1986-1991 CR250R Service & Repair Manual

HOW TO USE THIS MANUAL Follow the Competition Maintenance Schedule recommendations (page 3-2 ) to en- sure that the vehicle is always in peak operating cond iti on. Sections 1 through 3 apply to the whole motorcyc le, while sections 4 through 1 5 describe parts of the motorcycle , grouped ac- cording to location. Find the section you want on th is page, then turn to the table of conte nt s on page 1 of that sect ion . M ost sections start with an assembly or syste m illustration and specifications , torque values, general instructions, tools and troubleshooting for the section . The subse- Quent pages give detailed procedures for the sect ion. If you are not familiar wit h this motorcycle . rea d Section 16. Technical features. If you don't know the source of the trouble, see section 17, Troubleshooting. w ;!!: to Z w CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINOER HEAO/CYLINOER/PISTON H.P.P (Honda Power Port) / COOLING SYSTEM !!1 REAR WHEEL/BRAKE/SUSPENSION ~ ~============================ « :r HYORAULIC BRAKE (J=~== IGNITION SYSTEM TECHNICAL FEATURES TROUBLESHOOTING INDEX

I l GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS GENERAL SAFETY @. i;i.!@i 1-1 1-1 1 -2 1 -4 1/ the mgine muSI be running to do some ... ·ork , moh sure the area is we/I-I't'ntilaud. Nel'er run the engine in a closed area. The exhaust contains poisonous carbon monoxide gtu that may cauu loss 0/ consciousness Qnd lead 10 dealh. Brake dust rna)' contain asbestos. .u. Inhaled asbestos jibl!f$ hal'l! been found to cauu respiratory distase and cancer. Nel·er use an air host or dr)' brush (0 clean brake assemblies. Use an OSHA-approl' td vacuum delmer or a/ternote method apprm'ed by OSHA designed to minimize the hazard caused by airborne asbestos jibers. GasolJne Is alremtly flammable and; s explosive under certain conditions. Work in a tlrel/ ventilated area with the engine Slopped. Do not smoke or allow flam~s or sparks in your working area or K'h~r~ gasoli,,~ is stored. SERVICE RULES 1. GENERAL INFORMATION TOR QUE VALUES TOOLS CA BLE AND HARNESS RO UTING OPTI ONAL PARTS LIST The shock absorber has a gas·filled reservoir, , . 1, 1 -6 1-B 1-11 1-22 Use only nitrogen to pr~ssuris~ th~ shock absorber, The use 0/ anstab/~ gas can cause a fire or explosion resulting in serious injur)'. The rear shock absorber contains nitrogen under high pressure, Do not allow /ire or heat near the shock absorber, B~/ore disposal oj the shock absorber, rtltQS~ the nitrogen b)' prening the I'ah'e core. Then remolle the I'all'e /rom the shock absorber. CAUTI ON Used transmission oil may cause skin cancer if repeatedly lejt in conlact with the skin /or prolonged periods. AI/hough this is unlikely unless you handle used oil on a daily basis, il is sli/l advisable 10 thoroughly wash your hands with soap and waler us soon as possible a/ter handling used oil. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or theit equivalent. Parts that do not meet HONDA 's design specifications may damage the motorcycle , 2, Use the special tools designed for this product. 3. Install new gaskets, O-rings, cotter pins, lock plales, etc. when reassembling. 4. When torquing boilS or nuts, begin with larger-diameter or inner bolt first, and tighten to the specified torque, diagonally, in incremental steps unless a particular sequence is specified. 5. Clean parts in non-flammable or high flash point solvent upon disassembly. lubricate any sliding surfaces before reassembly. 6. When installing a new oil seal, make sure that the sealing lip is lubricated with grease, If an oil seal and related parts have been washed, apply proper grease to the lip of the oil seal. 7. After reassembly, check all parts for proper installation and operation. S. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with any other type of fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION ' 86 : ' 87 : ' 88 : ' 89 : '90: After ' 90 : 1-2

The frame serial number is stamped on the r ight side of the steering head. The carburetor identification number is on the left IAlter '88: right) side of the carburetor. GENERAL INFORMATION The engine serial number is stamped on the lowe r left side of the crankcase. 1-3

