2002-2004 CR250R Service & Repair Manual

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HOW TO USE THIS MANUAL This service manual describes lha service procedures f or the CR250R. Follow 1m. Maintllnance Schedule (Section 3) .e<:ommendu\iol'ls 10 en.u,e Ihat the vehicle is In peak operating condition. Performing the first sCheduled rn.inienancot is very impOrlant. II camp"n· SItu for the In itia l wear that occurs during Ihe break-in period. Sections 1 and lapply to tha whole motorcycle. Section 2 Illustrates proce- dur es lar .emovaVinslalielion of componllnts Ihal may be required to per- form service described in Ihe following sections. Section 4 IhrouQh 15 describe parts of the motorcyde. grouped '<:<;(I,ding 10 location. Find Iha SBction you want on this page. then turn to lha lable of contents on the firs! peg, of th e section. Most sections start with an assembly or system illustration. service informa- t!on and troub!eshooting for the 5""tion. Thll 5ubsaquent pages give dellli!ed p.OCIIduru. If you don'1 ~nowthe source ofthlt traubla, go to section 17 Troubleshooting. Your safety. and the safety of othllrs, is very important. To hll ip you make informed <I",,;.ions we have provided s8fety mns8ges and othllr infor· mation throughout this manual. Of courSlI, it is n O! p"ctkal Or possible to warn you about all thlt hlllllrds associated with servicIng thIs vehicle. You must UH your own good judgement. Yau will find Important safety information in a variety offorms including: - Safllly LIbel. - on the vahicla , Safely Messages _ pr eceded by 8 safety alert symbol'&' 8"d ana of three ,ignal words, DANGER, WARNING. or CAUTION. The.... signal words mean: .. & You WILL be KILLED or SERIOUSLY HURT if !..!'W'4W 1 f13i C you don't follow Instructions. You CAN he KILLED o. SER I OUSLY HURT if f!1",(o'iJt1I'W1 you do,,'1 follow i"5tructions. '!jq,ii"j.I~1 ~os~r:~ns~ HURT if you don't follow • Instructions - how to serviclI this vehicle corre<:tly and safely. Date of Issue: July, 2003 z <i c:: >- w > ii' o o ~ CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON REAR WHEEL/SUSPENSION. HYDRAULIC BRAKE IGNITION SYSTEM WIRING DIAGRAM TECHNICAL FEATURES TROUBLESHOOTING INDEX

. SYMBOLS The svmbols used throughout this manual show specific service procedures. If supplementary information is required per- taining to these symbols, it woul d be explained specifically in the text wit h out the use of the symbols. ",," .... Replace the part(s) with new one(s) before assembly. , Use the recommended engine oil, unless otherwise specified. 7J Use molybdenum oil solution (mixture of the engine oil and mo l ybd enum grease In a ratio of 1 : 1). - fiijjjiJ, Use multi · pu rpose grease (lithium based multi-purpose grease NLGI #2 or equivalent ). . Use molybdenum disulfide grease (containing mo re than 3% molybd enum disulfide, NlGI #2 or ~ equivalent). Example: Molykote- BR-2 plus manufactured by Dow Coming U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, Nl GI #2 or equivalent. ~ Ex ample: Molykole- G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. on l y) Rocol ASP manufactured by Rocollimited , U.K. Roco1 Paste manufactured by Sumico lubricant, Japan ...-'iiSiII Use silicone grease. 0,. Apply a locking agent. Use a medi um strength locking agent unless otherwise specified. .,(ftlIl Apply sealant. I Use DOT 4 brake fluid. Use the recommend ed brake fluid unless otherwi se specified. .. Use fork or suspens io n fluid . • • • • • • • • • • •

1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES SERVICE RULES 1-1 1-1 1-3 1-10 TOOLS LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING OPTIONAL PARTS 1-13 1-15 1-17 1-24 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special toots deSigned for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cone r pins, and lock plates when reassembling. 5. When tightening bolts or nuts, negio wi th the l arger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. Aher reassembly, check all parts for proper installation and ope ration. S. Route all electrical wires as shown on pages 1-17 through 1-23, Cable and Harness Routing . MODEL IDENTIFICATION 1-1

