1995-2007 CR80R / CR85R CR80 CR85 Service & Repair Manual

HOW TO USE THIS MANUAL Follow the Competition Maintenance Schedule rec- ommendations (page 3-3 through 3-6) to ensure that the vehicle is always in peak operating condition . Sections 1 and 3 apply to the whole motorcycle. Sec- tion 2 describes procedures for remova l/ installation of components that may be required to perform service described in the following sections. Sections 4 through 13 describe parts of the motorcycle, grouped according to locations. Find the section you want on this page, then turn to the table of contents on the first page of that section. Most sections start wi th an assembly or system illus- tration, service information and troubleshooting for the section. The subsequent pages give detailed pro - cedures. If the don't know the source of a problem, go to section 15, TROUBLESHOOTING_ w Z C; Z w CONTENTS GENERAL INFORMATION MAINTENANCE FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION REAR WHEEL/SUSPENSION HYDRAULIC DISC BRAKE IGNITION SYSTEM WIRING DIAGRAM TROUBLESHOOTING

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to Ihese symbols. it would be explained specifically in the texi without the use of the symbol. !:!~ .... Replace the panls) with new onels) before assembly. r- [S TOOL I Use special tool. [_ ·"7_ 1 Use optional tool. Use the same procedure you use to order parts. 'I Use recommended engine oil, unless otherwise specified. - , Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). - .-.. Use multi ·purpose grease (lithium basad 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 manufac tured by Dow Corning . U.S.A. Multi · purpose M·2 manufa ctured by Mitsubishi Oil. Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl 1i2 or equivalent). ~ Example: Molykote- G·n Paste manufactured by Dow Corning . U.S.A. Honda Moly 60 (U.S.A. only) Roeol ASP manufactured by Rocol Limited, U .K. Roeol Paste manufactured by Sumico Lubricant, Japan ..--riSit1 Use silicone grease. --- C)"" Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ,",' &lID! Apply sealant. I Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid unless otherwise specified. .. I Use Fork or Suspension Fluid.

General Safety Model Identification Specification Torque Values GENERAL SAFETY Carbon Monoxide 1-1 1-3 1-4 1-26 If th e engine must be r unning to do some work, make sure the ar ea is well ventilated. Never r un the en gine in an enclosed area . The exhaust contains poisonous carbon monox - Ide gas that un cause loss of conscioisness and may lead to death . Run the engine in an open area or with an exhaust evac- uation system in an enclosed area. Gasoline Work in a well ventilated area. Keep cigarett es. flames or sparks away fr om the wo rk area or whe re gaso l ine is stored. Gasoline is 8.lCtremely flammable and is explosive under certain conditions . KEEP OUT OF REACH OF CHILDREN. Hot Component s Engine and 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 eKhaust system have cooled before these 1. GENERAL INFORMATION Tools lubrication & Seal Points Cable & Harness Routing Optional Parts list Used Engine/Transmission Oil 1-29 1 -31 1-33 1-44 Used engine oil (or transmission oil in two-strokes) 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 a 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 Dust Never use an air hose or dry brush to dean brake assem· blies. Use an OSHA-app r oved vacuum deaner or alter- nate me t hod approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers. Inhaled asbestos fibers have been found to cause Brake Fluid CAUTION Spilling f luid 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 condi tions, the ethylene glycol in engine coolant is combustible and its flame is nol visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. A void spilling engine cool ant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and bum without a vis- ibleflame . Coolant (ethylene glycol! can cause some skin irri- tation and is poisonous if swa llowed. KEEP OUT OF REACH OF CHILDREN. Keep out of reach of pets . Some pets are attracted to th e smell and taste of coolant and can die if they drink it. 00 not remove the radiator cap when the engine is hot . The coolant is under pressure and could sca ld CAUTION Using coo lant with silicate inhibitiors may cause permature wear of water pump seals or blockage of radiator passage. Using tap wa ter may cause engine damage. If it contacts your skin, wash th e affected areas immedi - ately with soap and water. If it contacts your eyes, flush them thoroughly with fresh water and get immedia te medical attention. If it is swallowed, the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical atlention. 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 absorbers with a gas-filled reservor: Use only nitrogen to pressuri ze the shock absorber. The use of an unstable gas can cause a fire or explosion r es ulting in serious injury. The shock absorber contains nitrogen under high pressure . Allowing fire or heat near the shock absorber co uld lead to an explosion that could r esult in serious injury. Failure to relea se the pressure from a sh ock absorber before disposing of it may lead to a possible eKplosion and serious injury if it is heated or To prevent 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 oil in a manner acceptable to the En vironmental Protection Agency (EPA ). ,. Use genuine Honda or Honda - recommended parts and lubricants or their equivalents Parts that do not meet Honda 's design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English 'asteners. The use of incorrect tools and fasteners may damage the motorcycle. 4. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. 5. When tightening a series of bolts or nuts, begin with the l arger-diameter of inner bolts first, and tighten to the speci-fied torque diagonally, in increment al steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembl y. 7. After assembly, check all parts for proper installation and operation. S. Route all electrical wires as shown on pages '-33 through '- 43 , Cable and Harness Routing. 1-2