GENERAL INFORMA nON SPECIFICATIONS ITEM SPECIFICATIONS Dimension O", erall length ' 86 , ' 87 , ' 88 : 2,180 mm 185.8 in) ' 89 : 2. 195 mm (86 .4 inj Alter ' 89 : 2, 188 mm IS6 . 1 in) Overall wi dth '86, ' 87 , ' S8 : 825 mm 132.5 in ) After ' 88 : 835 mm 132.9 in) Overall height '86 , '87, ' 88 : 1.215 rnm 147.B in) ' 89 : 1, 253 mm 1 49 .3 in) After ' 89 : 1. 255 mm (49 .4 inj Wheelbase ' 86 , ' 87 , ' S8 : 1.480 mm (58 .3 inj ' 89 : 1, 495 mm (5 8.9 in j After ' 89 : , ,488 mm 158.6 inj Soal height ' 86: 960 mm 137.8 in) '87 . ' 88 : 950 mm 137.4 inj After ' 88 : 970 mm 138.2 Inl FOOl peg heighl ' 86, 'S7. ' 88 : 440 mm 117.3 inj Afte. ' 88 : 445 mm 1 17 .5 in ) Ground clearance ' 86 , ' 87 , ' 8S : 340 mm (13.4 in) After ' 88 : 350 mm 03 .8 in) Drv weight '86, '87: 97.5 kg 1214. 9Ib) After ' 87 : 97 .0 kg 1213.81bl frame Ty" Semi-double cradle F. suspension, trallel Telescopic forlt, 305 mm (12 .0 in ! R. suspension , nallel Pro· Unit. 330 mm 113.0 in! F. tire sil.e. pressure 801100 21 51M, 15 psi (100 ItPII , 1.0 kg/cm1) R. tira size, pressure 110/ 100 18 64M. 1 5 psi (100 ItPII, 1.0 Itg/ cmtl F. bralte, swept area '86 : Single disc, 329 cm t (5 1.0 sq-inl After '66: Single disc, 306 cm' 1 47 .3 sq·inl R. brake, lining area '66: Internal expanding shoes , 102 .1 cm' 115.8 sq·;n! R. bllke . swept area After ' S6 : Single disc, 303 cml147.0 sq·inl Fuel capaci ty ' 86 : 7. 0t 11.8 U.S. ga!., 1 .5 Imp. gal.) After ' 86 : 7. 5' 12.0 U.S. gal., 1 .6 Imp. gal.l Caster angle '86, '87, '88: 27°30' '89 : 28"12' Alter ' 89 : 28 " 03' Trail ' 86 : 112 mm 14 .4 inl ' 87 , '88: 114 mm 14 .5 inl ' 89 : 123 mm 14 .8 inl After ' 69 : 125.5 mm (4.94 inl Fork oil capacity '86, '87, '86: 564 cc (19 . 1 ozl (Standard) '89: 657 cc 122.2 oll '90: 640 cc 12 1.6 oll After ' 90 : 651 cc 122.0 ol l Engine TV" liquid-cooled, 2-snoke Cylinder arrangement Single 7" inclined from lIenical Bora and Itroke 66.4)( 72 .0 mm 12.6 1 I( 2.831nl Displacement 249.3 cm] (15.2 cu-In) Compression ratio '8 6: 9 .0 : , ' 87 : 9.1 : 1 ' 88 : 9.0 : 1 '89: 8.8 : 1 After ' 89 : 8.5 : 1 Trllnsmission oil capacity 'B6, '87, '88 , '8 9: 0.6' (0.63 U.S. qt., 0.53 Imp. qt.1 (It disassemblyl After ' 89 : 0.63' (0. 67 U. S. Qt .. 0.55 Imp . Qt .) 1-4

Drive train Electrical ITEM Main Jel tSlandard] I J" . """ 'M 'hp poSitIOn Slow jet Istandard] Air screw initial opening FI," ho',", Clo"h "po P,'m", , G .... "" I Gear ratio II Gear rClllO III G •• , ,Ol" IV G8,1I rat io V ,, p."", "''''40 I "".m Sp'" ~o, ' GENERAL INFORMATION AI<" PJ28C ' B6 , ' 87 , AI,,, ' 89 , '175 AI", '90, R'369N5 3,' '''". h,m "P ~----~~~' r~ .,:~::--------------------~ AI,,, ' 86 , 2.0'010' '0' '86, '87, AI, .. ' 88 , '6 mm 10. 63 "I Woo, I "'". ,m .. h 3.000 , 1.800 , I 1271151 . 389, 1251181 1.470, I 12511" 1.150' I 1231201 , 1.210 , ~91 1.000, I 1211211 1. 869, 1201231 0.833, I 120124) 3.786, 3. 643 , Lo" 100' '''10m ,,,10m, '- N- : COl INGKI BR9EG INDI I 1-5

