1982-1983 CR480R Service & Repair Manual

SHOP MANUAL CR4BOR

IllrFJi ·;~· ,ii~; I~b~ i i~!a;-~/n:d~': ·': Q:re:'~Q~':"~ o:n~.g~p:o: ,",:·1~ t~ ~f R s!~~~er ;o ~~J~! j~rY ~~!!s C o ~ life if instructions are not !olfowed. CAUTIO N: indicQtes a possibiliry a/personal inJury or equipmcllt damage if ;/lSlnlctlOI/S arc lIut fullowed NOTE: Gives helpful information. Detailed descnptlons 01 standard workshop procedures . safety ormcio les and service operations are not mcludec . II IS Imporlan! to note that this manual conta ins some warnings and cautions agamst some specific service methODS wh i ch rould cause PERSONAL INJ URY 10 service perronnel or could dam<Jge a vehicle or render it unsafe P lease understand that those warn ings could not cover all can cell/able ways In .... hich service, whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceIVable way . nor cou ld Honda inve5 l ula te all such way~. Anyone uSing senllce procedures or tools , whether or not recommended by Honda musr satisfy himself thoroughly that neither personal safety nor vehicle safety wi ll be jeo pard ized by the service method or tOO lS selected .

~ HON'DA ~ CR480R HOW TO USE THIS MANUAL Fo llow the competition Maintenance Sche· du le recommendations (Page 1-8) to ensure that the vehicle is always in peak operating condition. Performing the first scheduled maintenance is very important. It compen- sates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motorcycle. while sections 4 through 12 describe parts of the motorcycl e, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sect ions start wi th an assembly or system illustration and specifications, torque va lues, general instructions, tools and troubleshooting for the sectio n. The subsequent pages give detailed procedures for the section. If you are not familiar with this motorcycle, read TECHNICAL FE AT U RES, secti on 13 . If you don 't know the source of the trouble, see section 14, TROUB LE SHOOTING. Refer to the addendum at the back of the Shop Manual for 1983 CR 4 80R service i nformation. HO N DA MOTOR CO. , LTD. Service Publications Office Date of Issue: November, 1982 w Z " Z w C American Honda Motor Co ., Inc. 1982 - All Rights Reserved CONTENTS GENERAL INFORMATION LUBRICATION PR AND PRERACE FUEL SYSTEM ENGINE REMOVAl/INSTALLATION CYLINDER HEAD/ CYLINDER / PISTON I CRANKCASE FRONT WHEE l/ BRAKE/ REAR WHEE l/ BRAKE/ SUSPENSION REAR FENDER/ EXHAUST PIPE IGNITION SYSTEM TECHNICAL FEATURES TROUBLESHOOTING ' 83 C R480R ADDENDUM

~ HONDA ~ CR480R 1. GENERAL INFORMATION GENERAL SAFETY 1- 1 SERVICE RULES 1- 1 SPECI F ICATIONS 1- 2 TOROUE VALUES 1-4 SPECIAL TOOLS/COMMON TOOLS 1-5 WIRING DIAGRAM 1-6 CABLE AND HARNESS ROUTING 1-7 COMPETITION MAINTENANCE SCHEDULE 1-8 OPTIONAL PARTS GENERAL SAFETY 'M· Wi@i If the engine //lust be running to do some work, moke sure the area is wel/-I'eJuiiat ed. Never run th e engine in a dosed area. The exhauH contains poisQuolls carbon monoxide gas. SERV ICE RULES 1- 9 Gasoline is extremely flammable and is explosive under certain cOl/dilioll s. Do nOI smoke or aI/ ow flames or sparks ill ),our working area. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their eQuivalent. Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools des igned for this product. 3. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. 4. When torquing bolts or nuts, being with larger<iiameter or inner bolt first, and tighten to the specified torque diagonally, in incremental steps unless a particular sequence is specified. 5. Clean pans in non·flammable or high flash point solvent upon disassembly . lub ricate any sliding surfaces before reassembly. 6. When installing a new oil seal, make sure that the sealing lip is lubricated with grease. If an oit seal and related pans have been washed, apply proper grease to the lip of the oit seal. 7. After reassembly, check all parts for proper installation and operation. 8. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. Date of Issue; September, 198 1 © HONDA MOTOR CO., LTD. 3 1 -1 II