MODEL IDENTIFICATION '95 model After '02: '95 s hown: The engine serial number is stamped on the lower left side of the crankcase. GENERAL INFORMATION ' 96- ' 02 '95 shown : The frame serial number is stamped on t he right side of the steering head. '95 shown: The carburetor identification number is on the right side of the carburetor. 1-3

GENERAL INFORMATION SPECIFICATIONS '95 ITEM SPECIFICATIONS DIMEN SIONS Overall length 1,815 mm (71.5 in) Overall width 745 mm (29.3 in) Overall height 1,080 mm (42.5 in) Wheelbase 1,255 mm (49.4 in) Seat height 810 mm (31.9 in) Footpeg height 390 mm (15.4 in) Ground clearance 310 mm 112.2 in) Dry weight 63 .0 kg (138.9 Ibs) FRAME Type Semi-double cradle Front suspension Telescopic fork Front axle travel 275 mm (10.8 in) Rear suspension Pro-link Rear axle travel 280 mm (11.0 in) Rear damper Decarbon type with nitrogen filled reservoir Fronllire size 70/100-17 40M Rear tire size 90/ 100-1449M Tire brand (BAIDGESTONE ) Fr ont M23 Rear M22 Front brake Hydraulic single disc Front brake swept area 177.0 cm 1 (27.4 sq in) Rear brake Hydraulic single disc Rear brake swept area 128.9 cm 1 ( 20 .0 sq in) Caster angle 26" 40' Trail length 79 mm 13. 1 in) Fuel tank capacity 5 liters 11.3 US gal. 1.1 Imp gal) ENGINE Type liquid cooled, 2-stroke Cylinder arrangement 15" inclined from vertical Bore and stroke 47 .0 x 47 .8 mm 11.85 x 1.88 in) Displacement 82.9 em' (5.06 cu in) Compression ratio 8.4 : 1 lubrication system Fuel/oil pre·mixed Air filtration Oiled polyurethane foam Crankshaft type Assembly type Port timing Intake Open Reed valve controlled Close Reed valve controlled Exhaust Open 93 .45" BBDC Close 94 .61 " ABDC Scavenge Open 63 .05" BBDC Close 64 .38" ABDC Engine dry weight 14.3 kg (31.5 Ibs) 1-4

GENERAL INFORMATION - (c ant 'd) ITEM SPECIFI CA TION S CARBURETOR Type Piston valve Venturi diameter 28 mm (1.10 in ) DRIVE TRAIN Clutch type Wet, multi-plate Transmission 6-speeds, constant mesh Primary reduction 4.117 (70/17) Gear ratio 1st 2.333 (35/ 15 ) 2nd 1.722 (31 / 18) 3,d 1.400 (28/20) 4th 1.174 (27/23) 5th 1.000 (25/25) 6th 0.B85 (23/26) Final reduction 3.333 (50/ l5 ) Gearshift pattern Left foot operated return system l-N-2-3-4-5-6 ELECTRICAL Ignition system COl 1-5

GENERAL INFORMATION '9 6 - '02 - CR80R ITEM SPECIFICATIONS DIMENSIONS '96, '97: Overall length 1,831 mm (72.1 in) Overall width 743 mm (29.3 in) Overall height 1,132 mm (44.6 in) Wheelbase 1,266 mm (49.8 in) Seat height 842 mm (33. 1 in) Footpeg height 396 mm (15.6 in) Ground clearance 330 mm (13.0 in) Dry weight 65.0 kg (143.3Ibs) '98: Overall length 1,839 mm (72.4 in) Overall width 748 mm (29.4 in) Overall height ',,20mm(44.' in) Wheelbase 1,266 mm (49.8 in) Seal height 825 mrn (32.5 in) Footpeg height 378 mm (14.9 in) Ground clearance 320 mm (12.6 in) Dry weight 64.8 kg (142.9 Ibs) Aher '98: Overall length 1,787 mm pO.4 in) Overall width 772 mm (30.4 in) Overall height 1,120 mm (44.1 in) Wheelbase 1,246 mm (49.1 in) Seat height 833 mm (32.8 in) Footpeg height 388 mm (15.3 in) Ground clearance 320 mm (12.6 in) Dry weight 65.0 kg (143.3 Ibs) FRAME Type Semi-doub le cradle Front suspension Telescopic fork Front suspension stroke 275 mm (10.8 in) Front axle travel 246 mm (9.7 in) Rear suspension Pro-link Rear axle travel 275 mm (10.8 in) Rear damper Decarbon type with nitrogen filled reservoir Front tire size 70/100-17 40 M Rear tire size 90 /100-14 49M Front tire brand K490G (Dunlop) Rear tire brand K695 (Du nlo p) Front brake Hydraulic single di sc Front brake swept area 358.1 cm 2 (55.5 inl ) Rear brake Hydraulic single disc Rear brake swept area 257.8 cm2 (40.0 inl ) Caster angle '96, '9 7: 26 0 57' ' 98 : 27° 5' ' 99 -' 02 26°43' Trail length ' 96 , '97: 77.4 mm (3.05 in) ' 98 : 8 1.0 mm (3.19 in) '99 - ' 02 75.0 mm (2.95 in) Fuel tank capacity 5.8 liters (1.5 US gal, 1.31mp gal) 1-6

1995-2007 CR80R / CR85R CR80 CR85 Service & Repair Manual

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