GENERAL INFORMATION TORQUE VALUES ENGINE Thread dia Torque Item x pitch N·m kg -m ft-Ib Cy linder head nut 8 x 1.25 24-29 2.4-2.9 17 - 21 Cylinder nut '86, '87, '88: 'Oxl.2S 38 - 48 3.8 - 4.8 27 -35 After '88: 10x1.25 35 - 45 3.5 - 4.5 25 -3 3 Clutch center nut 18 x 1.0 55 - 65 5.5-6.5 40 - 47 80 - 84 B.0-8.4 58 - 61 Clutch spring bolt 6 x 1.0 8- 12 0.8 - 1.2 6- 9 Primary drive gear bolt 10 xt.2S 40 - 50 4 .0 - 5.0 29 - 36 • Gearshift drum center pin 8 x 1. 25 20-24 2.0 - 2.4 14 - 17 Transmission oil drain bolt 12 x 1.5 25-35 2.5 - 3.5 18 - 25 ·Countershaft bearing set plate 6 x 1.0 8-12 0.8 -1 .2 6 -9 Alternator cover screw 6 x 1.0 3- 5 0.3-0 .5 2- 4 Flywheel nut 12x1.25 50 - 60 5.0-6.0 36 - 43 Drive sprocket bolt B x 1.25 25 - 29 2.5-2.9 18-21 Water pump impeller 7 x 1.25 10 - 14 1.0 - 1.4 7-10 Right crankcase cover bolt 6 x 1.0 8- 12 0.8 - 1.2 6-9 Rocker arm holder screw 5 II: 1 .0 6- 8 0.6-0.8 4-6 Exhaust valve rack hole plug 8 x 1.25 8- 12 0.8 - 1.2 6-9 Exhaust valve adjusting sc rew lock nut 5 x 1.0 6- 8 0.6 - 0.8 4- 6 (,86, '87, After '89) Gearshift drum stopper arm bolt 6 x 1.0 10 - 14 1.0 - 1A 7- 10 Cylinder stud bolt 10x1.25 10-14 1.0 - 1.4 7- 10 Cylinder coolant drain bolt 6 x 1.0 8- 12 0.8-1.2 6-9 Water pump cover coolant drain bolt 6 x 1.0 8- 12 0.8-1.2 6-9 Spark plug 14x1.25 15 - 20 1. 5-2.0 11 -14 Oil check bolt 6 x 1 .0 8- 12 0.8 - 1.2 6-9 Exhaust valve adjusting bolt lock nut 5 x 0.8 5 -7 0.5 - 0.7 4- 5 Water pump cover bolt (After '88) 6 x 1.0 10 -14 1.0 - 1 A 7- 10 Cylinder and exhaust valve cover bolt (After '88) 6 x 1.0 10 - 14 1.0 - ' A 7- 10 .: Apply Honda Thread Lock or an equivalent. FRAME Thread dia Torque Item x pitch N·m kg·m ft·lb Steering stem nut '86, '87, '88, After '89: 24 x 1.5 95 - 140 9.5 -1 4.0 69-101 '89: 24 x 1,0 95 - 140 9.5- 14.0 69 - 101 Steering head adjusting nut ' 86, '87, '88: 26 xl ,S 1- 2 0.1 - 0.2 0.7 - 1.4 '89: 26 x 1.0 1- 2 0.1 - 0.2 0.7 - 1.4 After '89: 26 x 1,5 8- 12 0.8- 1.2 6- 9 Fork tube pinch bolt IT op) '86, '87, '88, '89: 0 • 8 x 1.25 18 - 25 1.8 - 2,5 13- 18 After '89:* 0 8 x 1.25 30 - 34 3.0 - 3A 22 - 25 (Bottom) '86, '87, '88, '89:"' 8 x 1.25 18-25 1.8- 2.5 13- 18 After '89:" • 8 x 1.25 24-30 2A-3 .0 17-22 Handlebar upper holder 8 x 1.25 18- 25 1,8- 2.5 13- 18 Handlebar lower holder nut '86, '87, '88: 10xl.25 30 - 40 3.0 - 4.0 22 - 29 Front axle '86, '87, '88, '89: 12xl.25 55-70 5.5-7,0 40 - 51 After '89: 16 x 1.5 80 - 93 8.0- 9.3 58-67 Front axle holder 6 x 1.0 10 - 12 1.0 - 1.2 7- 9 Rear axle nut 18xl ,5 85 - 105 8.5- 10.5 61 - 76 Engine hanger bolt ( 10 mm) 10x1 .25 38- 48 3.8 - 4,8 27-35 (8mml 8 x 1.25 24-29 2.4-2.9 17-21 Engine mounting bolt '86, '87, '88, '89: 10xl.25 38 - 48 3.8 - 4.8 27- 35 After '89 : 10x1,25 60 - 70 6.0 - 7.0 43 - 51 Driven sprocket '86, '87, '88, '89: 8 x 1,25 32-37 3.2-3.7 23 - 27 After '89:'" 8 x 1.25 25 - 31 2.5 - 3.1 18-22 " . : Apply all to the threads. 1-6

