1997-1999 Honda CR250R OEM Service & Repair Manual

HOW TO USE THIS MANUAL This service manual describes the service procedures for the CA250R. Follow the Maintenance Schedule recommendations (page 3-31 to ensure that the motorcycle is al ways in peak operating condition. Sections 1 and 3 apply to the whole motorcycle. Section 2 desc r ibes procedures for removallinstaHation of comp onents that may be required to perform service described in th e foll owing sections. Section 4 t hrough 15 descr ibe parts of the motorcycle, grouped according to location. Find the section you want on this page, the n turn to the table of co ntents on the first page of the section. Most sections start with an assembly or system illustration, service info r mation and troubleshooting for the section. The subsequent pages give detailed procedure. If you are not familiar with this motorcycle, read the Technical Features in section 16. If you don't know the source of the trouble, go to section 17 Troubleshoot ing. z ;;: a: .... w > ;;: a: o o z ..: w z Cl Z w CONTENTS FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON COMPOSITE RACING VALVE (CRV) 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 informa t ion is required pertaining 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 r ecommended engine oil, unless otherwise speci fied. 'I Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of I : II , - - 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: Molykote·BR-2 plus manufactured by Dow Corning, U.S.A. Multi -purpose M-2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide grease (conlaining more than 3 % molybdenum disulfide, NlGI #2 or equivalent). ~ Example: Molykote e BA -2 plus manufactured by Dow Corning, U.SA Honda Moly 60 (U.S.A only) Racol ASP manufactured by Rocol limited, U.K. Rocol Paste manufactured by Sumlco lubricant, Japan ...- Use silicone grease. Oum Apply a locking agent. Use a middle strength locking agent unless otherwise specified . .,( , om Apply sealant. I Use brake fluid, DOT 4. Use the recommended brake fluid, unless otherwise spec ified . .- 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 1-12 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work , make sure the area is well ven t ilated. 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. Run 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 extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS Engine snd exhaust system parts become very hot and remain hot for some time after the engine is run . Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. TOOLS 1-15 LUBRICATION & SEAL POINTS 1-17 CABLE & HARNESS ROUTING 1-19 OPTIONAL PARTS 1-25 USED ENGINE OIL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on II 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 OUST Never use an ai r 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 air borne asbestos fibers. Inhaled asbestos fibers hav e been found to cause respiratory disease and cancer. BRAKE FLUID CAUTION Spilling fluid on painted. plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is 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 ethylene glYCOl does ignite, you will not see any flame, but you can be burned. Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without II visible flsme . Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN. Do not remove the radiator cap when the engine is hot . The coofant is under pressure and CQuid scald you. Keep hands and clothing away from the cooling fan, as it starts automatically. CAUTION Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. If it contacts your skin, wash the affected areas immediately with soap and water. If it contacts your eyes, flush them thoroughtly with fresh water and get immediate medical attention. If it is swall owed, the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical attention. Because of these dangers, always store coolant in a safe place, always fr om the reach of children. Recycle used coolant in an ecologically 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 unstable gas can cause a fire or exprosion 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 prevent the possibility of an explosion , release the nitrogen by pressing the valve co re. Then remove the valve stem from the shock absorber reservoir. Dispose of the oil in a manner acceptable to the Environmental Protection Agency (EPA). Before disposal of the shock absorber, release the ni trogen by pressing the valve core. Then remove the valve stem from the shock absorber. 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 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, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Cl ea n 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 show on pages 1-18 through 1-20, Cable and Harness Routing. 1-2

f MODEL IDENTIFICATION (1) The frame serial number is stamped on the right side of the steering head. (3) The carburetor identification numbers are stamped on the left side of the carburetor body as shown. GENERAL INFORMATION (2) The engine serial number is stamped on the lower left side of the crankcase. 1-3