GENERAL INFORMATION SPECIFCATIONS ITEM DIMENSION Overall length Overall wid th Overall height Wheel base Seat height Footpeg height Ground clearance Dry weight (without muffler! spark arrester) FRAME Tvpe F. suspension, travel R. suspension, travel F. tire size, pressure R. tire size, pressure F. Brake, lining area A. brake , lining area Fuel capacity Caster angle Trai l length Front fork oil capacity (Standard) ENGINE TV"" Cylinder arrangement 80re and stroke Displacement Compression ratio Transmission oil capacity CARBURETOR TV"" Ma in jet (standard) Slow jet (standard) Air screw opening Float height DRIVE TRA IN Clutch type Transm ission Primary reduction Gear ratio I Gear ratio II Gear ratio III Gear ratio IV 1-2 2,200 mm 845mm 1,220 mm 1,505 mm 980mm 430mm 340mm 103 kg Cj\ HONDA @ CR480R 86.6 in 33.3 in 48.0 in 59.3 in 38.6 in 16.9 in 13.4 in 227 Ib Semi-double cradle Telescopic fork. travel 305 mm (12.0 in) Pro link, travel 305 mm (12.0 in) 3.00-21 (4 PAl. air pressure 14 psi (100 kpa. 1.0 kg/ em') 5.10-18 (4 PAl , air pressure 14 ps i (100 kpa, 1.0 kg/cm 2 ) Internal expanding shoes, lining swept areas 102.1 em' (15 .8 inl) Internal expanding shoes, lining swept areas 102.1 cm' (15.8 in' ) 4 9.31 I 2.5 U.S. gal, 2.0 Imp gal 62° 50' 107 mm 4 .2 in 560cc 18 .90z Air cooted, 2-stroke Single 7° inclined from vertical 89x76mm 3.5 x 3.0 in 472 cm 3 28.8 cu-in 6.7 : 1 0.82 I 0.84 U.S. Qt . 0 .70 Imp Qt Piston valve # 178 # 68 1-1/2 turn 22 .5 mm I 0. 88 in Wet, multi-plate type 4-speed , constant mesh 2.500 1. 625 1.211 0. 952 0.792 Date of Issue: September. 1981 ~ HONDA MOTOR CO .• lTD.

~ HONDA ~ CR480R ITEM DRIVE TRAIN Final reduction Gear sh ift pattern ELE CTR I CAL I gn it ion Starti ng system Spark plug Date of Issue: September, 1 98 1 © HONDA MOTOR CO., LTD. GENERAL INFORMATION 3.857 left foot operated return system 1·N·2·3·4 COl Kickstarter (CHAMPION) QN-86 (NGK) 8R8EG (N O) W24 ESR -V (QN · 2GI (BRSEV) (W24ESA ·GI 5 1-3

GENERAL INFORMATION TORQUE VALUES • ENG I NE Cylinder head Cvlinder Item Alternator Itywheel Clutch center nUl Clutch $Pring bolt Left Cfilf'lkcase (;olltlr Carburetor insulator Primary drive gear Alternator cover • FRAME Sleering Item nut Fork bridge Handlebar upper holders Handlebar lower holders Ste ering starn pinch bolts Front axle Fronl ade holder Rear axle :mah Engine mounting bolts Final driven sprocket Rear brake tOrque ilrm Rear $hock absorbers OOmm bolt) I 8 mm bold liront) (rear) (uwer) !lower) Stee1'ing stem adjuster nut From spokes Rear spokes Bead stopper Front spoke flange Sw;ngarm pillot bolt Front fo<k boh Front fork drain bolt Rear shock arm (swingarm side) (:mock rod side) Rear :mod; rod Front fork lOCket bolt Rear shock spring lock nut Threi!ld diB. )( pitCh N·m 8 l< 1.25 25- 29 lOx 1.25 38 - 38 12)(1 . 25 55-65 20 )( 1.0 55-65 Sit 1.0 8- 12 6)( 1.0 7- 10 6)( 1.0 7- 10 10)(1.25 40- 50 6 x 1.0 2-4 24 x 1.0 80- 120 8)( 1.25 18- 25 8 II 1.25 18- 25 10 K 1.25 30---40 8" 1.25 18- 25 12,.1.25 55- 70 6 x 1.0 10-12 18 I< 1.25 85 - 105 10" 1.25 38-48 8 I< 1.25 24- 29 8 I< 1.25 32- 37 8 I< 1. 25 18- 25 8 x 1.25 18- 25 10 I< 1.25 40-50 lOx 1.25 38 - 48 26 x 1.25 1.0- 2.0 8C. 3.5 2.5- 5.0 BC. 3.5 2.5- 5.0 8 I< 1.25 10- 15 6 x 1.0 14-16 16 I< 1.5 80 - 100 40 I< 1.0 15- 30 4 I< 0 .7 1.0- 2.0 12 I< 1.25 55- 70 10 I< 1.25 40 - 50 10 I< 1.25 40 - 50 18 I< 1.0 50- 60 54)( 1.5 80-100 r::iJ\ HONDA ~ CR480R TorQue k9~ ft-lb 2.5-2.9 17-21 3.8--4.8 28-35 5.5- 6.5 40--47 5.5- 6.5 40--47 0.8-1.2 6- 9 0.7- 1.0 5-7 0 .7- 1.0 5-7 4.0- 5.0 29- 36 0.2 - 0.4 1.6- 3.5 8.0- 12.0 58- 87 1.8- 2.5 13- 18 1.8- 2.5 13- 18 3.0-4 .0 22-29 1.8- 2.5 13 - 18 5.5- 7.0 40- 51 1.0- 1.2 7- 9 8.5-10.5 62- 76 3.8-4.8 28- 35 2.4- 2.9 17-21 3.2- 3.7 23-27 1.8- 2.5 13-18 1.8- 2.5 13-18 4.0 - 5.0 29- 36 3.8-4.8 28- 35 0.1--0.2 0.7_1.4 0.25--0.5 1.8-4.3 0.25- 0.5 1.8--4.3 1.0- 1.5 7- 11 1.4- 1.6 10- 12 8.0- 10.0 58- 72 1.5- 3.0 11 - 22 0.1- 0.2 0.7- 1.4 5.5- 7.0 40-51 4.0- 5.0 29-36 4.0- 5.0 29- 36 5.0--6.0 36--43 8.0- tO.0 58- 72 The torque values listed above are for the most important tighten ing points . If a torque specification is not listed. use the standards given below. STANDARD TORQUES Size 6mm screw 6 mm hel<. bolt 8 mm he l<. bolt 10 mm hel<. boh 1-4 7-10 8- 12 18 - 25 30-40 Torque k9~ 0.7- 1.0 0.8- 1 .2 1.8- 2.5 3.0--4.0 h'lb 5-7 6- 9 13- 18 22- 29 6 Size N·m 6 mm flange nut to- 14 8 mm flange bolt 24 - 29 10 mm flange bolt 38--48 Torque k9~ h·lb 1.0- 1.4 7-1 0 2.4- 2.9 17- 21 3.8--4.8 28- 35 Date of Issue: September. 1981 © HONDA MOTOR CO .• LTO.

