5 upper pinch bolts 20 fork tube PRO T us A 6 fork cap 32 upper fork clamp wy qe 17 lower pinch bolts E 38 Position the wear ring 33 with its end gap 12 fork protector bolts 14 fork protectors facing rearward 13 brake hose clamp bolts 33 wear ring Adjustments for Competition 89 Front Suspension Adjustments 40 Clean the surfaces where the front axle shaft and axle clamps contact each other 41 Install the left and right side collars into the wheel hub 42 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 43 Tighten the axle nut 9 to the specified torque 65 Ibf ft 9 axle nut 90 Adjustments for Competition 44 Align the brake caliper 16 and hose with the left fork leg making sure that the brake hose is not twisted An improperly routed brake hose may rupture and cause a loss of braking efficiency Route the hose carefully 45 Clean the threads of the caliper mounting bolts 15 and brake caliper thoroughly 46 Apply locking agent to the bolt threads 47 Install the brake caliper on the fork slider and t
67. aner case cover 6 10 Remove the fuel tank 1 Turn the fuel valve 1 OFF 7 Unhook and remove the fuel tank band 7 8 Remove the fuel tank bolt 8 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 fuel valve 5 breather tube 6 air cleaner case cover 7 fuel tank band 8 fuel tank bolt Remove the seat page 29 Remove the shroud A bolts collars 2 Remove the shroud B bolts collars 3 and shrouds 4 AUN 1 fuel valve 9 fuel line 2 shroud A bolts collars 3 shroud B bolts collars 4 shrouds 30 Servicing Your Honda Fuel Tank Removal Installation 7 Install the shrouds 7 and shroud B bolts 1 Install the fuel tank on the frame collars 8 2 Connect the fuel line 1 to the fuel valve 2 1 fuel line 7 shrouds 2 fuel valve 8 shroud B bolts collars 9 shroud A bolts collars Install the fuel tank bolt 3 Hook the fuel tank band 4 9 Install the seat page 29 Hook the air cleaner case cover 5 Put the breather tube 6 in the steering stem nut ON UA E CS 3 fuel tank bolt 4 fuel tank band 5 air cleaner case cover 6 breather tube Servicing Your Honda 31 Subframe Removal Refer to Safety Precautions on page
68. ar 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 Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent changes will also assure consistent performance of both shifting and clutch action page 36 Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the cleaner closely each time it s serviced for evidence
69. ark Plug Cap Install a small plastic tie wrap around the spark plug cap to reduce any possibility of it loosening or of water penetration Spark Plug Some non resistor plugs may cause ignition problems Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range Replace periodically as specified in the Maintenance Schedule page 21 48 Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Additional corrosion protection is offered by using Honda Dielectric Grease on all electrical connections 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 Gaskets Always use new gaskets when reassembling components Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 50 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
70. ature Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order HELM P O BOX 07280 DETROIT MI 48207 Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your Honda dealer If he doesn t have the answer right away he will get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the following information in your letter name address and telephone number 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 133 Your Honda Dealer
71. buretor 123 Inarmtenatice eed eae Decretos t teuer ce 104 WON ESTATE seors ooieoe aieea EEE pereo Ere tuia 13 personal Hit arabe UP Earth 110 minor adjustments essere 103 environment protecting seeeeeee 114 suspension front csseseeeeeeenen 82 Care appearance oie teeenn erroe eer ihrer trend 78 expansion chamber see 45 SUSPENSION TO etie tree 92 chain dELV8 5st ta ER ERR ERR ace 72 suspension track conditions 96 chassis adjustment for track conditions 96 F tire seleetlon ui ertet mes 109 choke Knob ena teat ts 13 after competition maintenance 22 CLEANSE AIT siet ettet gere aerea 40 filter ait C leatiet oen tad 40 cleaning appearance care sees 78 DIE Leontii dui T 40 air pressure clutch system adjustment sess 44 flooded engine starting esses 13 front suspension eeeeeeeenen 82 component locations fork n 70 Mantenan E x uictor eren epa ropes 28 front suspension adjustment 82 American Honda contacting 133 OpeFalLlOTn iie tn tien Pec n E Cirad 6 front suspension inspection 60 apparel protectlve costes eene reote caes 2 competition logbook eese 125 oil recommen
72. cannot warn you of every conceivable 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
73. cket changing should be done by your Honda dealer Higher Gearing less rear sprocket teeth increases top speed in each gear provided the engine will pull the higher gearing reduces frequency of shifting wider gear ratios reduces engine rpm at a given throttle setting or ground speed which may allow better rear wheel traction on slippery or loose terrain 108 Adjustments for Competition However the engine may not pull the higher gearing the spacing between gears may be too wide engine rpm may be too low Lower Gearing more rear sprocket teeth decrease top speed in each gear increases frequency of shifting narrower gear ratios increases engine rpm at a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However spacing between gears may be too narrow engine rpm may be too high Some tracks may be watered heavily prior to the first race then lightly or not at all during the day This results in a track surface that is slippery during the first few races then changes from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutc
74. clicks and the punch marks are aligned Rear Suspension Adjustments Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 30 positions or more Turning the adjuster one full turn advances the adjuster 8 positions Rebound damping can be increased by turning the adjuster clockwise Tr 3 rebound damping adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 20 24 clicks with the punch marks on the adjuster and the shock absorber aligned Adjustments for Competition 93 Rear Suspension Adjustments Rear Suspension Race Sag Setting the proper race sag ride height is very important for competition use Race sag refers to the amount of rear wheel travel used by your CR at rest ready to ride with you on the seat As a general rule of thumb the race sag dimension should be about one third of the maximum travel On your CR ride height is changed by adjusting the rear suspension spring pre load Spring Pre load amp Race Sag Adjustment The following adjustment procedure establishes the correct starting point for any suspension tuning the proper rear spring pre load adjustment for your specific needs Your CR should be at normal racing weight including fuel and transmission oil You should be wearing all your
75. d to Motorcycle Safety as well as a number of Safety Messages throughout the manual Safety Messages are preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions A WARNING You CAN be KILLED or SERIOUSLY HURT if you don t 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 eren 1 Important Safety Information 2 Important Safety Precaution 2 Accessories amp Modifications ssss 3 Safety Lahel Sasien 4 OPERATING CONTROLS e 5 Operation Component Locations 6 BEFORE RIDING e ceeeee eren enne tnt z Are You Ready to Ride sss 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection ace ottenere 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Precautions esses 12 Starting amp Stopping the Engine 13 Preparat OMi irn tertio 13 Starting Procedure tete 13 Elooded Engine et
76. dation see 62 Coolant siete vec tee aate ERE Rde 38 consumer information seen 131 rame number 5 bee are er theres 118 appearance Care 2 ete tate eterne n eh eran Reda 78 contacting Honda eee 133 front brake lever adjustment 65 authorized manuals esse 132 controls operating serne enea 5 front suspension maintenance 82 COOLABU ce eet tt tte Peri ETO 38 fuel B customer SerVICE use re etr ER eer ad 134 lic M 35 Cylindet SVSLOTIL siete Hee erre xo e ege xod 49 iili 35 basic operation ssisieissireenisoneniseneii esia 11 recommendation esee 34 DeTOFe TAMING oor dee ise e UR FEE ER 7 D POPU SIG suce idein tt ie retta p ieee 35 between motos amp practice maintenance 26 ira X NES 34 brakes damping adjustments OXygenated eerte ertet ea 124 fluid leyel 55 nni ete 66 iro EE 83 tank Capacity irr ente ets 33 lever front adjustment 65 Ir 96 VALVE 2e ciet itd uet t E T 35 pad wear i5 exccdedhesebon ute d 68 dealer your Honda eben 134 pedal height tenete td 65 diagram WITI o ect teret reine 130 break in guidelines sees 15 drive CHAIN o aoi ore de HO PRI OE 72 Index 137 Index
77. ditions or situations that may require additional adjustments It should not be necessary to go more than one jet size richer or leaner to fine tune your CR If larger jetting changes are necessary check for air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Condition Main Jet Adjustment long straights next larger uphill sections sand mud high humidity next smaller raining hotter than 113 F 45 C 102 Adjustments for Competition Once you ve adjusted the carburetor for temperature and altitude it shouldn t need major readjustment unless race conditions change drastically However there are some unique atmospheric conditions or race day situations that may require additional adjustments They are as follows To prevent engine damage always adjust the main jet before adjusting the jet needle Always choose the next richer jet if there is any doubt so there is a margin for safety Main Jet Go richer on the main jet by one number when the track has a very long straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is hotter than 113 degrees F After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CR If larger je
78. e Honda Rider s Club USA only 135 TABLE OF CONTENTS eren 136 INDEX Q 137 QUICK REFERENCE Motorcycle Safety This section presents some of the most important Important Safety Information 2 information and recommendations to help you Important Safety Precaution 2 ride your CR safely Please take a few moments Accessories amp Modifications 3 to read these pages This section also includes Safety Labels i225 lanes Hips 4 information about the location of safety labels on your CR Motorcycle Safety 1 Important Safety Information Important Safety Precautions Your CR can provide many years of pleasure if you take responsibility for your own safety and understand the challenges you can meet in competitive racing As an experienced rider you know there is much you can do to protect yourself when you ride The following are a few precautions we consider most important Never Carry a Passenger Your CR is designed for one operator only Carrying a passenger can cause an accident in which you and others can be hurt Wear Protective Gear Whether you re practicing to improve your skills or riding in competition always wear an approved helmet eye protection and proper protective gear Take Time to Get to Know Your CR Because every motorcycle is unique take time to become thoroughly familiar
79. e 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 the official Honda Service Manual page 134 Clutch System Other Inspections amp Lubrication Check that the clutch lever assembly is positioned properly and the securing bolts are tight Check the clutch cable for kinks or signs of wear If necessary have it replaced Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Clutch Operation 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage Servicing Your Honda 45 Clutch System Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 37 2 Remove the rear brake pedal 1 by removing its pivot bolt 2 1 rear brake pedal 2 pivot bolt 3 Remove the five clutch cover bolts 3 and clutch cover 4 3 clutch cover bolts 4 clutch cover 4 Remove the five clutch spring bolts 5 and clutch springs Loosen the bolts in a crisscross pattern
80. e standard recommended settings under average load climatic and barometric conditions However to fine tune the engine s power output the carburetor may require adjustments for specific competition needs Optional main jets and slow jets are available for your CR See your Honda dealer Any engine or airbox modifications or the use of an aftermarket exhaust system may require jetting changes Carburetor Components Starting Circuit A very rich mixture must be delivered to the cylinder when the engine is being started When the choke knob 1 is pulled up fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 to provide a rich mixture for starting The mixture discharges through the orifice 4 into the cylinder 1 choke knob 2 starter jet 3 air passage 4 orifice 100 Adjustments for Competition Slow Circuit Fuel is metered by the slow jet 5 and is mixed with air that has been metered by the air screw 6 The mixture enters the venturi through the bypass 7 and slow jet outlet 8 5 slow jet 6 air screw 7 bypass 8 slow jet outlet Main Circuit Fuel is metered by the main jet 9 jet needle 10 and needle jet 11 It is then mixed with air coming from the air jet 12 and enters the venturi past the needle jet Baffle Plate The baffle plate 13 prevents foaming of fuel or abnormal fuel level around the main jet Float Chamber The float 14
81. ead nuts carburetor insulator bolts engine mounting bolts axle nuts handlebar holder bolts fork triple clamp bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt 120 Before Riding 9 10 Before Riding This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions sesss 12 Starting amp Stopping the Engine 13 Prepara Omenesti ee T ette e Ere rete re 13 Starting Procedure nere 13 Flooded Engine etr ree 13 How to Stop the Engine 14 Break in Guidelines sss 15 Basic Operating Instructions Basic Operating Instructions 11 Safe Riding Precautions Before riding your CR for the first time please review the Important Safety Precautions beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CR s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 12 Basic Operating Instructions Always follow the proper starting procedure described below Your CR can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter Preparation Make sure that the transmissio
82. eck wheel rim runout If runout is noticeable see the Honda Service Manual for inspection instructions Servicing Your Honda 69 Tires amp Tubes Refer to Safety Precautions on page 19 To safely operate your CR the tires must be the proper type off road and size in good condition with adequate tread and correctly inflated A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement 70 Servicing Your Honda Air Pressure Properly inflated tires provide the best combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also cause wheel damage on hard terrain Overinflated tires make your motorcycle ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install a new cap Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your CR has only been ridden for a
83. ed edge on the end of either spring smooth the roughness with a file and some emery cloth Clean the spring and spring seat thoroughly with a high flash point solvent to remove all metal particles and dirt 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 Check that the O ring 30 on the fork cap is in good condition Apply the recommended fork oil to the O ring 30 O ring cont d Adjustments for Competition 87 Front Suspension Adjustments 24 Loosen the lock nut 25 slightly 25 Attach a two foot length of mechanic s wire 31 to the threaded portion on the lock nut Wrap the wire securely around the threads 26 Install the fork spring 27 as follows With the fork spring held upright on its marked end feed the mechanic s wire up through the spring Angle the fork spring and slowly slide it down into the fork using a gentle rocking motion Gia en 27 25 lock nut 31 mechanic s wire 27 fork spring 27 Pull the mechanic s wire up and hold the damper rod 24 Remove the mechanic s wire from the damper rod Screw the lock nut 25 by hand until stops 24 damper rod 25 lock nut 88 Adjustments for Competition 28 Place the spring seat 26 on the fork spring 27 with its flat side faci
84. er clean amp oiled sealed in a plastic bag optional carburetor jets needles chain amp masterlinks chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs front amp side number plates handlebar grips levers brake amp clutch clutch lever handlebar mount clutch cable throttle assembly throttle cable shift lever brake pedal spokes front amp rear each side sprockets larger amp smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins 128 Technical Information Additional Spares front brake master cylinder rear brake assembly wheels amp tires front amp rear mounted clutch plates amp transmission oil seat ignition components top end complete radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end amp box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CR purchased from your Honda dea
85. er cap Repeat steps 1 4 After inspecting the oil level or adding oil tighten the oil check bolt and filler cap securely and oil check bolt to the specified torque 7 Ibf ft 10 N m 1 0 kgf m Transmission Oil Replacing Transmission Oil Run the engine for three minutes then shut it off 2 Support the CR in an upright position on a level surface 3 Remove the oil filler cap from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the drain bolt 1 5 Pour the drained oil into a suitable container and dispose of it in an approved manner page 118 NOTICE Improper disposal of drained fluids is harmful to the environment 6 After the oil has drained completely install the drain bolt with a new sealing washer and tighten it to the specified torque 21 Ibf ft 29 N m 3 0 kgf m 7 Add the recommended oil 0 60 US qt 0 57 at oil change 8 Check the oil level by following the steps in Checking amp Adding Oil 1 oil drain bolt Servicing Your Honda 37 Coolant Your CR s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and corrosion Coolant Recommendation Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze conta
86. es subjected to severe use require more frequent servicing NOTE 1 Clean after every moto for dusty riding conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride Servicing Your Honda 21 General Competition Maintenance Perform maintenance on firm level ground using the optional workstand or equivalent support When tightening bolts nuts or screws start with the larger diameter or inner fasteners and tighten them to the specified torque using a crisscross pattern Use genuine Honda parts or their equivalent when servicing your CR Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre ride Inspection Items Refer to Pre ride Inspection page 9 22 Servicing Your Honda Handgrips Always use Honda Hand Grip Cement U S A only or Honda Bond A when replacing handgrips Throttle Grip Align the index mark on the throttle grip with the edge of the throttle cable guide Left Handlebar Grip Align the A mark on the left handlebar grip with the paint mark on the handleb
87. facing out Install the lower drive chain roller Upper and lower rollers 9 Ibf ft 12 N m 1 2 kgf m 7 upper drive chain roller 9 gt mark 8 lower drive chain roller 8 Check the driven sprocket nut torque values after each race 24 Ibf ft 32 N m 3 3 kgf m Adjustment 1 Loosen the rear axle nut 1 2 Loosen both the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decrease slack or clockwise to increase slack Align the index marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm SEC 1 rear axle nut 2 lock nut 3 adjusting bolt 4 index mark 5 axle plate 6 reference marks 3 Tighten the rear axle nut to the specified torque 94 Ibf ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 Loosen the adjusting bolt counterclockwise lightly until it touches the axle plate Then while holding the adjusting bolt with a wrench tighten the lock nut to the specified torque 20 Ibf ft 27 N m 2 8 kgf m Drive Chain Lubrication Commercially 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 Servicing Your Honda 73 Drive Chain Removal
88. 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 69 Nuts Bolts Etc Application of a thread locking agent to essential fasteners offers added assurance and security Remove the nuts clean the threads of both the nuts and bolts apply Honda Thread Lock or an equivalent and tighten to the specified torque Servicing Your Honda 25 Before amp After Competition Maintenance Be sure the fuel and oil is mixed well by agitating it thoroughly before pouring pre mix into the fuel tank WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Between Motos amp Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments Clean accumulated dirt from under the fenders wheels suspension components hand a4 grips controls and footpegs A stiff nylon Ss 1 parts cleaning brush works well QN Check tire air pressure EREN Check spoke tension and rim lock nut securely 1 chain adjuster index marks Check sprocket bolt and
89. for tacky soil and mud but with a few more knobs Adjustments for Competition 109 Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input Control Positioning Position the control levers so that you can use them comfortably when seated and standing Adjust the mounting bolt torque of the clutch and brake lever assemblies so that they can rotate on the handlebar in a fall If an assembly does not rotate it may bend or break a control lever Make sure that the bolts are torqued securely enough to prevent slippage during normal operation Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first x a a eos 1 1 control lever mounting bolts As an alternative consider wrapping the handlebar area under the control assemblies with teflon tape Then tighten the assemblies to their normal torque Upon impact the fully tightened assemblies should rotate on the Teflon tape 110 Adjustments for Competition e Position the shift lever and brake pedal so they are close to your boot for rapid access but not so close that either is depressed when sitting or standing comfortably on your CR Handlebar Position Width amp Shape e Position the handlebar so that both gripping the bar and operating the controls