r FRAME ITEM Q'TY FRAME/ BODY PANELS/EXHAUST SYSTEM: Seat mounting bolt 2 Sub· frame mo u nting bolt (upper) 1 (lower) 2 Radiator shroud mounting bo lt 2 Seat bracket screw 1 Front chamber stay boll (chamber side/After '97) 1 ENGINE MOUNTING : Engine hanger plate nut 2 Engine upper mounting nut 1 Engine lower mounting nut ('97 - '98) 2 (After '98) 2 FRONT WHEEL/SUSPENSION/STEERING: Front axle nut 1 Front axle holder bolt 4 Front spoke nipple 36 Front rim lock 1 Front brake disc nut 6 Steering stem nut 1 Steering stem adjust nut 1 Fork tube pinch bolt (top) 4 (bottom) 4 Fork cap ('97) 2 (After '97) 2 Fork center bolt 2 Fork center bolt lock nut 2 Plug bolt 2 Fork damper ('971 2 (After '97) 2 Fork damper lock screw 1'97) 2 Fork protector mounting bolt 6 Front brake disc cover bolt 2 Brake lever pivot bolt/nut 1/ 1 Handlebar upper holder bolt 4 Handlebar lower ho l der nut (After '98) 2 Clutch lever pivot bolt 1 Clutch lever pivot nut 1 Clutch lever holder bolt 2 Throttle housing bolt 2 Throttle housing cover screw 1 Engine stop button screw 1 THREAD DIA.( mm ). 8 8 8 5 5 6 8 10 10 10 16 8 Be 3.5 8 6 26 30 8 8 50 39 30 " 5 40 50 4 6 6 6/6 8 10 6 6 6 6 4 4 GENERAL INFORMATION TORaUE N·m (kgf ·m. Ibf· ft ) REMARKS 2612.7,20) 30 (3. 1, 22) 41 14.2,30) 6 (0.6, 4.3) 6 (0.6, 4.3) 10 (1.0, 7) 2612.7,20) NOTE 4 39 (4.0, 29) 49 (5.0, 36) NOTE 4 64 (S.S, (7) NOTE 4 88 (9.0, 65) 20 (2.0, 14) 3.8 (0.38, 2.8) 13(1.3,9) 16 (1.6,12) 147 (15.0, 108) 7 (0.7, 5.1) 22 (2.2, 16) 20 (2.0, 14) 54 (5.5, 40) 29 (3.0, 22) 69(7.0,5 1) 22 (2.2, 16) 1.2 10.12, 0.9) 118 (12.0, 87) 54 (5.5, 40) 0.7 (0.07, 0.5) 7 (0.7, 5.1) NOTE 1 13 (1.3,9) NOTE 1 5.9 (0.6, 4.3) 22 (2.2, 16) 44 (4.5, 33) NOTE 4 2 (0.2, 1.4) 10 (1.0, 7) 910.9.6.5) 9 (0.9, 6.5) 1.5 (0.15. 1.1) 1.5(0.15,1.1) 1-13 1 1 1 I

GENERAL INFORMATION r GENERAL (Cont'd) ITEM SPE CIFI CAn ONS DRIVE TRAIN Clutch system Multi-plale. wet Clutch operation system Cable operated Transmission Constant mesh, 5-speed Primary reduction 3.000 (63/21) Final reduction '97 3.769 (49/13) After '97 3.846 (50!13) Gear ratio 1st 1.800 (27/15) 2nd 1.470 (25/17) 3,d 1.210 (23/19) 4th 1.000 (21/21) 5th 0.869 (20/23) Gearshift pattern Left foot operated return system, 1- N - 2 - 3 - 4 - 5 ELECTRICAL Ignition system CDI 1-5

GENERAL INFORMATION Unit: mm (in) r LUBRICATION SYSTEM ITEM SPECIFICA nONS Recommended engine oil PRO HONDA HP2 2-stroke oil or equivalent motor oil FueVoil mixing ratio 32:1 Transmission oil capacity At draining a.75 liter (0.79 US qt , 0.66 Imp qU At disassembly 0.85 liter (0.90 US qt, 0.75 Imp qt) Recommended transmission oil PRO HONDA HP Trans oil, PRO HONDA GN4 4-stroke oi l or equivalent moto r oil API service classification SF or SG Viscosity: SAE 10W· 40 r FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification number '97 - '98 PJ28L After '98 PWKOOA Main jet '97 - '98 #175 After '98 #190 Slow jet '97 - '98 #55 After '98 #42 Power jet '97 - '98 only #42 Jet needle '97 - '98 R1369MS After '98 A1370DKA Jet needle clip position (Standard) 3,d Pilot screw initial opening 2 turns out Float level 16.0 mm (0.63 in) Throllle grip free play 3 - 5 mm (118 - 1/4 in) r COOLING SYSTEM ITEM SPECIFICA nONS Coolant capacity at change 1.26 l iter (1.32 US qt, 1.13 I mp qU at disassembly 1.28 l iter (1.35 US qt, 1.13 1mp qt) Radiator cap relief pressure 108 - 137 kPa fl. 1 - 1.4 kgf /c mJ, 16 - 20 psi) Recommended antifreeze PRO HONDA HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors. Standard coolant concentration 50% mi xture with soft water 1 1 1-6

1997-1999 Honda CR250R OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed