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CR85RB Expert (2005)
Owner's Manual
134 pgs3.21 Mb0

Honda CR85 Expert (2005), CR85RB Expert (2005) Owner's Manual

2005 Honda CR85/85RB EXPERT OWNER’S MANUAL & COMPETITION HANDBOOK
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Introduction
Congratulations on choosing your Honda CR motocross motorcycle.
Your CR is a high performance racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned, closed-course events by experienced riders only.
Be aware that motocross is a physically demanding sport that requires more than just a fine motorcycle. To do well, you must be excellent physical condition and be a skillful rider. For the best results, work diligently on your physical conditioning and practice frequently.
Before riding, take time to get acquainted with your CR and how it works. To protect your investment, we urge you to take responsibility for keeping your CR well maintained. Scheduled service is a must, of course. But it’s just as important to observe the break-in guidelines, and perform all the pre-ride and other periodic checks detailed in this manual.
You should also read the owner’s manual before you ride. It’s full of facts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a table of contents, a detailed list of topics at the beginning of each section, and an index at the back of the book.
As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your Honda, other property, or the environment.
Unless you are mechanically qualified and have the proper tools, you should see your Honda dealer for the service and adjustment procedures discussed in this manual.
The official Honda Service Manual for your CR is available (page 120). It is the same manual your dealer uses. If you plan to do any service on your CR beyond the standard maintenance procedures in this manual, you will find the Service Manual a valuable reference.
If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your CR best and is dedicated to your complete satisfaction.
Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information.
You may also want to visit our website at www.honda.com.
Happy riding!
NOTICE
Introduction
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A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.
To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.
Safety Messages are preceded by a safety alert symbol and one of three signal words: DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good judgement.
Safety Messages
DANGER
WARNING
CAUTION
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Contents
MOTORCYCLE SAFETY................................1
Important Safety Information...............................2
Important Safety Precautions..........................2
Important Message to Parents ........................2
Accessories & Modifications ...............................3
Safety Label .........................................................4
OPERATING CONTROLS ..............................5
Component Locations ..........................................6
BEFORE RIDING..............................................7
Are You Ready to Ride?.......................................8
Is Your Motorcycle Ready to Ride?.....................9
Pre-ride Inspection..........................................9
BASIC OPERATING INSTRUCTIONS .......11
Safe Riding Precautions................................12
Starting & Stopping the Engine .........................13
Preparation ....................................................13
Starting Procedure ........................................13
Flooded Engine.............................................13
How to Stop the Engine................................14
Shifting Gears.....................................................15
Break-in Guidelines ...........................................16
SERVICING YOUR HONDA.........................17
Before You Service Your Honda
The Importance of Maintenance ........................18
Maintenance Safety............................................19
Important Safety Precautions........................19
Maintenance Schedule .......................................20
General Competition Maintenance ....................22
Before & After Competition Maintenance.........26
Between Motos & Practice Maintenance .....26
After Competition Maintenance ...................27
Service Preparations
Component Locations ........................................28
Seat Removal .....................................................29
Fuel Tank Removal ............................................30
Subframe Removal.............................................32
Service Procedures
Fluid & Filters
Fuel System........................................................34
Transmission Oil ................................................36
Coolant ...............................................................38
Air Cleaner .........................................................40
Engine
Throttle ...............................................................42
Clutch System ....................................................44
Spark Plug ..........................................................46
Cylinder System .................................................47
Chassis
Suspension..........................................................52
Brakes.................................................................57
Wheels................................................................61
Tires & Tubes .....................................................62
Drive Chain ........................................................64
Expansion Chamber ...........................................67
Additional Maintenance Procedures ..................68
Appearance Care ................................................69
ADJUSTMENTS FOR COMPETITION ......71
Front Suspension Adjustments...........................72
Rear Suspension Adjustments............................80
Suspension Adjustments for Track
Conditions ..............................................84
Suspension Adjustment Guidelines....................85
Carburetor Adjustments & Tuning Tips.............88
Chassis Adjustments...........................................95
Gearing ...............................................................96
Tire Selection for Track Conditions...................97
Personal Fit Adjustments ...................................98
TIPS ..................................................................99
Transporting Your Motorcycle .........................100
Storing Your Honda..........................................101
You & the Environment ...................................102
Troubleshooting................................................103
TECHNICAL INFORMATION...................105
Vehicle Identification .......................................106
Specifications ...................................................107
Torque Specifications.......................................109
High Altitude Carburetor Adjustment ..............111
Oxygenated Fuels.............................................112
Competition Logbook.......................................113
Optional Parts List............................................115
Spare Parts & Equipment .................................117
Wiring Diagram................................................118
CONSUMER INFORMATION....................119
Authorized Manuals .........................................120
Contacting Honda.............................................121
Your Honda Dealer...........................................122
The Honda Rider’s Club (USA only) ..............123
TABLE OF CONTENTS ...............................124
INDEX .............................................................126
QUICK REFERENCE
Contents
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Motorcycle Safety
This section presents some of the most important information and recommendations to help you ride your CR safely. Please take a few moments to read these pages. This section also includes information about the location of the safety label on your CR.