90. fork rake and trail and should improve stability in a straight line The effective suspension travel will be transferred toward the firmer end of wheel travel Keep the race sag adjustment page 94 in the 3 5 3 9 in 90 100 mm range Fork Height Angle The position of the fork tubes in the clamps is not adjustable Standard Position The standard position 1 aligns the index groove 2 with the top of the upper clamp 3 2 1 1 standard position 0 3 in 7 mm 2 index groove 3 upper fork clamp Standard Position For Optional Front Wheel If you install the optional 20 inch wheel align the top of the fork tube 5 not the top of the fork cap with the top of the upper fork clamp 6 Ga 6 4 Arm i 4 standard position puo for optional front wheel 0 in 0 mm 5 top of fork tube 6 top of upper fork clamp Chassis Adjustments Wheelbase Adjusting your CR s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to re check race sag and adjust if necessary In the past a general rule was lengthen the wheelbase to add straight line stability shorten the wheelbase to improve turning However we suggest you do not lengthen the wheelbase of your CR unless you are racing on a track with more fast sections than normal As a general reco
91. h 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 where the gearing feels wrong If you decide to try a gearing change have someone check your times with a stopwatch before and
92. handling braking durability and comfort across a broad range of riding conditions Front 80 100 21 51M Rear 100 90 19 57M Type bias ply tube Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Tires amp Tubes Servicing Your Honda 71 Drive Chain Refer to Safety Precautions on page 19 The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets When the motorcycle is ridden on unusually dusty or muddy tracks more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and check that your transmission is in neutral 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 vertical movement by hand 1 1 3 8 in 25 35 mm 72 Se
93. he adjuster 2 counterclockwise To position the clutch lever closer to the handgrip turn the adjuster ZA clockwise 5 o 3 Tighten the lock nut 4 lock nut 5 integral cable adjuster increase freeplay decrease freeplay 6 Adjust the cable end adjuster for minor adjustment 44 Servicing Your Honda Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster Cable end adjuster 2 cable end adjuster increase freeplay decrease freeplay Turning the cable end adjuster 2 in direction will increase freeplay and turning it in direction will decrease freeplay If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn and make the adjustment with the integral cable adjuster Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained Integral cable adjuster 3 lock nut 4 integral cable adjuster increase freeplay decrease freeplay 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 3 8 3 4 in 10 20 mm 4 Tighten the lock nut Check the adjustment 5 Start th
94. heck the brake pads for wear page 68 It should be above the LOWER level mark 1 If Worn brake pads should be replaced If the pads the level is at or below the LOWER level mark are not worn have your brake system inspected check the brake pads for wear page 68 for leaks Worn brake pads should be replaced If the pads If the brake pedal freeplay exceeds 0 9 in are not worn have your brake system inspected 23 mm there is probably air in the brake for leaks system and it must be bled Refer to the Honda If the brake lever freeplay exceeds 0 8 in Service Manual or see your Honda dealer for 20 mm there is probably air in the brake brake bleeding system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding 66 Servicing Your Honda Brakes Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 Make sure there are no fluid leaks brake fluid from a sealed container or an brake fluid from a sealed container or an Check for deterioration or cracks in the hoses equivalent equivalent and fittings When adding brake fluid be sure the reservoir is When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake horizontal before the cap is removed or brake fluid may spill out fluid may spill out 1 screws 3 upper level mark 4 bolts 6
95. ifications 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 123 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by Volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol b
96. ighten the caliper bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m Fit the brake caliper over the disc taking care not to damage the brake pads Sa 15 brake caliper mounting bolts 16 brake caliper 48 Install the handlebar 4 mounting rubbers 34 washers and handlebar holder nuts 3 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 3 washers handlebar holder nuts 4 handlebar 34 mounting rubbers 49 Install the number plate 2 by aligning its hole 35 with the tab 36 on the steering stem 2 number plate 35 hole 36 tab Front Suspension Adjustments 50 Install and tighten the number plate bolt 1 53 Tighten the left axle pinch bolts 38 54 Clean the threads of the bolts and axle holder 51 Install the handlebar pad 37 alternately first thoroughly g While keeping the forks parallel alternately 55 Apply locking agent to the bolt threads tighten the right axle pinch bolts 39 to the 56 Install the disc cover 7 and tighten the specified torque bolts 8 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 10 Ibf ft 13 N m 1 3 kgf m AB un i ON 1 number plate bolt W BRL as 37 handlebar pad N 7 m 52 With the front brake applied pump the fork N THAN N x up and down several times to seat the axle 7 disc cover 8 bolts and check front brake operation NOTICE 57 Turn
97. ill keep your Honda looking newer longer Frequent cleaning also identifies you as an owner who values his motorcycle A clean CR is also easier to inspect and service While you re cleaning be sure to look for damage wear and gasoline or oil leaks General Recommendations To clean your CR you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CR or discolor the seat and decals If your CR is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your CR High pressure washers like those at coin operated car washes can damage certain parts of your CR The force of water under extreme pressure can penetrate the dust seals of the suspension pivot points and steering head bearings driving dirt inside and needed lubrication out 78 Servicing Your Honda If you use a high pressure washer avoid spraying the following areas wheel hubs expansion chamber outlet area under seat engine stop button brake master cylinders under fuel tank drive chain carburetor steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points NOTICE High pres
98. in 2 or 3 progressive steps 46 Servicing Your Honda 5 5 clutch spring bolts 6 clutch pressure plate 6 T 7 clutch lifter 8 clutch lifter rod Remove the clutch pressure plate 6 Clutch Disc Inspection Replace the clutch discs 1 if they show signs of scoring or discoloration Measure the thickness of each clutch disc Service Limit 0 112 in 2 85 mm Replace the clutch discs and clutch plates as an assembly Remove the clutch lifter 7 and clutch lifter rod 8 Remove the eight clutch discs and seven clutch plates 9 Turn the lifter bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing plate does not turn smoothly 1 clutch disc Clutch Spring Inspection MW 1 1 clutch spring Measure the free length of each spring Service Limit 1 39 in 35 2 mm 9 clutch discs and plates Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch plates have been burnt heat discolored Clutch Disc Plate Cover Installation 1 Coat the clutch plates 1 and discs 2 with transmission oil 2 Install the eight clutch discs and seven clutch plates alternately starting with a clutch disc 1 clutch plates 2 clutch discs 3 Apply grease to the clutch lifter rod 3 4 Insert the clutch lifter rod into the mainshaft 5 Install
99. ing you Always let the engine and radiator cool down before removing the radiator cap 2 Add coolant up to the filler neck if the level is low Inspect the coolant level before each outing A coolant loss of 0 7 2 0 US oz 20 60 cm through the over flow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 06 US qt 1 00 at disassembly 0 98 US qt 0 93 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 Refer to Safety Precautions on page 19 Honda Service Manual for troubleshooting of leaks Check water hoses 1 for cracks deterioration and clamp bands for looseness Check the radiator mount for looseness Make sure the overflow tube 2 is connected and not clogged Check the radiator fins for clogging Check the water leakage check hole 4 below the water pump for leakage Make sure the hole remains open If water leaks through the check hole the water pump seal is damaged If oil leaks through the check hole the transmission oil seal is damaged See the Honda Service Manual or consult your Honda dealer for replacing the water pump seal or the transmission oil seal Both seals should be
100. ining 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 level is correct when it is at the bottom of the radiator filler neck 1 radiator cap A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scald
101. int 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 78 Servicing Your Honda 27 Maintenance Component Locations integral clutch cable adjuster front brake lever clutch lever front brake fluid clutch cable reservoir adjuster
102. ion includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your CR 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 132 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety suits er ont rettet 19 Important Safety Precautions 19 Maintenance Schedule sssss 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 Service Preparations Maintenance Component Locations 28 Seat REMOVAL ss ssscvecevcisscsevvcasessvevave eanniensaawenesoetess 29 Fuel Tank Removal eem 30 Subframe Removal ccccccceseeeeeseeesesereneees 32 Service Procedures Fluids amp Filters UCL Syste Minses eere eerte teen 34 Transmission Oll cccccccceceeeessceceeeseesessaeeeeees 36 IG FELINE RT T 38 Air CIeangeE s otocuteo meae en cpm Tan 40 Engine Throttle ceo tete dioeceseos eet e b Perte 42