Shock absorber (upper) (lower) Front/rear spoke Swingarm pivot bolt Item Fork boot clamp screw (' 86. '87. ' 88) Fork cap bolt Fork drain bolt ('86, '87. '88) Shock arm (swin9arm side) (shock link side) Shock link (frama side) Fork center bolt Shock absorber lock nut Fork cap lock nut Fork piston retainer /'S6, 'S7, '88) Fork protector bolt (After '88 ) Front/rear rim lock Front/rear brake disc retaining bolt Front wheal hub COVflr I'S6, 'S7, 'SS , ' 901 Brake hose joint Imaster cylinder side ) Brake hose joint nut (brake hose side) 818ke hose bolt (caliper) Front master cylinder holder bolt Brake level pivot bolt Brake lever pivot lock nut Brake lever adjuster lock nut Clutch lever pillot bolt Clutch leller pillot lock nut Thronle housing cover screw Gearshift pedal pinch bolt Kickstarter pedal bolt Seat mounting bolt Sub-frame mounting bolt Shock absorber banjo bolt 1'86) Brake caliper bleed vallie Clutch lever holder bolt Thronle hoosing bolt Rear brake torque arm bolt /'86) ' 86, '87 : After '87: 'S6, ' 87, ' S8: After 'S8 : '86. ' 87. 'S8 : Alter'S8 : 'S6, ' 87. ' S8: After 'S8 : '86 , ' 87 . ' 88 : ' S9 : ' 90 : After ' 90: 'S6: '87 , '8S, '89. ' 90 : After '90 : ' S6 , ' 87 , ' 8S. 'S9 : After 'S9: After '90 '86 . ' 89 , After ' 89 : ' 87, '88: After ' 90 Rear brake master cylinder mounting bolt (After '86) Brake pedal pillot bolt ' 86: Silencer case bolt (After 'S6) Pad pin plug [After '86) Rear disc guerd screw (After '86) Front brake caliper mounting bolt Front caliper pin bolt ('86): upper : lower (After '86) : upper" : lowe," Rear caliper pin bolt ('87 , '88, ' 89): front side " (After '89) : front side" : tear side" Brake caliper pad pin • : Apply Honda Thread Lock or an equivalent. •• : Apply oil to the threads. After '86: ' 86 , '87. ' 88 : ' 89: '90 : After ' 90:"" Thread die )( pitch 10)( 1.25 10 Jt 1. 25 Be . 3.S/ Be . 4.0 15)( 1.5 16)( 1.5 3.5)( 0.6 39)( 1.0 50)( 1.5 6)( 1.0 12 it 1. 