Important Safety Information...............................2
Important Safety Precautions..........................2
Important Message to Parents ........................2
Accessories & Modifications ...............................3
Safety Label .........................................................4
Motorcycle Safety 1
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Important Safety Information
Important Safety Precautions
Your CR can provide many years of pleasure, if you take responsibility for your own safety and understand the challenges you can meet in competitive racing.
As an experienced rider, you know there is much you can do to protect yourself when you ride. The following are a few precautions we consider most important.
Never Carry a Passenger.
Your CR is designed for one operator only. Carring a passenger can cause an accident in which you and others can be hurt.
Wear Protective Gear.
Whether you’re practicing to improve your skills, or riding in competition, always wear an approved helmet, eye protection, and proper protective gear.
Take Time to Get to Know Your CR.
Because every motorcycle is unique, take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine, and yourself, in competition.
Learn and Respect Your Limits.
Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, illness and fatigue can reduce your ability to perform well and ride safety.
Don't Drink and Ride.
Alcohol and riding don't mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse
with every additional drink. So don't drink and ride, and don't let your friends drink and ride either.
Keep Your Honda in Safe Condition.
Maintaining your CR properly is critical to your safety. A loose bolt, for example, can cause a breakdown in which you can be seriously injured.
Important Message to Parents
Your child's safely is very important to Honda. That's why we urge you to read this message before you let any young person ride this motorcycle. Competitive riding can be fun. But bad judgement can result in injury, and we don't want that to happen. As a parent, you can help prevent accidents by making good decisions about when and how your youngster rides this motorcycle.
• Remember, this CR is designed only for competition use by experienced junior riders. It is an operator only model, and the maximum load capacity is 150 lbs. Rider weight must not exceed this limit.
• The junior rider must be fall enough to hold the motorcycle up while straddling it with both feet on the ground. He or she must also be strong enough to pick up the motorcycle if it is on its side.
• The parent and junior rider must be fully familiar with the motorcycle, the motorcycle controls and control functions. Both must also Fully understand everything in this manual before riding begins.
• For your child's safely, be sure to make pre-practice and pre-race inspections, and impress on the junior rider the importance of checking all the items thoroughly before riding.
2
Motorcycle Safety
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Important Safety Information
Accessories & Modifications
Installing non-Honda accessories, removing original equipment, or modifying your CR in any way that would change its design or operation, could seriously impair your CR’s handling, stability, and braking, making it unsafe to ride.
Motorcycle Safety 3
WARNING
Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed.
Follow all instructions in this owner’s manual regarding modifications and accessories.
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4 Motorcycle Safety
Safety Label
Read this label carefully and don’t remove it.
If the label comes off or becomes hard to read, contact your Honda dealer for replacement.
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Operating Controls 5
Operating Controls
Read this section carefully before you ride. It presents the location of the basic controls on your CR.
Component Locations ..........................................6
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6 Operating Controls
Component Locations
clutch lever
kickstarter
engine stop button
fuel valve shift lever
rear brake pedal
throttle grip
front brake lever
choke knob
fuel fill cap
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Before Riding 7
Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and what items you should check on your CR.
For information about suspension, carburetor, and other adjustment for competition, see page
71.
Before Riding
Are You Ready to Ride?.......................................8
Is Your Motorcycle Ready to Ride?.....................9
Pre-ride Inspection .............................................9
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8 Before Riding
Are You Ready to Ride?
Before riding your CR for the first time,we should also that you read this owner’s manual, make sure you understand the safety messages, and know how to operate the controls.
Before each ride, it’s also important to make sure you and your CR are both ready to ride.
For information about suspension, carburetor, and other adjustments, see page 71.
Whether you’re preparing for competition or for practice, always make sure you are.