103. ion Spark Plug Appearance Mixture Normal Dark brown to light tan correct color with dry electrode Overheating Lean Light gray or white color lean Wet Wet or sooty rich Rich Remember that in addition to improper jetting A lean condition can be caused by air leaks in the inlet tract in the center crankcase joint and leaking ignition side crank seal A rich condition may be caused by a leaking primary drive side seal that draws transmission oil into the fuel air mixture Excessive smoking will occur The same simple throttle opening identification system used in the Break In section of this manual can also be used to accurately identify where carburetion problems occur should they arise page 15 The following suggestions may improve a specific concern Subtle changes in overall handling may also be noted Rear End If you have a problem with rear wheel traction raise the rear end of your CR by increasing the rear spring pre load Instead of running 3 9 in 100 mm of sag you can run 3 5 in 90 mm so the rear of the bike will sit a little higher This should produce more traction because of the change to the swingarm and the location of your CR s center of gravity If you have a problem with the steering head shaking when you use the front brake hard or if your CR wants to turn too quickly lower the rear of the motorcycle by reducing the rear spring pre load This will increase
104. ion chamber for cracks or deformation A damaged chamber may decrease engine performance 1 springs Expansion Chamber Removal Remove the expansion chamber by removing the expansion chamber springs 1 and mounting bolts 2 Remove carbon deposits from the head pipe of the expansion chamber Expansion Chamber Expansion Chamber Installation Install the expansion chamber in the reverse order of removal Tighten the front and rear mounting bolts to the specified torque Front 9 Ibf ft 12 N m 1 2 kgf m Rear 7 lbf ft 10 N m 1 0 kgf m Servicing Your Honda 75 Additional Maintenance Procedures Refer to Safety Precautions on page 19 Steering Head Bearing Inspection 1 With your CR on a box or 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 in the steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer 76 Servicing Your Honda Handlebar Inspection Remove the handlebar pad Check the handlebar 1 for bends or cracks Check that the handlebar has not moved from its p
105. ions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cable from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cable with a commercially available cable lubricant to prevent premature rust and corrosion Servicing Your Honda 43 Clutch System Refer to Safety Precautions on page 19 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns Clutch Lever Freeplay Clutch Lever Adjustment Cable end adjuster The distance between the tip of the clutch lever and the grip may be adjusted Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable is disconnected 1 clutch lever 3 cable end adjuster increase freeplay Inspection decrease freeplay Check freeplay Freeplay 3 8 3 4 in 10 20 mm CA Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay 3 8 3 4 in 10 20 mm at the tip of lever Tighten the lock nut If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear 1 lock nut 2 adjuster Integral cable adjuster ER Loosen the lock nut 1 2 To position the clutch lever farther away from the handgrip turn t
106. ips 111 Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda we recommend that you follow these guidelines Use a loading ramp Make sure the fuel valve is off 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 112 Tips To secure your CR brace the front wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach to the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that you do not transport your CR on its side This can damage the motorcycle and leaking gasoline could be a hazard If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CR running again To reduce or prevent deterioration that can occur during storage also follow the following
107. lation 1 Clean the piston ring groove 2 Lubricate the piston ring and piston ring groove with clean 2 stroke oil 3 Install the piston ring on the piston with the marks facing up Locate the piston ring end gap on the pin in the ring groove 4 Lubricate the small end bearing and piston pin 1 with clean 2 stroke oil 5 Install the connecting rod small end bearing piston and piston pin Install the piston with the IN mark 2 facing the intake side If the IN mark is not found on the piston install the piston with the hole 3 facing the intake side 6 Install new piston pin clips 4 Never reuse old clips Take care so that the clips do not fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 1 piston pin 2 IN mark 3 hole 4 piston pin clip Cylinder Installation 1 Clean off any gasket material from the gasket surface of the crankcase being careful not to let any material fall into the crankcase Be careful not to remove any metal from the gasket surface 2 Remove the shop towel Do not let any gasket debris fall into the crankcase 3 Place the new cylinder base gasket 1 and dowel pins 2 on the crankcase 1 cylinder base gasket 2 dowel pin 4 Lubricate the piston and ring with 2 stroke oil Align the ring end gap with the piston ring pin 3 in the ring land and slip the cylinder 4 over the piston while compressing the piston
108. ler spoke wrench 6 6 mm 070MA KZ30100 spoke wrench 5 8 x 6 1 mm 07701 0020300 lock nut wrench 46 mm 070MF KSRO100 Chemical Products Pro Honda HP Trans Oil or Pro Honda GN4 or HP4 without molybdenum additives only Pro Honda HP Fork Oil 5W Pro Honda HP2 2 stroke Oil Honda thread Lock Honda Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda brite Cleaner Honda Contact Cleaner Honda Dielectric Compound Honda Hand Grip Cement Honda Hondalock Honda Moly 60 Paste U 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 pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape ENGINE STOP BUTTON e BI kiH sim BI Bu 6 BIW e i 3 a PUL GND STOP SW IGN GND 1 1GN EXT HIGH EXT LOW EXT WPC 8P BI IGNITION CONTROL MODULE IGNITION COIL 5V TPS OUT TPS GND PULSE WPC 4P 1 Bu Y G W rw Bu Bu Y CTA W Bu Y Wiring Diagram G H B1 Y W P
109. lly 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 get instructions on how to dispose of nonrecyclable wastes 114 Tips NOTICE Improper disposal of drained fluids is harmful to the environment The items that are serviceable using this Manual are followed by the page number reference in parenthesis The items that require use of the Honda Service Manual are followed by an asterisk POOR PERFORMANCE AT LOW AND IDLE SPEEDS CHECK 1 Check ignition timing CORRECT 2 Check carburetor air screw adjustment P 103 CORRECT 3 Check if air is leaking past manifold
110. measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service Replacement chain DID 520MA2 Service limit 10 20 in 259 0 mm cU ON MEASURE A SPAN OF 17 PINS 16 PITCHES Lubricate the drive chain Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation Recheck chain slack and adjust as necessary More About Drive Chain The master link is the most critical element of drive chain 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 1 2 3 Expansion Chamber Inspection Check the expansion chamber springs and replace them if they are damaged or stretched Check the flange bolts for tightness Check the expans
111. ments Maintenance Performed etc Make several photocopies of this page for future use 126 Technical Information These parts and tools may be ordered from your authorized Honda dealer Optional Parts List CARBURETOR Remarks Main jet Standard 430 10 370 490 in increments of Slow jet Standard 55 45 65 in increments of 5 Jet Needles Standard needle 6DGY28 68 Straight diameter 92 68 mm Jetneedle number Jet needle number standard series Jet needle number 1 2 clip position richer than standard series at FRAME Remarks FRAME Remarks Driven sprocket Drive chain links Shock spring Higher gearing 51 Teeth Aluminum 116 Softer 246 4 Ibf in 4 4 kgf mm Standard 52 Teeth Aluminum lt 116 gt e Green mark Lower gearing 53 Teeth Aluminum lt 116 gt Handlebar lower Standard 257 6 Ibf in 4 6 kgf mm holder No mark Standard 3 mm offset factory products Optional no offset or White mark Front wheel aftermarket parts Standard 21 inch Fork height 0 3 in 7 0 mm Stiffer 268 8 Ibf in 4 8 kgf mm align the index groove with the Blue mark top of the upper clamp 280 0 Ibf in 5 0 kgf mm Optional 20 inch Red mark wheel assembly except brake disk e tire tube Fork springs 23 52 Ibf in 0 42 kgf mm
112. mmendation keep the wheelbase as short as possible This positions the wheels closer together improves turning response increases weighting traction on the rear wheel and lightens weighting on the front wheel With your CR you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits Adjustments for Competition 107 Gearing You can adjust the power delivery of the standard engine to suit track conditions by changing gearing This allows you to utilize a different portion of the engine s power range at a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion of your engine s power range you use can be adjusted by changing the final drive ratio with different sized rear sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There is a choice of both higher and lower final drive ratios with two optional aluminum driven sprockets For muddy or sandy courses there is a more durable steel driven sprocket with the standard number of teeth Like the optional springs these sprockets are listed in the Optional Parts List section of this manual Unless you have the required mechanical knowhow tools and an official Honda Service Manual spro
113. mpetition Fork Oil Level Standard 0 44 kgf mm Fork Spring sX No mark factory products Optional Stiffer 0 46 kgf mm Fork Spring 2 separate scribe marks Standard oil 3 0 in level 75 mm Standard oil 2 8 in level 71mm Maximum oil 1 6 in level 41 mm Slightly stiffer as it nears full compression Maximum oil 1 5 in level 37 mm Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil 4 6 in level 117 mm Minimum oil 4 4 in level 113 mm Slightly softer as it nears full compression Optional Softer 0 42 kgf mm Fork Spring Q 1 scribe mark Standard oil 2 6 in level 67 mm Maximum oil 1 3 in level 33 mm Slightly stiffer as it nears full compression Minimum oil 4 3 in level 108 mm Slightly softer as it nears full compression e 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 If 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 20 2 22 23 Front Suspension Adjustments Inspect both ends of the fork spring If you find any roughness or burr
114. n is in neutral Turn the fuel valve ON Starting Procedure Check the transmission oil and coolant levels before starting the engine page 37 38 2 choke knob 1 fuel valve Cold Engine Starting 1 2 3 4 Turn the fuel valve 1 ON Shift the transmission into neutral Pull the choke knob 2 up With throttle closed operate the kickstarter Starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion After the engine starts the choke knob should be pushed down as soon as possible to prevent spark plug fouling Allow the engine to warm up for at least 2 minutes before riding off preferably until the side of the cylinder is very warm to the touch through your riding glove Slowly increase rpm and don t blip the throttle Warming the engine is important to prevent cold seizures Warm Engine Starting 1 2 3 4 Turn the fuel valve ON Shift the transmission into neutral Push the choke knob down Open the throttle 1 8 1 4 and operate the kickstarter Starting amp Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine Push the choke knob down all the way to OFF 2 Open the throttle fully 3 While pushing the engine stop button crank the engine several times with the kickstarter 4 Release the engi