25 10)( 1.25 12)(1.25 10)( 1.25 12)( 1.25 14)( 1.0 22 x 1.0 22 x 1.0 14 )( 1.0 56)( 1.5 10)( 1.0 10 x 1.0 '2 x 1.0 22 x 1.0 6)( 1.0 B)( 1.25 6 x 1.0 8 x 1.25 4 x 0.7 4 xO .7 '0)( 1.25 10 x 1.25 10x1.25 10x1 .25 6 x 1.0 6 x 1.0 6)( 1.0 5 x 0.5 6)( 1.0 6 x 1.0 4 x 0.7 6)( 1.0 B x 1.25 8 x 1.25 8 x 1.25 B x 1.25 10 x 1.0 ex 1.25 6 x 1.0 6 x 1.0 8 x 1.25 6 x 1.0 8 x 1.25 8 x 1.25 5 x 0.8 10 x 1.0 6 x 1.0 8)( 1. 25 8 x 1.25 8 x 1.25 8 x 1.25 8 x 1.25 8)( 1.25 8 x 1.25 8 II 1. 25 8 x 1.25 12 x 1.25 8 x 1.25 10 x 1.0 GENERAL INFORMA nON 40 50 38~48 2.5 - 5.0 80 - 100 80-'00 0 .8 - 1.6 15 - 30 30 - 40 6-9 55-70 40 - 50 55 - 70 40 - 50 55-70 30 - 40 40 - 45 50 - 55 40 - 50 80 - 100 12 - '5 17.5 - 22.5 20-24 3- 6 12-'4 10-'5 14 - 16 40 - 45 1.0 - 2.0 0. 5-1.0 30 - 40 12 - 15 30 - 40 25 - 35 8- 12 8- 12 8-12 5- 7 1- 3 8- 12 1- 2 10-14 24 - 30 18 - 25 18 - 25 24 - 30 27.5- 32 .5 4-7 8-12 8- 12 18 - 25 14 - 16 18-25 24 - 28 4.5 - 6.0 2- 3 6-8 20 - 30 32-36 24 - 30 28 - 34 20-25 15 - 20 20-25 10 - 15 20 - 25 25-30 10 - 15 15-20 Torque 4.0 5 .0 3.8 - 4 .8 0. 25-0.50 8 .0 - 10.0 8.0 - 10.0 0.08-0. 16 1.5- 3.0 3.0- 4.0 0.6 - 0.9 5.5 - 7.0 4.0-5.0 5.5 - 7.0 4.0 - 5.0 5.5- 7.0 3. 0-4.0 4 .0 - 4.5 5.0 - 5.5 4.0 - 5.0 8.0-10.0 1.2-1.5 1.75 - 2. 25 2.0- 2.4 0.3 - 0.6 1.2 - 1.4 1.0 - 1.5 1.4 - 1.6 4.0 - 4.5 0.1 - 0.2 0.05 - 0.1 3.0-4.0 1.2 - 1.5 3.0- 4.0 2.5- 3.5 0.8 - 1.2 0.8 - 1.2 0.8-1.2 0.5- 0.7 0.1- 0.3 0.8- 1.2 0.1 - 0.2 1.0-1.4 2.4 - 3.0 1.8 - 2.5 1.8 - 2.5 2.4-3.0 2. 75 - 3. 25 0.4-0.7 0.8 - 1.2 0.8- 1.2 1.8- 2.5 1.4 - 1.6 1.8-2.5 2.4 - 2.8 0.45 - 0.60 0.2-0.3 0.6-0.8 2.0 - 3.0 3.2-3 .6 2.4- 3.0 2.8 - 3.4 2.0-2.5 1.5 - 2.0 2.0-2 .5 1.0 - 1.5 2.0 - 2.5 2.5- 3.0 1.0 - 1.5 1.5 - 2.0 ft-Ib 29 36 27-35 1.8 - 3.6 58-72 58 - 72 0 .6 - 1.2 11 - 22 22 - 29 4- 7 40 - 51 29 - 36 40-51 29-36 40 - 51 22 - 29 29 - 33 36 - 40 29 - 36 58 - 72 9- 11 12.7- 16.3 14 - 17 2.2- 4.3 9- 10 7- 11 10 - 12 29 - 33 0.7- 1.4 3.6- 0.7 22 - 29 9- 11 22 - 29 18 - 25 6- 9 6- 9 6- 9 3.6 -5 0.7- 2.2 6- 9 0.7 - 1.4 7-10 17 - 22 13 - 18 13 - 18 17 - 22 20 - 24 3- 5 6- 9 6- 9 13 - 18 10 - 12 13 - 18 17 - 20 3.3 - 4.3 1.4 - 2.2 4-6 14 - 22 23-26 17 - 22 20 - 25 14 - 18 11 - 14 14 - 18 7- 11 14 - 18 18 - 22 7- 11 11 - 14 { cont'dl 1-7

1986-1991 CR250R Service & Repair Manual

You're Reading a Preview

Recently Viewed