GENERAL INFORMATION (11 The frame serial number is stamped on the fight side of the steering head. (3) The carburetor identification number is stamped on the front side of the carburetor body as shown. 1-2 , E,NGINE SE'"Al (2) The engine serial number is stamped on the lower left side of the crankcase. ~ After '03: ~ (3) The carburetor identification number is stamped on the right side of the carburetor body as shown. • • •

GENERAL INFORMATION SPECIFICATIONS GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length '02 '03: 2,190 mm (86.2 in) After '03: 2,173 mm (85.5 in) Overall width 823 mm (32.4 in) Overall height '02 - '03: 1,269 mm (50.0 in) After '03: 1,263 mm (49.7 in) Wheelbase '02 - '03: 1,491 mm (58.7 in) After '03: 1.482 mm (58.3 in) Seat height '02 - '03: 950 mm (37.4 in) After '03: 952 mm (37.4 in) Footpeg height '02 - '03: 436 mm (17.2 in) After '03: 429 mm (l6.S in) Ground clearance '02 - '03: 346 mm (13.6 in) After '03: 339 mm (l 3.3 in) Dry weight '02 - '03: 96.5 kg 1213 Ibs) After '03: 96.6 kg 1213 Ibs) FRAME Frame type Twin tube Front suspension Telescopic fork Front suspension axle travel 281 mm (' 1,1 in) Front suspension cushion stroke 315 mm (12.4 in) Rea r suspension Swin garm/Pro--link Rear wheel travel 3 19 mm (12.6 in) Rea r damper Decarbon type with nitrogen gas fitled damper Front tire si ze 80/100-21 51M Rea r ti re size 110/90-1962M Front tire brand (Dunlop) K490G Rea r tire brand (Dunlop) KS95 Front brake Hydraulic single disc Front brake swept area 334.5 cm 1 (51.8 inl) Rear brake Hydraulic single disc Rear brake swept area 39 1.1 cm l (60.6 inl) Caster angle '02 - '03: 2S" 44' After '03: 2S' 49' Trail length '02 - '03: 10S.7 mm (4.2 in) After ' 03: 107.3 mm (4.2 in) Fuel tank capacity 7.7 liter (2.0 US gal, 1.7 Imp gal) ENGINE Bore and stroke 66.4)( 72.0 mm (2.61 x 2.83 in) Displacement 249.3 cm' (15.2 cu -in) Compression ratio '02 - ' 03: 8.5: 1 After '03: 8.S: 1 Lubrication system Fuel/o il mix Cooling system Liquid cooled Air filtration Oiled polyurethane foam Crankshaft type Assembly-type Engine dry weight '02 - '03: 23.0 kg (50.7 Ibs) After '03: 23 .3 kg (51.4 Ibs) Cylinder arrangement Single cylinder, inclined 9° fr om vertical CARBURETOR Carburetor type Piston valve type Venturi dia. '02 - '03: 38.3 mm (1.50 in) After '03: 38.0 mm (1.50 in) 1-3

GENERAL INFORMATION GENERAL ICon,'d) ITEM SPECIFICATIONS DAIVE TRAIN Clutch syst em Multi-plale. wet Clutch operation system Cable operated Transmission Constant mesh, 5-speeds Primary reduction 3.000 (6312 1) Final reduction '02 - '03: 3.692 (48/ 13) Aher '03: 3.846 (SO/ 13) Gear ralio '" 1.800 (27/ 15) 2nd 1.470 (25117) 3,d 1.210 (23/19) 4th 1. 000 (2 1/21) 5th 0.869 (20{23) Gearshift pattern Left f oot operated return system, 1 - N - 2 - 3 - 4 - 5 ELECTRICAL Ignition system CDI • • 1-4

