1992-1996 CR250R Service & Repair Manual

Introduction This service manua l describes the service procedures fo r the CR250R. Also available , but not necessary to service you r model : The Honda Common Service Manual (part Number: 61CMOOO) explains the theory of operation and provides basic service information for var ious systems common to all Honda motorcycles, scooters, ATVs and pilots . It is an excellent sou rce for those who want a grealer knowledge of mOTorcycles and the ir component systems . Follow the Competition Ma i ntenance Schedule re commendations (page 3- 4) 10 ensure that the vehicle is always in peak operating co nd iti on . Sections 1 and 3 apply to th e whole motorcycle. Seclion 2 illustrates procedures for removal / installation of compone nts that may be required to perform service describ ed in the fo l lowing sections . Sections 4through 15describe parts of the motorcycle. gr ouped 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 . If you are not familiar with this motorcycle, read Section 16, Technical Featu re . If you don't know the so urce of the trouble , go to sect io n 17 Troubleshoot i ng. ~ ' iij ,:: Contents General Information Frame/Body Panels/Exhaust System Maintenance Fuel System Cooling System Engine Removal/Installation ~ d I Cylinder Head/Cylinder/Piston ~ ~===================== ~ I Re Valve '~ ~================================ w Clutch/Kickstarter/Gearshift linkage Crankcase/Crankshaft/Transmission Front Wheel/Suspension/Steering Rear Wheel/Suspension Brake System Ignition System / Alternator Wiring Diagram Technical Feature Troubleshooting Index

Svmbols The symbols used throughout this manual show spec ifi c service procedures . If supplementary information is required pena i ning to these symbols . it would be explained specif ically in the texl without the use of the symbols . ~ Replace the pan(s ) with new one(s) before assembly. (. Tw.. ! Use spec iatloo!. [0 , "7_ 1 Use optional tool. These tools are obtained as you order parts . e Torque specification. 10 N'm 11 .0 kg·m, 1 ft· lbl 100 .0, 7) 'I Use recommended engine oil. Use Honda Engine Oil (U.S.A Only) or an equivalent of the type specified . , Use molybdenum oil solution ( mixture of the engine oil and molybdenum grease with the ratio 1 : 1) . - - Use multi - purpose grease (lithium based multi - purpose NlGI1I2 or equivalent). U~e molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGI ~ 112 or equivalent ). example : Molykote " BA ·2 plus manufactured by Dow Corning, U.S.A. Multi -purpose M-2 manufactured by Mitsub ishi Oil Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NlGI #2 or equivalent). ~ example: Molvkote~ G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. Only) Aocol ASP manufactured by Aocollimited , U.K. Aocol Paste manufactured by Sumico lubricant , Japan ..-liSiII Use silicone grease. n Apply a locking agent . Use Hondalock 2 (U.S.A. Only) or an equivalent , unless otherwise 1'1" specified . ..,oru Apply sealant. Use Hondabond 4 (U.S.A. Only) or an equivalent. unless otherwise specified . I Use brake fluid DOT 3 or DOT 4. Use DOT 4 Brake Fluid (U.S.A. Only ) or an equivalent . .. Use Fork or Suspension Fl uid . Use Honda Suspension Fluid (U.S.A. Only) or an equivalent of the type specified. •

General Safety Service Rules Model Identification Specifications Torque Values General Safety Carbon Monoxide 1-1 1-2 1-3 1-4 1-12 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. Theexhaust contain s poisonous ca rbon mono xi de gas that can cause l oss of consciousness and may l ead to death . Aun the engine in an open area or with an exhaust evacuation system in an enclosed area. Gasoline Work in a we ll ven t ilated area . Keep ciga r ettes, flames or sparks away from the work area or where gasoline is stored . Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Hot Components Engine and exhaust system parts become very hot and remain h ot for sometime after the engine is run . Wear insulated gloves or wait until th e engine and exhaust system have coo led before these 1. General Information Tools 1- 15 Lubrication & Seal Points 1-17 Cable & Harness Routing 1- 19 Optional Parts List 1-25 Used Engine / Tran s mi ss ion Oil Used engine oil (o r transmis si on oil intwo· stroke) may cause skin cancer if repeatedly left in contact with the skin for prolonged periods . Although this is unlikely unless you handle used oi l on a daily basis , it is still advisable to thoroughly w ash your hands with soap and water as soon as po ss ible after handling used oil . KEEP OUT OF REACH OF CHILDREN. Brake Dust Brake dust may contain asbestos. Never use an air hose or dry brush to clean brake assemblies . Use and OSHA - approved vacuum cleaner or alternate method app r oved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers . Inhaled asbestos fibers have been found to ca use respiratory disease and cancer . Brake Fluid CAUTION Spilling fluid on pained , plastic or rubber parts will damage them. Place a cle an shop tow el over these parts whenever the syste m is serviced . KEEP OUT OF REACH OF CHILDREN. 1-1

General Information Coolant Under some conditions, the ethylene glycol in engine coo l ant is combustible and its flame is not vis ible. If the ethylene glycol does i gnite, you will not see any flame, but you can be burned. Avoid spilling engine coo lant on the exhaust system or engine parts . They may be hot enough to cause the coolant to ignite and burn without a visible flame . Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed . KEEP OUT OF REACH OF CHILDREN. Keepout of reach of pets . Some pets are attracted to the smell and taste of coolant and can die if they drink it . Do not remove the radiator cap when the engine is hot . The coolant is under pressure and could scald you. If it con tacts your skin, wash the affe cte d areas immediate ly with soap and water. If it contacts your eyes, flush them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaini ng medical attention. Because of these dangers, always store coolant in a safe place, away from the reach of children. Recycle used coolant in an ecologically correct manner. Service Rules Nitrogen Pressure For shock absorber with a gas -f illed reservoir. Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or exp l osion resulting in serious injury. The shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock absorber could lead to and explosion that could result in serious injury. Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is heated or pierced . To pr event the possibility of an explosion, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorber reservoir. Dispose of the oi l in a manner acceptable to the Environmental Pr otection Agency (EPA ). Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorber . 1. Use genuine HONDA or HONDA-re commen ded parts and lubricants or their equivalent. Parts that do not meet HONDA's design sp ecificatio ns may damage the motorcyc le. 2. Use the special tools designed for this product. 3. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. 4. When torquing bolts or nuts, begin with lager-diameter or inner bolt first, and tighten to the specified torque, diagonally, in inc r ementa l steps unless a particular sequence is specified. 5. Clean parts in non-flammable or hi gh flash point solvent upon disassembly. Lubricate any sl iding surfaces before reassembly. 6. When installing a new oil seal, make sure that the sealing lip is lubricated with grease. If any 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 i nstallation and operation. 8. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not int erchangeable with any other type of fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 1-2

Model Identification '92 shown : (l iThe frame serial number is stamped on the right side of the head. 'CARBURETOR I I I (3lThe carburetor identification number is on the left side of the carburetor body. General Information (2)The engine serial number is stamped on the lower left side of the crankcase. 1-3

General Information Specifications - General It em Specifications Dim ensio ns Overall length '92: 2,161 mm (85.1 in) '93: 2,165 mm (85.2 in) After '93: 2,177 mm (85.7 in) Overall width '92-'93: 825 mm (32.5 in) After '93: 835 mm (32.9 in) Overal l height '92: 1,262 mm (49.7 in) '93: 1,243 mm (48.9 in) After '93: 1,2 42 mm (48.9 in) Wheelbase '92: 1,467 mm (57.8 in) '93: 1,471 mm (57 .9 in) After '93: 1,483 mm (58.4 in) Seat height '92: 970 mm (38.2 in ) After '92: 958 mm (37.7 in) Footpeg height '92: 445 mm (17.5 in) '93: 436 mm (17.2 in) After '93: 448 mm (17.6 in) Ground clearance '92: 350 mm (13.8 in) '93: 343 mm (13.5 in) After '93: 345 mm (13.6 in) Dry weight '92-'93: 96.5 kg (2 12.7 Ibs) After '93: 97.0 kg (213.8 Ibs) Frame Type Semi-double cradle Front suspension Te l escopic Front wheel travel 309 mm (12.2 in) Rear suspension SwingarmlPro-Link Rear wheel tr avel 320 mm (12.6 in) Aear dampe r Decarbon type with nitrogen filled reservoir Front tire size 80/100-2 1 51M Rear tire size 110/100 - 1864 M Tire brand (Dunlop) Front K990 Rear K990 Front brake .Hydrauli c single disc Front brake swept area 306 cm~ (47.4 in 2 ) Rear brake Hydraulic single disc Rear brake swept area 303 cm~ (47.0 in 2 ) Caster angle '92 : 26° 03' '93 : 26° 45' After '93: 27° 17' Trail length '92: 103.7 mm (4.08 in) '93: 104.1 mm (4. 10 in) After '93: 111.5 mm (4.39 in) Fuel tank capacity 7.5 liter (2 .0 US gal, 1.6 Imp gal) Engine Bore and stroke 66.4 x 72.0 mm (2.612 x 2.83 in) Displacement 249.3 cm 3 (15.2 cu-in) Compression ratio 8.7 : 1 Lubrication system Fuel/ oil mix Cool ing system Liquid cooled Aire filtration Oiled polyurethane foam Crankshaft type Assembled type Engine dry weight 23.3 kg (51.4 Ibs) Cylinder arrangement Single cylinde r, in clined 5° from vertical 1-4

General Information r General (Cont 'd) Item Spec ifica ti ons Carburetor Carburetor type Piston va l ve Venturi diameter 38.0 mm (1. 49 in ) Dri ve Tr ain Clutch system Wet , mult i- plate type Clutch operation system Cable operat ed Transmission 5"speed c onstant mesh Primary reduction 3.000 : 1 (63/ 21 ) Final reduction 3.769 : 1 (49/13) Gear rat io 1st 1.800 : 1 ( 27/ 15 ) Gear ratio 2nd 1.470 : 1 (25/17 ) Gea r rat io 3rd 1.210 : 1 ( 23 / 19 ) Gear rat io 4th 1.000: 1 ( 21 / 21 ) Gear ratio 5th 0.869 : 1 (20/ 23 ) Gearshift pattern Left foot - operated return system 1 - N - 2- 3 - 4 - 5 Electrical Ignition system COl 1-5

General Information Unit · mm (in) r Lubrication Item Standard Service Limit Recommended engine oil PRO Honda HP2 2-Stroke Oil or -- equivalent -- Fuel/ oi l mixing ratio 32 : 1 -- Transmission oil capaci ty at draining '92: 0.85 lite r (0.90 US qt, 0.75 Imp qt) -- Aher '92: 0.75 l ite r (0.79 US qt , 0.66 Imp qt) -- at disassembl y '92: 0.95 liter (1.00 US qt, 0.84 Imp qt ) -- Afte r '92: 0.85 liter (0.90 US qt, 0.75 Imp qt) - - Recommended transmission oil U se PRO Honda GN4 4-Stroke Oil or equivalent API Service Classification: SF or SG Viscosity : SAE 10W-40 Other Viscosities shown in the chart may be used when the average I temperature in your riding area is within the indicated range . , ~ ~ M ~ 00 " , -~ -0 , 0 ~ ~ ~< r- Fuel Sy st em --------------,--- ---- - ------ ,-------, Carburetor identification number Ma in jet (Stan dard) Sl ow jet (Standard) Jet needle clip position (Standard) Air screw initial opening Float leve l Throttle grip free play '92: '93: After '9 3: '92, After '93: '93: PJ28E AJ28G PJ28H #175 #55 3rd gr oove 2 turns out 1-3/4 turns out 16.0 (0.63) 3 - 5 (1 /8 - 1/4) r- Cooling System ------------ --,--- -------- ----,--- ----, Recommended coolan t Cool ant capacity at change at disassembly Radiator cap relief pressure Use only a high quality ethylene glycol based anti -free ze containi ng corrosion protection inhi bi tors specially recommended for use in aluminum engines . A SO/50 mixt ure of anti-freeze and distilled wate r is recommended for most operating condit i ons. (See anti-freeze container label for other mix t ure ratios .) 1.10 l iter (1.16 US qt, 0.97 Imp qt) 1.15 liter (1.21 US qt, 1.01 Imp qt) 110 - 140 kPa (1.1 - 1. 4 kg/ cm l , 16 - 20 psi) r Clutch System -------------,--------------,--------, Clutch lever free play Clutch spring free length Clutch outer guide 0.0. Clutch disc thickness Clutch plate warpage 1-6 10 - 20 (3/8 - 3/ 4) '92-' 93: 44.7 (1.76) After '93: 45.7 (1.83) 27.987 - 28.000 (1 .1018 - 1.1024) 2.92 - 3.08 (0.114 - 0.12 1) 43.7 (1.72) 44.7 (1.76) 27.97 (1. 101) 2.85 (0. 112) 0.20 (0.008)

1992-1996 CR250R Service & Repair Manual

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