2000-2003 Honda CR125R Service & Repair Manual

HOW TO USE THIS MANUAL This service manual describes the service procedures for the CR125R. Follow the Maintenance Schedule recommendations (page 3·3) to ensure that the motorcycle is always in peak operating co ndition. Sections 1 and 3 apply to the whole motorcycle. Section 2 describes procedures for removal / installation of components that may be required to perform service described in the following sections . Sections 4 through 15 describe parts of the mOTorcycle, grouped according to location. Find the section you want on this page , then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section . The subsequent pages give detailed procedures. If you don't know the source of the trouble , go to section 17, Troubleshooting . z ~ ~ W > <1: a: c c z ..: w z a z w CONTENTS FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON RC VALVE REAR WHEEL/SUSPENSION HYDRAULIC BRAKE IGNITION SYSTEM/ ALTERNATOR WIRING DIAGRAM TECHNICAL FEATURES TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaini ng to these symbols, it would be explained specifically in the text without the use of the symbols . $" Replace the part(s) with new one(s) before assembly . ., Use recommended engine oil, unless otherwise specified . ., Use molybdenum oil solution ( mixture of the engine oil and molybdenum grease in a ratio of 1: 1) . • .s;;;; .. Use multi -purpose grease (Lithium based multi ' purpose grease NlGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 40 0/0 molybdenum disulfide, NLGI #2 or ~ equivalent). Exampl e: Molykote- BR -2 plus manufactured by Dow Corning , U.S.A. Multi -purpose M-2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGI #2 or equivalent). .... -'i'ID Example: Molykote· BA -2 pl us manufactured by Dow Corning, U.S.A . Honda Moly 60 (U.S.A only) Aocol ASP manufactured by Rocollimited , U.K. Aocol Paste manufactured by Sumico lubricant , Japan ~ Use silicone grease. n "-)'m! Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ,",' Ull! Apply sealant. I Use brake fluid, DOT 4. Use the recommended brake fluid , unless otherwise specified. GIl Use Fork or Suspension Fluid.

1. GENERAL INFORMATION GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-4 TORQUE VALUES 1-13 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work , make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Aun the engine in an open area or with an exhaust evacuation system in an enclosed area. GASOLINE Work in a well ventilated area. Keep cigarettes , flames or sparks away from the work area or where gasoline is stored . Gasoline is BKtremely flammable and is Bxpfos;ve under cfJriain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS '1 Wi i;ldW4 Engine and exhaust system parts become very hot and remain hot for some time aher the engine is run. Wear insulated glOVBS or wait until the engine and exhaust system have cooled belore handling these parts. TOOLS 1-16 LUBRICATION & SEAL POINTS 1-1 8 CABLE & HARNESS ROUTING 1-20 OPTIONAL PARTS 1-26 USED ENGINE OIL Used engine oil may cause skin cancer if repeatedly left in contact with the skin lor prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies . Use OSHA - approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers. BRAKE FLUID CAUTION: Spilling fluid on painted , plastic or rubber parts will damage them. Place a clean shop towel oller these parts whenever the system ;5 serviced. KEEP OUT OF REACH OF CHILDREN. 1-1

GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethy lene glycol does i gn ite. you will not see any flame, but you can be burned. Avoid spilling engine coolant on the ex haust system or engine parts. They may be hot enough to cause the coo/e nt to ignite and burn without II visible flame. Coolant (ethylene glyco l) can ca use some skin irritation and ;s poisonous if s wallowed. KEEP OUT OF REACH OF CHILDREN. Do not remove the radiator cap when the engine ;s hot. The coolant is under pressure and could scald you. CAUTION: Using coolant with silica te inhibitors may cause premature wear of water pump seals or blockage of radiator passagfJS. Usi ng tap wa ter may cause engine damage. If it contacts you r skin, wash the affected areas immediately with soap and water. If it contacts you r eyes, flush them thoroughly with fresh wate r and get imme diate med ical attention . If it is swallowed, the vi ctim must be f orced to vomit then rinse mouth and th roat with fresh water before obtaining me dical attention. Because of these dange r s, always store coo lant in a safe place, always from the reach of children . Recycle used coolant in an ecol ogically correct manner. SERVICE RULES NITROGEN PRESSURE For shock absorber with a gas-filled reservoir. Use only nitrogen to pressurize the shock absorber. The use of an unst able gas csn cause s fire or exprosion resulting in serious injury. The s hock a bsorber conta ins nitrog en under hi gh pressure. Allowing fire or heat near the shock absorber could lead to and explosion that could res ult in serious injury. Failure to release the pressure from a sh ock absorb er before disposing of it may lead to a possible explosion and serious injury if it is hested or pierced. To p revent the po ssibility of an explosion, r elease the nit rogen by pressing the valve core. Then remove the valve stem fr om the shock absorber reservoir. Dispose of the oil in a manne r acceptab le to the En vironmental Protection Agency (EPA). Before disposal of the shock absorber, release the nitrogen by pressing the valve co re. Then remove the valve stem from the shock absorber. 1. Use genuine HONDA or HONDA-recommended pa rt s and l ubricants or their equivalents. Parts that don't meet HONDA's design spec ificatio ns may cause damage to t he moto rcycle. 2. Use the special too ls designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Met ric bo lts, nuts and screws are not interchangeable wit h English fasteners . 4. Install new gaskets, O-ri ngs, cotter pins, and lock plates whe n reassembling. 5. When tighten ing bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified to r que diagonal ly in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upo n disassemb ly. lub ricate any slid ing su rf aces bef ore reassembly. 7. After reassembly, check all parts for proper installation and operation. S. Route all electrical wires as show on pages ' · 18 thr ough 1-20, Cable and Harness Routing. 1-2

GENERAL INFORMATION MODEL IDENTIFICATION 2000 SHOWN (After 2000 mode ls l ook simi lar) ~M."" SI~RI.", NUMBER (1) The frame serial number is stamped on the right side of the steering head. 200 0 - 200 1: CARBURETOR IDENTIFICATION NUMBE R (2) The engine serial number is stamped on t he left side of the crankcase. After 2001: CARB URETOR IDENTIFICATION NUMBER (3) The carburetor identification number is stamped on the engine side (After 2001: right side) of the carburetor body. 1-3

GENERAL INFORMATION SPECIFICATIONS r GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 2000: 2,169 mm (85.3 in) 2001: 2,173 mm (85.6 in) After 2001: 2,151 mm (84.7 in) Overall width 823 mm (32.4 in) Afte r 2001: 826 mm (32.5 in) Overall height 2000: 1,283 mm (50.5 in) 2001 : 1,27 1 mm (50.0 in) After 2001: 1.278 mm (50.3 in) Wheelbase 2000: 1,467 mm (57.B in) 2001: 1,471 mm (S7.9 in) After 2001: 1,458 mm (57 .4 in) Seat heigh I 2000: 942 mm (37.1 in) 2001: 936 mm (36.9 in) After 2001: 947 mm (37.3 in) Foolpeg height 2000: 420 mm (16.5 in) 2001 : 414 mm (16.3 in) After 2001: 434 mm (17.1 in) Ground clearance 2000: 340 mm (13.4 in) 2001 : 332 mm / 13.1 in) After 200 1: 345 mm (13.6 in) Dry weight 87.5 kg (193.0 IbsJ FRAME Frame type Twin-tube Front suspension Telescopic fo rk Front wheel axle travel 2000: 28 1. 9 mm 111.1 in) 2001: 280 mm (11.0 in) After 2001: 272 mm (10.7 in) Front suspension cushion stroke 2000 - 200 1: 315 mm (12.4 in) Afte r 2001: 305 mm (12.0 in) Rear suspension Swingarm/Pro·Link Rear wheel axle travel 2000: 323 mm (12.7 in) 2001: 3 19 mm 1 12.6 in) After 2001: 3 18 mm (12.5 i n) Rear damper Decarbon type with nitrogen gas filled damper Front tire size 80/100-2151M Rear tire size 100/90-1957M Tire brand Dunlop Front: K490C/Rear: K695 Front brake Hydraulic single disc Front brake swept area 334.5 cm 2 (51.8 in 2 ) Rear brake Hydrau l ic single disc Rear brake swept area 2000 - 2001: 334.5 cm 2 (51.B in 2 ) After 2001: 391.1 cm 2 (60.6 in 2 ) Caster angle 2000: 26° 21' 2001 : 27 0 3' After 2001: 25° 54' Tra il length 2000: 111 mm (4.4 in) 2001 : 116 mm 14.6 in) After 2001: 101 mm (4.0 in) Fuel tank capacity 2000 - 2001: 7.5 liter (2 .0 US gal, 1.61mp gal) After 2001: 7.7 liter (2.0 US ga l, 1.7 Imp gal) 1-4

GENERAL INFORMATION - GENERAL (Cont'dl ITEM SPE CIFICATIONS ENGINE Bore and stroke 54.0 x 54.5 mm (2.13 x 2.15 in) Displacement 124.82 cm 3 (7.6 cu-in) Compression rat io 2000 - 2001: 8.75 : 1 After 2001 : 8.7 : 1 Lubrication system Fuel/oil mix Cooling system Liquid cooled Air filtration Oiled polyurethane foam Crankshaft type Assembled type Engine dry weight 18.4 kg (40.5 Ibs) Cylinder arrangement Single cylinder. inclined 18.5° from vertical CARBURETOR Carburetor type Piston valve type Venturi diameter 36 mm (1 .4 in) DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operated Transmission Constant mesh, 5-speed Primary reduction 3.150 (63/ 20) Final reduction 2000 - 2001: 4.000 (52/13) After 2001: 3.923 (51/13) Gear ratio , st 2000 - 2001: 2.357 (33/ 14) After 2001: 2.307 (30/ 13) 20d 1.867 (28/15) 3cd 2000 - 2001: 1.579 (30; 19) After 2001: 1.529 (26/17) 4th 2000 - 2001: 1.333 (28/21) After 2001: 1.294 (22/17) 5,h 1.130 (26/23) Gearshift pattern left foot operated return system, 1 - N - 2 - 3 - 4 - 5 ELECTRICAL Ignition system COl (Capacitive Discharge Ignition) 1-5

GENERAL INFORMATION Unit: mm ( in ) r LUBRICATION SYSTEM ITEM STANDARD SERVICE LIMIT Re co mmended engine oil Pro~Honda HP2 2-stroke oil or equivalent motor oil Fuel/oil mixing ratio 32:1 -- Transm i ssion oil capaci ty al draining 0.57 liter (G.50 US qt. 0.50 Imp qt) - at disassembly 0. 65 liter (0.69 US qt, 0.57 Imp qt) -- Recommended transmission oil Pro-Honda HP Trans Oil, Pro-Honda GN4 -- 4-stroke Oi l or equivalent motor oil API service classification SF or SG Viscosity: SAE 10W-40 - FUEL SYSTEM ITEM SPECIFICATIONS Carburetor i dentifi cation number 2000: TMX01A 200 1 : TMX01S After 2001: TMX02A Main jet 2000: #360 2001 : #380 After 2001 : #400 Slow jet 2000: .50 2001 : #45 After 2001: #32.5 Jet needle 2000; 6BEG20 - 69 2001: 6BEG20 - 68 After 2001: BOFY5 - 74 Jet needle clip position 3rd groove fr om top Air screw initial opening 2000: 1-3/4 turns out 2001 : 2-1/4 turns out After 2001: 2-1/8 turns out Flo at level 2000 - 2001 : 15.0 mm (0.59 in) After 2001: 7.5 mm (0 .30 in) Throttle grip free play 3 - 5 mm (1 /8 - 1/4 in) Reed valve clearance serv ice l imit 0.2 mm (0.01 in) r COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity at change 0.88 liter (0.930 US qt, 0.774 Imp qt) at disassembly 0.97 liter 11 .025 US qt, 0.854 Imp qt) Radiator cap relief pressure 108-137 k Pa 11.1 1.4 kgf / cm1, 16 20 psi) Recommended antifreeze Pro Honda HP Coolant or an eq u ivalent high quality ethylene glycol antifreeze conta i ning silica-free corrosion inhibitors 1-6

2000-2003 Honda CR125R Service & Repair Manual

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