~ HONDA ~ CR480R SPECIAL TOOLS / COMMON TOOLS SPECIA L Description 27 x 17 mm lock nut wrench Retainer wrench 16 mm socket wrench 10 mm socket bit Crankcase puller Bearing driver Ball race driller Fork seal driver Driver attachment Fork piston handle holder Fork piston holder attachment Ball face remover Driver gear holder Needle bearing driver COMMON Flywheel puller Float gauge Universal holder Bearing driver outer (42 x 47 mml Bearing driver outer (52 x 55 mm) Bearing driver outer (62 x 6B mm) Bearing dr iver outer (32 x 35 mm) Driver handle outer A Driver pilot (17 mm) Driver pilot (22 mm) Driver pilot (25 mm) Dr iver pilot (20 mml DriverpHot (1Smm) Socket wrench (30 x 32 mm) Extension bar Nipple spanner (5.B x 6. 1) OPTIONAL Air gauge Pin spanner Flywheel puller bolt Da te of Issue: September, 1981 © HONDA MOT OR CO., L TO . GENERAL INFORMATION Tool No. Remark 07907 -4150000 Clutch nut and fork cap bolt 07910-4440000 Rear wheel bearing retainer 07916-3710100 Steering stem adjuster nut 07917-3710000 Front fork socket bolt 07937-4300000 Crankcase 07946-4300101 Steering stem bearing 07946-4300200 Steering stem bearing outer race 07947 -KASO l 00 Front Fork 07947-KA40100 Front Fork 07930-KA40200 Front Fork 07930-KA40 1 00 Front Fork 07953-KASOOOO Steering stem bearing 07924-KA50000 Primary drive gear 07946-KA50oo0 Swi ngarm pivot bearing 07733-0010000 Alternator 07401-0010000 Float level 07725 - 0030000 Drive sprocket and Alternator 07746-0010300 Rear wheel bearing and crankcase bearing 07746-0010400 Rear wheel bearing and crankcase bearing 07746 - 0010500 Crankcase bearing 07746-0010 1 00 Front wheel bearing 07749-0010000 07746 - 0040400 Crankcase bearing 07746-0041000 Crankcase bearing 07746-0040600 Rear wheel bearing 07746-0040500 Rear wheel bearing 07746 - 0040300 Front wheel bearing 07716-0020400 Stem nut 07716-0020500 Stem nut 07701-0020300 Spoke nipple 89301-KA4-811 Front fork 89201-KA4-S10 Rear shock spring 89202-KA4-810 89302 - KA4-S10 Alternator 7 1-5

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1982-1983 CR480R Service & Repair Manual

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