2004-2007 Honda CR125R Service & Repair Manual

HOW TO USE THIS MANUAL Thos MMCe manual desalbes the S8fVlO8 procedur8$ !Of the CAI25H Follow me Maonlenance Schedulll (SectIOf1 3) reeommendatlOtlS 10 _ur, that 1he vehICle fs If1 peak opera~ng con<IiIoon Per10fming the first scheduled maintenance IS very Important. II compeoS81es lor the inotlal W1l8r H'lat oocurs durong the break·ln period Sectoons 1 and 3 apply 10 the whOle motorcycle 5ecliOrl 2 ~lustral&5 proeedu'8$ for removaVIJlStallabon 01 ~lS !hat may be requIred 10 perIotm sefVICG described in the /oIIoww'Ig secloons SeI;bon 4 rtvough 14 desaibe pans 01 the motorcycle. grouped 8OOOf'dor'Ig 10 ~bOn Fond !he sectIOn you warn on thIS page. then turn 10 the table 01 conlents on !he fil$l page oIlhe sectIOI"I Most sectlOrlli stan WIth an IIssembly Of IySIem ~1U$tratJon, serVUI Inbmatoon and UoubIeshoollOg for 1he MCbOf'I The SUb$aquent p8I1t'S \IMI detailed procedures. II you doIl~ know the source 01 the trouble, go to S&cttOO 16 TroubJeshoot'ng Your S8/ety and the salety 01 ~_ is 'o'8<y omportanl To help you rnaII.e II'IIormed duosoons _ have pl'OVl<led safety messages and other II\b'mallOn Ihroughoul ItuS mar'IlIIIIl 04 00\.IfSe, it is not practl(:lolOf possible 10 warn you about aH !he hazards iISSOCIiIted WIth tIef'I/ICIrIQ !his \IehicIe Voo must '*' your own good jUdogement '(QI,j will fond omportant salety onfofmallon on a I'8nety 01 lorms Includtng • Satety Labels - on the vehICle • Satety Massages - preceOad by a salaly alert symbol J arid one 01 three S'9f\1I1 words, DANGER. WARNING. Of CAUTION These SIQIl3I worUs mean iH'@d3ai i ~RT~I~:n.~=~~~USLY You CAN be KILLED or SERIOUSLY HURT MWiW m m. ~ you dorn IoIIow IflSlI\lCtlOn5. eMi,U.g ::~ be HURT ~ you don1 IoIIow • IllStn.ICtIOnS - how to servICe tl'lil vehICle (:Offaetly and salely As you read thiS manua l. yoo will lind inlormatlO/1 thai is prec&ded by a MOTICt symtJoj The purpose 01 thIS meS$ll{le IS to help prevent damage to your vehICle. other property. or the efMlonment <; .. a: 0- W ~ a: o o z .. W z a z W !1l U) U) .. :z: u CONTENTS MAINTENANCE FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEAD/CYLINDER/PISTON RC VALVE CLUTCHIKICKSTARTER/GEARSHIFT LINKAGE CRANKCASEICRANKSHAFTITRANSMISSION FRONT WHEEUSUSPENSIONISTEERING REAR WHEEUSUSPENSION HYDRAULIC BRAKE IGNITION SYSTEM/ALTERNATOR WIRING DIAGRAMS TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols. it will be explained specifically in the 18)(1 wilhoullhe use 01 the symbols. 111 Replace the part(s) with new ona(s) before assembly. r-- , -, t" 'acommaodad ",loa oil, oo'a" olh.",I," ,p"dlled. 78 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease In a ratio of 1 : 1). f-- - • ..um.. Use multi-purpose grease (lithium based mUlti-purpose grease NLGI #2 or equivalent) . - Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent) . .... Example: Molykole® BR-2 plus manufactured by Dow Corning U.S.A. i-s MUIlI-p"'po,. M-2 maouract"ed by M,"ubl,hi Oil , Japao Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Motykot~ G-n Paste manufactured by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Aocol Limited, U.K. Aocol Paste manufactured by Sumico lubricant, Japan - ..-'iiSioI Use silicone grease. L1m:J Apply a lockIng agent. Use a mIddle strength locking agent unless otherwise speCIfied . .,(' ft1Il Apply sealant. - I t. DOT 4 br.lk" lIuld Usa the recommended brake flUId unless otherwIse specifIed - .. Use Fork or SuspenSIon FlUId

1. GENERAL INFORMATION SERVICE RULES ............. ... ............................ ' -2 MODEL IDENTIFICATION ············· ·· ··············· ' -2 GENERAL SPECiFiCATIONS ······················ ·· · ' -4 LUBRICATION SYSTEM SPECIFICATIONS · '-6 FUEL SYSTEM SPECiFiCATIONS················· ' -6 COOLING SYSTEM SPECIFICATIONS .. .... .. . '-6 CYLINDER HEAD/CYLINDER/PISTON SPECiFiCATIONS········································ ... ' -7 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECiFiCATIONS ·························· ' -7 CRANKCASE/ CRANKSHAFT/ TRANSMISSION SPECiFiCATIONS·············· '-8 FRONT WHEEL/ SUSPENSION/ STEERING SPECiFiCATIONS············································' -9 REAR WHEEL/SUSPENSION SPECiFiCATIONS············································ ' -9 HYDRAULIC BRAKE SPECIFICATIONS ······· , -,O IGNITION SYSTEM/ALTERNATOR SPECiFiCATIONS··········································' - '0 STANDARD TORQUE VAlUES ··················· , -" ENGINE & FRAME TORQUE VAlUES ········ , -" LUBRICATION & SEAL POINTS ·················· ' -' 6 CABLE & HARNESS ROUTING ··················· ' -'8 OPTIONAL PARTS ········································ ' - 2S 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda- recommended parts and lubricants or their equivalents. Parts that don 't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed fo r this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and sc r ews are not interchangeable with English fasteners. 4. Install new gaskets, O-rings. colter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then lighten 10 the specified torque diagonally in incremental sleps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly . Lubricate any sliding surfaces before reassembly. 7, After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown on page 1- 18, Cable and Harness Routing. MODEL IDENTIFICATION '04 model sh own: 1-2

The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. The engine serial number is stamped on the left side of the crankcase. The carburetor identification number is stamped on the right side of the carburetor body. GENERAL INFORMATION 1-3 -

GENERAL INFORMATION GENERAL SPECIFICATIONS fENSIONS ITEM 1 Overall length Overall width Overall height Wheelbase Seat height Foolpeg height Ground clearance Dry weight FRAME Frame type Front suspension Front wheel axle travel Front suspension cushion stroke Rear suspension Rear wheel axle travel Rear damper Front lire size Rear tire size Tire brand Front brake Front brake swept area Rear brake Rear brake swept area Caster angle Trail length I ENGINE Fuel tank capacity Bore and stroke Displacement Compression ratio lubrication system Cooling system Air filtration Crankshaft type Engine dry weight Cylinder arrangement CARBURETOR Carburetor type Venturi diameter 1-4 '04: After '04: '04: After '04: '04: After '04: '04: After '04: '04: After '04: '04: After '04: '04: After '04: Front Rear '04: After '04: '04: After '04: SPECIFI CATI ON 2,157 mm (84.9 in) 2,163 mm (85.2 in) 821 mm (32.3 in) 1,280 mm (50.4 in) 1,282 mm (50.5 in) 1,466 mm (57.7 in) 1,470 mm (57.9 in) 952 mm (37.5 in) 954 mm (37.6 in) 436 mm (17.2 in) 439 mm (17.3 in) 349 mm (13.7 in) 352 mm (13.8 in) 87.5 kg (192.9Ibs) _ ___ _ Twin -tube Telescopic fork 275 mm (10.8 in) 305 mm (12.0 in) SwingarmlPro-link 325 mm (12.8 in) 320 mm (12.6 in) Decarbon type with nitrogen gas filled damper 80/100-21 MIC 51M 100/90-19 M/C 57M D742F (Dunlop) 0756 (Dun l op) Hydraulic single disc 334.5 cm 2 (51,8 in 2 ) Hydraulic single disc 391.1 cm 2 (60.6 in 2 ) 25°39' 25°45' 100 mm (3.9 in ) 7.7 liter (2.0 US gal, 1.7 Imp gal) 54.0 x 54.5 mm (2.13 x 2.15 in) 124.8 cm 3 17 .6 cu·in) 9.1 : 1 8.6: 1 Fuel/ oil mix Liquid cooled Oiled polyurethane foam Assemble type 18.5 kg (40.8 Ibs) ~ Single cylinder, inclined 18.5° from vertical Piston valve type 38 mm (1.5 in)

ITEM DRIVE TRAIN Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ralio Gearshift panern r- ELECTRICAL =-l Ignition system '04: After '04: 1st 2nd 3,d 4th 5th GENERAL INFORMATION I SPECIACATION Multi-plate, wet Cable operated Constant mesh, 5-speeds 3.150 (63120) 4.077 (53113) 4.000 (52/13) 2.307 (30113) 1.867 (28/ 15) Left foot operated return system, 1 1.529 (26117) 1.294 (22117) 1. 130 (26/23) ,-N·2·3·4·5 ~~~ __ __ ~ C~D ~ I (Capa;;'d"tiv:Ce~ DC;;s:;'''''''::: rge Ign i'.c';",on",I __ -.J 1-5

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS i i FUEL SYSTEM SPECIFICATIONS ITEM Carburetor identification number '04: After '04: Main jet '04: After '04: Slow jet '04: After ' 04: Jet needle '04: After '04: Jet needle clip position Air screw initial opening ' 04: After '04: Fl oat level Throttle grip free play Reed valve clearance service limit i GN4 4-stroke oil (U.S.A. and Canada) or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA SPECIRCATIONS TMX04A TMX05A #420 #430 #40 #55 6DGY26-69 6DGY28-68 3rd groove from lop 2 turns oul 1 ·314 turns out 7.5 mm (0.30 in 3 5 mm (118 1/4 in) 0.2 mm (0.01 inl COOLING SYSTEM SPECIFICATIONS oran ene glycol antifreeze containing silica-free corrosion 1-6

GENERAL INFORMATION CYLINDER HEAD/CYLINDER/PISTON SPECIFICATIONS ITEM STANDARD Cylinder head warpage Cylinder f LO. Unit: mm (in) --==:::::' ::S~E ~R ~VICE LlMIU 0.05 (0.002) , ~ ----:t~5~3~.9~7~6" 53.983 (2.1250 2.1253) 54.013 (2.1265) 53.968 53.976 (2.1247 2.1250) 54.006 (2.1262) 0.05 (0.002) Out of round , Taper Warpage 0.05 (o.002H 0.05 (0.002) Piston, pisto~Piston mark directio ec " .:,- -.-__ _ ring Piston 0.0. i A 53 .933 - 53.940 (2.1233 - 2.1236) 53.883 (2.1214) "IN" mark facing toward the intake"s"id""-t--,o, - ~ B Piston 0.0. mea- '04: surement point Aher '04: Piston pin bore 1.0. Piston pin 0.0. Piston-Io-piston pin clearance Piston ring·to -ring groove clear· ance ('04 model) Piston ring end gai,po.:===-- Cylinder·lo·piston clearance Connecting rod small end 1.0. 53.925 53.933 (2. 1230 - 2.1233) 53.875 (2. 12'1 ) 10 mm (0.39 In) from the bottom of skirt 11 mm (0.43 in) from the bottom of sk"irt;;---- 15.002 - 15.015 (0.5906 0.5911) 15.022 (O.59 14r 14-:-994 - 15.000 (0.5903 0.5906) 14.980 (0.5900) 0.002 - 0.021 (0.0001 0.0008) 0.03 (0.00' :1 0.045 - 0.080 (0.0018 0.0031) 0.09 (0.004) 0.40 - 0.55 (0.0 16 - 0.022) 0.65 (0.026) 0.035 - 0.050 (0.001 4 - 0.0020) 0.07 (0.003) 19.002 19.014 (0.748 1 - 0.7486) 19.022 (0.7489) CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS ITEM Clutch lever free play Clutch spring fre:;e~'~'Q"9~t~h==- Clutch outer gu~e 1.0. Clutch disc thicknc:e~,,~;:;;:::::_ I warpage gear 1.0. i spindle 0.0. Kickstarter idle gear 1.0. Countershah 0.0. at kickstilrter idle gear Unit: mm (in) STANDARD _==~ S~ E~ RVICE LlM 'I'fl -~'10 - 20 (318 - 31~4~' ~"",,=-- -----]- 36.1 (142) 35.4 (1.39) 20.000 20.021 (0.7874 0.7882) 20.05 (0.789) 2.92 3.08 (0.114~:~O.~'i21~'g~f 2.85 (0.006) 0.15 (0.008) _t--c',,60.5~16 16.534 --+-<:'6".5",5 (0.652) 16.466-16.484 16.45 (0.648) 17.016 17.034 ~'if.:~;:, 17.0510.671 - ' -- 16.983 16.994 6 __ ~_' ",6.97 (0.668) 1-7

2004-2007 Honda CR125R Service & Repair Manual

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