GENERAL INFORMATION LUBRICATION SYSTEM ITEM STANDARD Recommended engine oil Pro Honda HP2 2-stroke oil or equivalent FueVoi l mi)(ing ratio 32: 1 Transmission oil capacity After draining 0.65 liter (0.69 US qt, 0.57 Imp qt) After disassembly 0.70 liter (0.74 US qt, 0.62 Imp qt) Recommended transmission oil Pro Honda HP Trans oil, Pro Honda GN4, HP4 (wi thout molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher except oils labeled as energy conserving on the circular API service label Viscosity: SAE 10W-40 JASO TOO3: MA FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification number '02 TMX 118 'OJ TMX l'C After '03 TMX IDA Main jet '02 #380 '03 #420 After '03 #420 Slow jot '0' #32.5 '03 #30 After '03 #32.5 Jet needle '0' 6BEV30-74 '03 6BHY38-73 After '03 6CHY12-82 Jet needle clip position (Standard) "d Air screw initial opening "1/2 turns out Float level ' 02 - '03 15.0 mm (0.59 in) After '03 7.5 mm (0.30 in) Throttle grip free play 3 5 mm (1/8 - 1/4 in) COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity At change 1.08 li ter 0 .14 US qt , 0.95 Imp qU At disassembly 1.15 liter (1.22 US qt, 1. 01 Imp qt ) Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf/cm2, 16 - 20 psi) Recommended antifreeze Pro Honda HP coolant or equivalent high quality ethylene gly· col antifreeze containing silicate-free corrosion inhibitors Standard coolant concentration 1:' mixture with soft water 1-5

GENERAL INFORMATION CYLINDER HEAD/CYLINDER/PISTON Unit· mm (in) ITEM STANDARD SERVICE UMIT Cylinder head warpage -- 0.05 (0.002) Cvlinder 1.0. A 66.398 - 66.405 (2.6141 - 2.6244) 66.43012.615) B 66.390 - 66.398 (2.6138 - 2.6141) 66.428 (2.615) Out-of round 0.05 (0.002) Taper -- 0.05 (0.002) Warpage -- 0.05 (0.002) Piston, piston Piston mark direction ~ IN ~ mark facing toward the intake side -- rings Piston 0.0. A 66.330 - 66.338 (2.6114 - 2.6117) 66.28 (2.609) B 66.323 - 66.330 (2.6111 - 2.6114) 66.273 (2.609) Piston 0.0. measurement point 15 - 25 mm (0.59 - 0.98 in) from bottom of skirt -- Piston pin bore 1.0. 18.007 - 18.013 (0.7089 - 0.7092) 18.02 (0.709) Piston pin 0.0. 17.994 - 18.000 (0.7084 - 0.7087) 17.98 (0.707) Piston---to-piston pin clearance 0.007 - 0.019 (0.0003 - 0.0007) 0.04 (0.0016) Piston ring-to-ring groove Top 0.045 - 0.075 (0.002 - 0.003) 0.095 (0.0037) clearance Second 0.025 - 0.055 (0.001 - 0.002) 0.075 (0.0029) Piston ring end gap 0.40 - 0.55 (0.016 - 0.022) 0.65 (0.026) Cytinder-to-piston clearance 0.060 - 0.075 (0.0024 - 0.0029) 0.09 (0.004) Connecting rod small end J.D. 21.997 - 22.009 10.8660 - 0.8665) 22.02 (0.867) CLUTCH/GEARSHIFT LINKAGE Unit· mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever free play 10 - 20 (318 - 3/4) -- Clutch spring free length 45.7 (1.83) 44.7 (1.76) Clutch outer gulde 1.0. 23.000 - 23.021 (0.9055 0.9063) 23.03 (0.907) Clutch disc thickness 2.92 - 3.08 (0.114 - 0.1211 2.85 (0.1121 Clutch plate warpage 0.20 (0.008) Kickstarter pinion gear 1.0. 22.007 - 22.028 (0.8664 - 0.8672) 22.05 (0.8681 Klckstar1er spindle 0.0. 21.959 - 21.980 (0.8645 - 0.8654) 21.95 (0.864) Kickstarter idle gear 1.0. 20.020 - 20.041 (0.7882 0.7890) 20.07 (0.790) Kickstarter idle gear bushing 1.0. 17.000 - 17.018 (0.6693 - 0.6700) 17.04 (0.671) 0.0. 19.979 - 20.000 (0.7866 - 0.7874) 19.96 (0.786) Countershaft 0.0. at kickstarter idle gear 16.966 16.984 (0.6680 0.6687) 16.95 (0.667) • 1-6

2002-2004 CR250R Service & Repair Manual

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