115. n ordering replacement parts You may record these numbers in the Quick Reference section at the rear of the manual The VIN vehicle identification number 1 appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 1 VIN 3 engine number 118 Technical Information Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85 2 in 2 163 mm Type Liquid cooled 2 stroke Final reduction 4 000 Overall width 32 3 in 821 mm Cylinder arrangement Single 18 5 inclined from Left foot operated return Overall height 50 5 in 1 282 mm vertical Gear shift pattern system 1 N 2 3 4 5 Wheelbase 57 9 in 1 470 mm Bore and stroke 2 13 x 2 14 in 54 0 x 54 5 mm Electrical Seat height 37 6 in 954 mm Displacement 7 62 cu in 124 8 cm Ignition CDI Foot peg height 17 3 in 439 mm Compression ratio 8 6 1 Starting system Kickstarter Ground clearance 13 8 in 352 mm Transmission oil Spark plug Standard NGK capacity BR9EG Frame After draining 0 60 US qt 0 57 DENSO Type Twin tube After disassembly 0 69 US qt 0 65 W27ESR V F suspension travel 10 8 In 275 mm Carburetor Optional j ey stroke
116. nda dealer for replacement IMPORTANT INFORMATION Operator only No passengers This Honda Motorcycle is sold as is without warranty and the entire risk as to quality and performance is with the buyer Read owner s manual This vehicle is designed manufactured and sold for competition use only It does not conform to Federal Motor Vehicle Safety Standards or U S EPA Noise and Emissions Standards Operation on public streets roads highways or for off road recreation is illegal State and Federal laws prohibit operation of this vehicle except in an organized racing or competitive event on a closed course Or by permit issued by the local governmental agency having jurisdiction D gt NEVER OPEN WHEN HOT Hot coolant will burn you D gt NE JAMAIS OUVRIR A CHAUD Le liquide risque de vous br ler b RUBUS 4 Motorcycle Safety Operating Controls Read this section carefully before you ride It Operation Component Locations 6 presents the location of the basic controls on your CR Operating Controls 5 Operation Component Locations front brake lever clutch lever X engine stop button throttle grip east oe P7 uu um 8S C choke knob kickstarter fuel valve rear brake pedal 6 Operating Controls Before each ride you need to make sure you and your CR are both ready to ride To help get you prepared this section discusses how to evaluate your riding
117. ne stop button 5 Follow the Warm Engine Starting procedure Basic Operating Instructions 13 Starting amp Stopping the Engine How to Stop the Engine 2 F 1 throttle grip 2 engine stop button E Normal Engine Stop 1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle grip 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 Break in Guidelines Help assure your CR s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston ring is replaced cylinder is replaced crankshaft or crank bearings are replaced Basic Operating Instructions 15 16 Basic Operating Instructions Keeping your CR well maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CR in good shape this sect
118. nformation on page 101 and 102 When the engine is warm enough to run without the choke push the choke knob down to its off position Loosen the lock nut 1 and turn the throttle stop screw 2 to obtain the smoothest idle o decrease idle speed turn the screw counterclockwise o increase idle speed turn the screw clockwise Tighten the lock nut while holding the throttle stop screw to the specified torque 1 5 Ibf ft 2 N m 0 2 kgf m Adjust the air screw 3 to obtain the best off idle performance If the engine blubbers rich exiting a corner turn the air screw counterclockwise to lean the mixture If the engine surges lean exiting a corner turn the air screw clockwise to richen the mixture Carburetor Adjustments amp Tuning Tips increase decrease 1 lock nut 2 throttle stop screw 3 air screw The minimum to maximum range of air screw adjustments is 1 to 3 turns out from the lightly seated position If you exceed 3 turns out the next smaller slow jet is needed If you are under turn out the next larger slow jet is needed Adjustment Procedure 1 Warm up the engine 2 Make 2 3 laps of a course with the standard setting or corrected jetting page 101 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening Verify carburetion by removing the spark plug and reading its firing end page 48 109 It may take m
119. ng up 26 spring seat 27 fork spring 29 Screw the fork cap 6 on the damper rod 30 Hold the lock nut 25 and tighten the fork cap to the specified torque 21 Ibf ft 28 N m 2 9 kgf m 30 25 6 fork cap 25 lock nut 30 O ring 31 Temporarily thread the fork cap into the fork tube 32 Insert both fork legs into the fork clamps 33 34 35 36 34 Align the groove in the fork tube 20 with the top surface of the upper fork clamps 32 If installing the optional 20 inch wheel align the top of the fork tube not the top of the fork cap with the top surface of the upper fork clamp Temporarily tighten the fork lower pinch bolts 17 and then tighten the fork cap 6 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m For ease of releasing air pressure after the forks are installed loosen the lower pinch bolts and position the fork outer tubes so that the pressure release screws are in front of the rebound damping adjusters Tighten the fork lower pinch bolts to the specified torque 15 Ibf ft 20 N m 2 0 kgf m Tighten the fork upper pinch bolts 5 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m Tighten the bolts alternately in 2 or 3 steps Front Suspension Adjustments 39 Clean the threads of the fork protector bolts 12 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protectors 14 fork protector bolts
120. nie s 36 COOLATIE oett rer EEEE 38 Air 2 1 Cor ae asser r 40 Engine MT OUI E 42 Clutch System o iei rip eter 44 Spark PIG rct tte eere pee 48 Cylinder System oio tate terere 49 IRC Valves eenen tee EEEE E ee IS ead 55 Reed Valyeascuenetereif terit 58 Chassis SUSPENSION m 60 Brakes Hemd r i 65 bg 69 Tares amp TUDeS eite Peor 70 Drive Chat dero rore tuere Sae eta evs 72 Expansion Chamber eee 75 Additional Maintenance Procedures 76 Appearance Care ue ente oe egre dia 78 ADJUSTMENTS FOR COMPETITION 81 Front Suspension Adjustments 82 Rear Suspension Adjustments 92 Suspension Adjustments for Track Conditions 96 Suspension Adjustment Guidelines 97 Carburetor Adjustments amp Turning Tips 100 Chassis Adjustments eese 107 GEAT S rius erai aids ia pret ta 108 Tire Selection for Track Conditions 109 Personal Fit Adjustments sess 110 TIPS c 111 Transporting Your Motorcycle 112 storing Your Honda eee 113 You amp the Environment sess 114 Troubleshooting 115 TECHNICAL INFORMATION 117 Vehicle Identification esses 118 SPECIE CATIONS tieni ae erus 119 Torque Specifications
121. nt Locations 6 BEFORE RIDING eee eese een entente 7 Are You Ready to Ride sss 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection eene 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Precautions sess 12 Starting amp Stopping the Engine 13 PreparatiOD oic tir trt rete reet 13 Starting Procedure eese 13 Flooded Engrne order 13 How to Stop the Engine eens 14 Break in Guidelines sess 15 SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety sess 19 Important Safety Precautions 19 Maintenance Schedule sssss 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 136 Table of contents Service Preparations Maintenance Component Locations 28 Seat Removals eite e n ERR SERERE UR 29 Fuel Tank Removal ee 30 Subframe Remowval sse 32 Service Procedures Fluids amp Filters Fuel Syste tee rtt huno terea 34 Transmission Oll aserria e
122. ock nut Return the dust cover to its normal position 5 After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn Tighten the lock nut install the dust cover and make the adjustment with the lower adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you cannot get the proper adjustment with the upper adjuster 1 Kn 5 rubber cap increase 6 lock nut decrease 7 adjuster 1 Pull up the rubber cap 5 on the carburetor cap and loosen the lock nut 6 2 Turn the adjuster 7 in direction to decrease freeplay and in direction 4 to increase freeplay 3 Tighten the lock nut 4 Reinstall the rubber cap securely after adjustment 5 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range contact your Honda dealer Throttle Throttle Inspection 1 throttle grip 1 Check that the throttle assembly is positioned properly and the securing bolts are tight 2 Check for smooth rotation of the throttle grip 1 from fully open to fully closed in all steering posit
123. of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between 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 Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 40 Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model Using the wrong Honda air cleaner or a non Honda air cleaner which does not have equivalent quality may cause premature engine wear or performance problems Air Cleaner Housing Sealing Remove and reseal the air cleaner 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 Servicing Your Honda 23 General Competition Maintenance Sp
124. ollar 1 lock nut 2 5 Wipe off any excess oil from the spring guide spring guide 3 and O ring 4 3 Install the spring guide and new O ring 4 as shown 6 Loosely install the lock nut 2 onto the damper rod 9 Raise the fork tube 7 and cover the top of 7 Install the distance collar 1 into the damper the tube with your hand Compress the fork rod tube fully then release your hand Use your other hand to secure the fork tube Repeat vA this procedure 3 times 1 v 2 3 1 distance collar 3 spring guide 2 lock nut 4 O ring 3 Remove the partition plate 6 from the inside of fork tube 4 Pour out the fork oil by pumping the fork tube 4 dist il 3 spri id and damper rod 5 8 10 times with the rod o PE bbs a Ging di end down as shown 7 fork tube 62 Servicing Your Honda 12 Adjust the oil level by adding or removing the oil with an after market syringe 10 10 Pour the remaining fork oil into the damper rod 5 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 7 down onto the lower end of the slider pipe 8 Wait about 5 minutes 10 syringe 5 damper rod 8 lower end of the slider 7 fork tube pipe 11 With the fork tube held upright measure the oil level 9 from the top of the tube 9 oil level Fork
125. ompleting 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 ic Q Price Total Item No tem Description ly Each Price Prices are subject to change without notice and Sub Total Sales T without incurring obligation Mies por es ee ay Calif Add 8 25 Handlin Orders are mailed within 10 days Please allow Charge 5 00 adequate time for delivery Grand Total 132 Consumer Information NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation S al Customer Name l P Attention T Street Address No P O Box Number Apt O City State Zip Code Daytime Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash P Check here if billi eck here if your billing A Master VISA Di address is different from the Y al ISCover shipping address shown above M Account Number E N um T Expiration Date Mo Yr Customer Sign
126. on 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 10W 40 weight 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 Your CR does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch
127. ons eseeeeeneeree 2 I ijddq ts 62 IE 4 LEATISfDISSI R iiir i ER RR ERR 36 MAIN EN ANCE s oi ei opa s 19 identification vehicle sess 118 operation component locations 6 riding precautions eseeeeeee 12 idle speed engine cerises erento co 103 operating schedule maintenance esee 20 inspection pre ride oo ee ee eee eects eeeeeeeeeeeee 9 CONOIS NER 5 serial numbets ertet et te levees 118 IHSIPUCLIORS maonar ei or REESE 11 service L optional felis forti vi DET 134 parts st 32d e o IUOS ERSEOS 127 manuals 2 eoe rere ids 132 labels Safety i cete er urani ere e erbe e 4 Sero MN 127 spare pafis D 128 locations component oxygenated fuels rocne 124 Spark knock suse en Hid a 48 MAIMLEN ANCE uoc ao ete esta tope ete era dro 28 spark plug Operati oN eeno en e aE EEEE Ee 6 P mantin E aiit a 48 logbook competition eee 125 isnt ipe Peunes Siexsuebindeetedebtateeateuewal 106 pads Dtake ee tp ts 68 SPECI CAMONS i nere a itae ratesise 119 parts ODLIODal sesser usien eneen erp px eesi de 127 spring pre load rear suspension 92 personal fit adjustments sess 110 starting pitigimg englhe iore ocio eee edu ett edet bue 34 CN SING a Leder eripe reete de fud 13 plug Spark ies Rt Encres 48 troubleshooting iere eene 115 pre load rear
128. orate 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 r Steering Head Bearings l j l l ji l l k l I l l l l l i l l l l l L l 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 Periodically inspect the frame closely
129. ore than 2 3 laps to get a good spark plug reading with a new spark plug 3 Change carburetor settings or select suitable carburetor jets taking into consideration the engine conditions and factors for temperature and altitude page 101 4 If you ve determined that the main and slow jets must be changed you must remove the float chamber plug Removing the float chamber plug will allow the fuel in the float chamber to drain Do not remove the plug if the engine is hot 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 5 Turn the fuel valve OFF and disconnect the fuel line from the fuel valve 6 Loosen the connecting and insulator band screws Rotate the carburetor Remove the float chamber plug 4 4 float chamber plug Adjustments for Competition 103 Carburetor Adjustments amp Tuning Tips ds Change the main jet 5 and slow jet 6 as required 5 main jet 6 slow jet 8 9 10 11 12 13 104 Check the O ring for wear then reinstall the float chamber plug securely Remove the carburetor top throttle valve and cable holder this page and then change the jet needle clip position as required Reinstall the jet needle throttle valve cable holder and carburetor top page 105
130. pension 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 on page 68 Brake Caliper Inspection Be sure both the front and rear calipers are able to move freely on the caliper bracket pins Check pad thickness periodically and replace when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Replace the hydraulic fluid in the brake system every two years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteri
131. per bolts damage hold both the outer tube and slider when 13 brake hose clamp bolts 16 brake caliper removing the fork damper 14 fork protectors 9 axle nut 11 front axle shaft 10 axle pinch bolts 18 slider pipe 20 fork tube 19 dust seal 21 guide bushing Adjustments for Competition 85 Front Suspension Adjustments 13 Record the rebound damping adjuster 17 Pour the recommended fork oil into the fork position and turn the adjuster screw 22 tube 20 until a little oil flows out of the top counterclockwise until it stops of the damper rod Leave the damper rod for 14 Hold the fork tube 20 then remove the about one minute fork cap 6 from the fork tube Gently 18 With the fork held upright measure the oil slide the fork tube down onto the lower end level 28 from the top of the fork tube to the of the slider pipe 23 fork oil 28 y d d T 6 fork cap 22 adjuster screw 1 20 fork tube 23 slider pipe lower end 20 fork tube 28 oil level 15 Remove the fork cap 6 from the damper rod 24 by holding the lock nut 25 19 Adjust the oil level by adding or removing 16 Remove the spring seat 26 and fork spring oil with an aftermarket syringe 29 27 6 25 24 29 syringe 6 fork cap 26 spring seat 24 damper rod 27 fork spring 25 lock nut 86 Adjustments for Co
132. pression Damping Compression damping may be adjusted in two stages with separate adjusters The high speed damping adjuster 1 is effective when damping adjustment is desired for high speed operation The low speed damping adjuster 2 should be used when damping adjustment is desired at relatively low speeds Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise Adjust the high speed compression adjuster in 1 12 turn increments 1 high speed damping adjuster 2 low speed damping adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed compression damping adjuster has 2 turns or more To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 1 6 1 1 2 turns and the punch marks are aligned Low Speed Damping The low speed damping can be adjusted by turning the center screw of the compression adjuster The low speed compression adjuster has 18 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4 positions To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 8 12
133. r Adjustments amp Tuning Tips 10 Remove the carburetor to the left side Be careful not to damage the area around the throttle sensor Do not assemble or move the carburetor while holding the throttle sensor lead 11 Remove the float chamber screws 15 and float chamber 16 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 15 float chamber screws 16 float chamber 12 Use a float level gauge 17 to measure the float level 18 with the float tab just contacting the float valve and the carburetor intake 19 facing up The float level should be 0 30 in 7 5 mm Adjust the float level by bending the float tab carefully 17 float level gauge 19 carburetor intake 18 float level 13 To assemble reverse the disassembly procedures To install the carburetor reverse the removal procedures After installing the carburetor check the air vent hoses 20 and overflow hose 21 for kinking or pinching and correct routing as necessary 20 air vent hoses Adjustments for Competition 105 Carburetor Adjustments amp Tuning Tips 21 overflow hose 20 air vent hoses Spark Plug Reading Refer to Spark Plug page 48 Check any jetting change by reading the spark
134. readiness and what items you should check on your CR For information about suspension carburetor and other adjustments see page 81 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection Before Riding Before Riding 7 Are You Ready to Ride Before riding your CR for the first time we strongly recommend that you read this owner s manual make sure you understand the safety messages and know how to operate the controls Before each ride it s also important to make sure you and your CR are both ready to ride For information about suspension carburetor and other adjustments see page 81 Whether you re preparing for competition or for practice always make sure you are n good physical and mental condition Free of alcohol and drugs 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 Is Your Motorcycle Ready to Ride Competitive riding can be tough on a motorcycle so it s important to inspect your CR and correct any problems you find before each ride Check Pre ride Inspection the following items p
135. roper position by inspecting the punch mark 4 Tighten the front bolt first WN 5 Check the torque of the upper holder 2 bolts 16 Ibs ft 22 N m 2 2 kgf m 1 handlebar 2 handlebar upper holders Control Cables Periodically disconnect the throttle clutch and hot start 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 nut 20 27 2 8 2 Cylinder mounting nut 20 27 2 8 3 Carburetor insulator bolt T 10 1 0 4 Clutch cover bolt 7 10 1 0 5 Water pump cover bolt 9 12 12 6 Right RC cover bolt 9 12 12 7 Right RC cover screw 1 5 2 0 2 8 Alternator cover bolt 7 10 1 0 9 Left RC cover bolt 9 12 1 2 RIGHT SIDE 1 cylinder head nut 2 cylinder mounting nut 3 carburetor insulator bolt 4 clutch cover bolt 5 water pump cover bolt LEFT SIDE 8 alternator cover bolt 9 left RC cover bolt Additional Maintenance Procedures 6 right RC cover bolt 7 right RC cover screw Servicing Your Honda 77 Appearance Care Refer to Safety Precautions on page 19 Frequent cleaning and polishing w
136. rt dust or water in the fuel tank 34 Servicing Your Honda NOTICE Too much oil will cause excessive smoking and spark plug fouling Too little oil will cause engine damage or premature wear Vegetable oils separate from gasoline more easily than mineral oils especially in cold weather It is advisable to use mineral oil when ambient temperatures below 32 F 0 C are expected If the gasoline oil mixture is left standing in a container for a long period of time lubricity will deteriorate Use the mixture within 24 hours or the time period recommended by the oil manufacturer Once an oil container is opened the oil must be used within one month since oxidation may occur 32 1 FUEL OIL MIXING CHART Fuel Oil 32 1 Gallons Liters Ounces cm 0 5 1 89 2 0 59 1 0 3 79 4 0 118 1 5 5 68 6 0 177 2 0 7 57 8 0 237 2 5 9 46 10 0 296 3 0 11 36 12 0 355 3 5 13 24 14 0 414 4 0 15 14 16 0 473 4 5 17 03 18 0 532 5 0 18 92 20 0 591 5 5 20 81 22 0 651 6 0 22 71 24 0 710 Refueling Procedure Fuel Tank Capacity 2 0 US gal 7 7 1 fuel fill cap 2 breather tube 3 steering stem nut 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3
137. rvicing Your Honda 5 Check the chain slider 4 for wear If the wear is 3 16 in 5 mm or more replace it 1 drive chain slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking 4 chain slider 6 Check the chain guide slider 5 for wear Replace the chain guide slider if it is worn to the bottom of the wear limit groove 6 NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear Replace the drive chain page 74 if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page 73 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed 5 chain guide slider 6 wear limit groove 7 Check the upper drive chain roller 7 and lower drive chain roller 8 for wear or damage Replace if necessary Upper roller 1 5 in 39 mm Lower roller 1 2 in 31 mm 7 upper drive chain roller 8 lower drive chain roller If the upper drive chain roller was removed install the drive chain roller with its gt mark 9 side
138. sents one tenth of an hour Competition Logbook Racing Records Information worth recording for this section of your logbook may include Your placing in each moto and overall finishing position Thoughts on what you could do to improve your performance next time Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future events Any places on the course where you chose the wrong line and were passed too easily Notes on strategy used by your competition or by riders in another event that are worth remembering Maintenance Records Regular maintenance items you ll want to record in your logbook should include Dates and results of cylinder piston and ring examinations Patterns for frequency of need for decarbonization with a particular oil When you last performed shock linkage and swingarm pivot bearing maintenance transmission fork and suspension oil changes chain sprocket chain guide and slider replacements coolant changes and related component replacements spark plug brake pad and control cable replacements In addition you should record any irregularities noted in component wear so you ll remember to keep a close eye on these areas in the future Technical Information 125 Competition Logbook Date Running Time Location Event Comments Jetting Suspension Settings Gearing Chassis Adjust
139. small bumps while riding at full throttle in a straight line Stiff on small cornering bumps Front end wanders while riding at full throttle in a straight line Test softer compression damping adjustments in one click increments Reduce the rebound damping adjustments in one click increments Check for dirt in the dust seals Check the fork oil for any contamination If the front end dives while cornering reduce the rebound damping in one click increments If that doesn t solve the problem install the optional stiff spring If the stiff spring makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained Middle travel too stiff e Stiff on bumps when cornering Front end wanders when cornering Stiff suspension on bumps especially downhill bumps While braking front end dives during initial travel then feels stiff If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on large bumps especially downhill b
140. still feels stiff replace the spring with a softer spring optional and begin with the standard settings to softer settings Soft suspension Entire travel too soft Test stiffer high and low speed compression adjustments simultaneously If it still feels soft replace the spring with a stiffer spring optional and begin with the standard settings to stiffer setting Rear end sways Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms Suspension bottoms at landing after jumping Test stiffer high speed compression adjustment If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after landing Test stiffer low speed compression adjustment If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after end of continuous bumps Test softer rebound dumping adjustment If it still bottoms test stiffer high and low speed compression adjustments and softer rebound damping adjustment and replace the spring with a stiffer spring optional if necessary Adjustments for Competition 99 Carburetor Adjustments amp Tuning Tips The carburetor on your CR should perform suitably with th
141. stment 1 lock nut 2 adjuster 3 piston 1 Loosen the lock nut 1 2 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay Less than 0 8 in 20 mm 6 Apply grease to the contacting faces of the adjuster and piston 3 Brakes Brake Pedal Height The brake pedal height should be approximately level with the right footpeg 1 Loosen the lock nut 1 and turn the adjusting bolt 2 in direction to raise the pedal 3 or in direction to lower it 2 Tighten the lock nut at the desired pedal height 1 lock nut 2 adjusting bolt 3 rear brake pedal raise the pedal height lower the pedal height Servicing Your Honda 65 Brakes Rear Brake Fluid Level Check Fluid Level Inspection Front Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check 1 LOWER level mark the fluid level It should be above the LOWER 2 level mark If With the motorcycle in an upright position check the level is at or below the LOWER level mark the fluid level c
142. sure 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 The air pressure should be adjusted according to the altitude and outside temperature 1 Place an optional workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings Remove the pressure release screws 1 Check that the O ring 2 is in good condition Install the pressure release screws to the specified torque 0 9 Ibf ft 1 2 N m 0 1 kgf m WN 1 pressure release screw 2 O ring Front Suspension Damping Compression Damping Compression damping affects how quickly the fork compresses The compression damping adjuster has 20 positions or more Turning the adjuster screw one full turn advances the adjuster 4 positions Always start with the full hard position when adjusting damping SS 1 compression damping adjuster To adjust to the standard position 1 Remove the rubber plug 2 Turn the compression damping adjuster 1 clockwise until it will no longer turn lightly seats This is the full hard position 3 Turn
143. sure water or air can damage certain parts of your CR You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Washing Your Motorcycle with a Mild Detergent 1 Rinse your CR thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CR with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damage or discolor the frame surface A muffler stain remover should only be used for removing stains on the non coated aluminum frame 4 After washing rinse your CR thoroughly with plenty of clean water to remove any residue 5 Dry your CR with a chamois or a soft towel 6 Lubricate the drive chain to prevent rusting 7 Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance
144. suspension sese 92 steering stem inspection seeeeeee 76 pre ride inspection seseeeeeene 9 StOPPING en Ie necne recae 14 protective apparel os erkers ireira 2 Hort P tenses 113 SUDAS in torte efte dd itte 32 138 Index suspension TTODU eia E bo Uds Reap 60 POAT oeste s ORI ED TORY eR v ee DN REI EUd 61 suspension adjustment JD LOS i 1 PANE 82 i E E E OE E E edP 92 for track conditions sssssss 96 guadelines ietete tree ti trees 97 T transmission Ollori reese eE iai 36 MNS IDS eM 100 throttle Treeplayz ounce EE RO RS TEE 42 IHiSDecLIORB o neto aa 43 tires alt DIeSSUEG 525 citi iecit iei Lorca tetods 70 IPIS 70 SCIECHON P 109 o e 128 torque specifications sese 120 TRANS POLUING da sese ea tore pe ce x OERS 112 troubleshootmng nct secet arces 115 tubes replacing Lerner eieiei 70 V VETE 35 valve RE oerte ei tees dude vans 55 valve TCG nosse reene pose Erreur eo erect 58 vehicle identification esses 118 W washing your motorcycle sesssss 78 Medos 69 Wrllins diagram ops 129 Index Index 139 Quick Reference The following is a brief but important collection of information you need to know about your Honda You ll also find space to record important notes
145. tandard 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 Symptoms and Adjustment Always begin with the standard settings Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 12 turn increments at a time Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment f after setting the suspension feels unusual find the corresponding symptom in the table and test stiffer or softer compression and or rebound damping adjustments until the correct settings are obtained as described Stiff suspension Symptom Action Suspension feels stiff on small 1 Test softer low speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large 1 Test softer high speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff N Test softer high and low speed compression adjustments and rebound adjustment simultaneously If it
146. te 13 How to Stop the Engine eee 14 Breakin Guidelines esses 15 SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety esses 19 Important Safety Precautions 19 Maintenance Schedule sss 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 27 Service Preparations Maintenance Component Locations 28 Seat REMOVAL ciet eer arse n ERE Et 29 Fuel Tank Removal eee 30 Subframe Removal sse 32 Contents Service Procedures Fluid amp Filters uel System iu eere qoi tee Ding eaa 34 Transmission Oll neret 36 Cool nt certes trt resp eerua 38 Ar Cleatiet itte ettet kind 40 Engine dci 42 Clutch Syste iiec oett nd 44 Spark Plug tr aene ceto deeds 48 Cylinder System enr ette 49 DOR 55 Reed Valy8 eit ort tpe menm 58 Chassis SUSDeHSIOD 25 certes trente a eco gebe ee 60 Brakes rocas pecu eter reed eec 65 bg 69 Tires Tubes iue Rr Eres 70 Drive Chalme idee tret eth bunker o 72 Expansion Chamber ees 75 Additional Maintenance Procedures
147. the alternator stator the ignition pulse generator pickup and the entire ignition cavity thoroughly The presence of dirt between the ignition pulse generator and the flywheel makes the ignition control module compensate to maintain the ignition curve Cleaning dirt from the ignition side main seal helps to prevent premature seal wear Close inspection of this seal can reveal a leakage problem before engine damage occurs Fuel Filter Periodically drain the fuel from the tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 Fuel Contamination Periodically drain the float chamber and inspect the carburetor for contamination from dirt page 34 Inlet Tract Sealing Air leaks around the carburetor insulator and reed valve assembly should be cured by disassembling cleaning and resealing with new gaskets and some sealing agent Be careful not to overtighten the mounting bolts this is the most common cause for leaks here Pressure Vacuum Leak Down Test Perform this test at regular intervals to minimize the possibility of engine damage from air leaks Swingarm Pivot Lubrication Clean inspect and lubricate when servicing suspension linkage pivots Be sure all of the suspension pivot seals are in good condition Use Honda Moly 60 paste U S A only 4 or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Sus
148. the clutch lifter 4 onto the rod 3 clutch lifter rod 4 clutch lifter ap 6 Install the clutch pressure plate 5 7 Install the five clutch springs and bolts 6 8 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 7 Ibf ft 10 N m 1 0 kgf m ap are tS 5 clutch pressure plate 6 clutch spring bolts 9 Install a new O ring 7 in the groove of the clutch cover 8 10 Install the cover by tightening the five cover bolts to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 8 clutch cover 7 O ring Clutch System 11 Lubricate the rear brake pedal pivot 9 and pivot bolt 10 with Honda Lithium Grease or an equivalent and install the pivot bolt Tighten the bolt to the specified torque 27 Ibf ft 36 N m 3 7 kgf m Connect the brake pedal return spring 11 if it was removed E S s 9 brake pedal pivot 10 pivot bolt 11 return spring 12 Add the transmission oil page 37 Servicing Your Honda 47 Spark Plug Refer to Safety Precautions on page 19 1 Measure spark plug gap 1 with a feeler 5 Tighten the spark plug 4 gauge and adjust by carefully bending the If the old plug is good p side electrode 2 1 8 turn after is seats Spark Plug Recommendation The recommended spark plug gap is e If installing a new plug tighten it twice to 0 020 0 024 in 0 5 0 6 mm prevent loosening The recommended standard spark plug is
149. the ground 2 Loosen the connecting tube clamp screw and remove the rear subframe s three mounting bolts then remove the subframe See page 32 92 Adjustments for Competition 3 Check that the spring preload is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 1 16 in 1 5 1 lock nut 2 adjuster nut 3 pin spanner 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 10 0 in 254 mm To decrease spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to increase the spring length 4 Do not increase to more than 10 8 in 275 mm Each turn of the adjuster changes spring length and spring pre load One turn equals spring length spring pre load 0 06 in 1 5 mm 15 2 Ibs 6 9 kg Pin spanners should be used for turning the lock nut and adjusting nut See page 127 for optional pin spanners Spring preload length Standard spring Standard 10 5 in 266 mm Min 10 0 in 254 mm Spring preload length Optional spring Min Softer 4 4 kgf mm 10 0 in 254 mm Min Stiffer 4 8 kgf mm 10 0 in 254 mm Min Stiffer 5 0 kgf mm 10 0 in 254 mm Rear Suspension Damping Com
150. the rebound damping adjuster screws back to their original settings To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface Adjustments for Competition 91 Rear Suspension Adjustments The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only Puncture or exposure to flame may also result in an explosion causing serious injury Service or disposal should only be done by your authorized Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the official Honda Service Manual If your CR is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the silencer page 32 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place an optional workstand under the engine to raise the rear wheel off
151. the silencer outlet Then tie a plastic bag over the end of the silencer to prevent moisture from entering Store your CR in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation Cover your CR with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Storing Your Honda Removal from Storage 1 Uncover and clean your CR Change the transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the silencer and remove the rag from the silencer outlet 3 Fill the fuel tank with pre mixed fuel page 34 4 Pour a fresh recommended coolant mixture page 38 slowly into the radiator filler hole up to the filler neck Capacity 1 06 US qt 1 00 at disassembly 0 98 US qt 0 93 at draining Lean your CR slightly right and left several times to bleed trapped air in the cooling system If the coolant level lowers add coolant and repeat the above procedure Install the radiator cap securely 5 Perform all maintenance checks page 9 Tips 113 You amp the Environment Owning and riding a motorcycle can be enjoyable but you must do your part to protect nature When you show respect for the land wildlife and other people you also help preserve the sport of off road riding Following are tips on how you can be an environmenta
152. the valve shaft assembly 2 with its MEME position e s 4 Install the collar 3 6 washer 8 stopper plate 7 nut 9 socket bolt 1 RC valves 3 collar 8 Install the cylinder page 52 2 valve shaft assembly 5 Make sure that the cut outs of the valve shaft 4 and collar 5 are aligned 4 cut out of the valve shaft 5 cut out of the collar Servicing Your Honda 57 Reed Valve Refer to Safety Precautions on page 19 Reed Valve Removal Remove the carburetor page 104 Remove the insulator 1 and reed valve 2 from the cylinder by removing the six carburetor insulator mounting bolts 3 3 Remove the gasket NR A Y 1 insulator 2 reed valve 3 carburetor insulator mounting bolts 4 Remove the reed valve inner 4 from the reed valve assembly 5 4 reed valve inner 4 5 reed valve assembly 58 Servicing Your Honda Reed Valve Inspection 1 Check the reed valves 1 for damage or fatigue and replace them if necessary 2 Replace the reed valves with new ones if the seats are cracked or damaged 1 reed valves Reed Valve Disassembly Assembly 1 Remove the reed valve mounting screws 1 stopper 2 sub reed valve 3 and reed valve 4 2 Align the cut outs 5 between the reed valves and stoppers then install them onto the cage 1 reed valve mounting screws 2 stopper 3 sub reed valve 4 reed valve 5 cut out
153. tire flap SE C394 1 scribe mark rim lock bead stopper front tire 90 100 20 56M Fork height O in 0 mm Standard 24 64 Ibf in 0 44 kgf mm align the top of the fork tube cum with the top of the upper clamp E 4 No mark S factory products TOOLS Remarks Stiffer Pin spanner A To adjust shock spring preload 25 76 Ibf in 0 46 kgf mm 2 scribe marks V two spanners required Workstand pa For maintenance The standard fork and shock springs mounted on the motorcycle when it leaves the factory are not marked Air gauge For checking tire air pressure Before replacing the springs be sure to mark them so 1 8 to 3 4 throttle 6DGY28 65 6DGY29 65 2 65 mm 2 65 mm 6DGY28 66 6DGY29 66 S 5 02 66 mm 9 2 66 mm 9 6DGY28 67 6DGY29 67 v T 122267 mm 9 2 67 mm wo G co standard needle 5 t 6DGY28 68 6DGY29 68 8 m 9 2 68 mm 9 2 68 mm 8 5 6DGY28 69 6DGY29 69 a S x 2 69 mm 2 69 mm c 5 d 6DGY28 70 6DGY29 70 2 70 mm 2 70 mm 6DGY28 71 6DGY29 71 2 71 mm 2 71 mm they can be distinguished from other optional springs 127 Technical Information Spare Parts amp Equipment There are numerous spare parts you can take to an 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 clean
154. to Safety Precautions on page 19 Cylinder Head Removal Clean the area above the engine before disassembly to prevent dirt falling into the engine Drain the radiator coolant page 39 Turn the fuel valve OFF Remove the seat and fuel tank page 29 30 Loosen the water hose clamp and remove the water hose 1 from the cylinder head Disconnect the spark plug cap 2 and remove the spark plug BRWN eR Nn 1 water hose 2 spark plug cap Cylinder System 6 Remove the upper engine hanger plate bolts and nuts 3 then remove the clamp 4 and hanger plates 5 o WAY 8 Remove the cylinder head gasket 8 and dowel pins 9 3 hanger plate bolts and nuts 5 hanger plates 8 gasket 4 clamp 9 dowel pins 7 Remove the five cylinder head nuts 6 using the technique described below and remove the cylinder head 7 To avoid warping the cylinder head use a crisscross pattern to loosen each nut about 1 4 then remove the nuts 7 cylinder head 6 cylinder head nuts Servicing Your Honda 49 Cylinder System Cylinder Removal 1 Remove the expansion chamber page 75 2 Remove the bolts 1 exhaust pipe joint 2 and gasket 1 bolts 2 exhaust pipe joint 3 Remove the bolts 3 screw 4 right RC cover 5 gasket and grommet 6 4 Remove the B clip 7 and setting collar 8 then remove the valve rod 9 from the RC valve arm NOTICE
155. tting changes are necessary check for worn crankshaft seals air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Pre Adjustment Checks Before adjusting carburetor settings check the following air cleaner air leaks float level clogged carburetor jets spark plug fouling improper heat range or other cause freshness of fuel and fuel oil ratio owner modifications such as exhaust system holes in the air box etc ignition timing compression If the above check out then adjust the carburetor for your specific racing conditions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition Refer to the list on page 127 for the optional carburetor parts To prevent engine damage always adjust the main jet before adjusting the jet needle If there is any doubt always choose the next richer jet so there is a margin for safety Carburetor Minor Adjustments The standard carburetor settings are ideal for the following conditions 32 to 1 premix ratio using Pro Honda HP2 2 stroke oil or its equivalent sea level altitude and 68 F 20 C air temperature If your conditions are different you may need to adjust the carburetor settings using the tuning information on page 101 and 102 Confirm your settings are correct before proceeding Minor Adjustments 1 2 Adjust the carburetor setting using the turning i
156. u read this manual you will find information that is preceded by a NOTICE symbol This information is intended to help you avoid damage to your CR other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in this manual The official Honda Service Manual for your CR is available page 130 It is the same manual your dealer uses If you plan to do any service on your CR beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CR best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding California Proposition 65 Warning WARNING This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely is an important responsibility To help you make informed decisions about safety this manual contains a section devote
157. umps Stiff on large bumps when cornering If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If final travel is still stiff after the above adjustment or If initial and middle travel becomes stiff Install the optional soft spring Test softer compression damping adjustments in one click increments If the entire travel feels stiff after the above adjustment Test softer 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 damping adjustments in one click increments Reduce the rebound damping in one click increments Lower the oil level by 0 2 in 5 mm 98 Adjustments for Competition Rear Suspension Adjustment Adjustments for Type of Track 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 s
158. uspension 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 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
159. y volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system 124 Technical Information If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated the fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately 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
160. you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 93 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and rebound damping adjusters 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 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 61 Suspension 8 Pour half of the recommended fork oil into Recommended Fork Oil the fork slider and fork tube Before pouring the fork oil make sure that the viscosity weight 5 W partition plate is removed suggested oil Pro Honda HP Fork Oil or equivalent Fork Oil Change 1 Remove the fork cap spring seat and fork spring as described in Front Suspension Oil 5 damper rod 6 partition plate Level Adjustment page 84 91 2 Remove the distance c

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