• In good physical and mental condition
• Free of alcohol and drugs
•Wearing an approved helmet, eye protection, and other appropriate riding gear
Although complete protection is not possible, wearing the proper gear can reduce the chance or severity of injury when you ride.
WARNING
Not wearing a helmet increases the chance of serious injury or death in a crash.
Be sure you always wear a helmet, eye protection and other protective apparel when you ride.
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Before Riding 9
Is Your Motorcycle Ready to Ride?
Competitive riding can be tough on a motorcycle, so it’s important to inspect your CR and correct any problems you find before each ride. Check the following items (page numbers are at the right):
Pre-ride Inspection
Check the following before each ride:
•Transmission oil level...................................37
• Coolant for proper level................................38
• Cooling system and hoses for condition.......39
• Spark plug for proper heat range, carbon fouling and high tension cord terminal for
looseness .......................................................46
• Air cleaner for condition and
contamination................................................40
• Clutch operation and freeplay.......................44
• Steering head bearings and related parts
for condition..................................................68
• Carburetor throttle operation ........................42
•Tires for damage or improper inflation
pressure ........................................................62
• Spokes for looseness.....................................61
• Rim locks for looseness................................61
• Front and rear suspension for proper
operation .................................................52, 53
• Front and rear brakes, check operation ........54
• Drive chain for correct slack and adequate
lubrication .....................................................64
• Drive chain guide, sliders and guide rollers
for damage or wear.......................................64
• Expansion chamber springs for damage or
lack of tension...............................................67
• Every possible part for looseness (such as cylinder head nuts, carburetor insulator bolts, engine mounting bolts, axle nuts, drive chain adjusters, drive chain guide, handlebar holder bolts, kickstarter mounting bolts and wire
harness connectors).......................68, 109, 110
WARNING
Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed.
Always perform a pre-ride inspection before every ride and correct any problems.
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10 Before Riding
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Basic Operating Instructions 11Basic Operating Instructions 11
Basic Operating Instructions
This section gives basic information on how to start and stop your engine as well as break-in guidelines.
Safe Riding Precautions .....................................12
Starting & Stopping the Engine .........................13
Preparation ....................................................13
Starting Procedure ........................................13
Flooded Engine.............................................13
How to Stop the Engine................................14
Shifting Gears.....................................................15
Break-in Guidelines ...........................................16
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12 Basic Operating Instructions12 Basic Operating Instructions
Basic Operating Instructions
Safe Riding Precautions
Before riding your CR for the first time, please review the Important Safety Precautions beginning on page 2 and the previous section, titled Before Riding.
For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Yo ur CR’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.
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Basic Operating Instructions 13Basic Operating Instructions 13
Starting & Stopping the Engine
Always follow the proper starting procedure described below.
Your CR can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter.
Preparation
Make sure that the transmission is in neutral. Turn the fuel valve ON.
Starting Procedure
Always follow the proper starting procedure described below.
Check the transmission oil and coolant levels before starting the engine (page 37, 38).
Cold Engine Starting
1. Turn the fuel valve (1) ON.
2. Shift the transmission into neutral.
3. Pull the choke knob (2) up.
4. With closed throttle, operate the kickstarter. Starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion.
5. After the engine starts, the choke knob should be pushed down as soon as possible to prevent spark plug fouling.
6. Allow the engine to warm up for at least 2 minutes before riding off, preferably until the side of the cylinder is very warm to the touch through your riding glove. Slowly increase rpm and don’t blip the throttle. Warming the engine is important to prevent cold seizures.
W
arm Engine Starting
1. Turn the fuel valve ON.
2. Shift the transmission into neutral.
3. Push the choke knob down.
4. Open the throttle (1/8 – 1/4) and operate the kickstarter.
Flooded Engine
If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine:
1. Shift the transmission into neutral.
2. Push the choke knob down all the way to OFF.
3. Open the throttle fully.
4. While pushing the engine stop button, crank the engine several times with the kickstarter.
5. Release the engine stop button.
6. Follow the Warm Engine Starting procedure.
(1) fuel valve (2) choke knob
(1)
(1)
(2)
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14 Basic Operating Instructions
Starting & Stopping the Engine
14 Basic Operating Instructions
How to Stop the Engine
Normal Engine Stop
1. Shift the transmission into neutral.
2. Turn the fuel valve OFF.
3. Lightly open the throttle (1) 2 – 3 times, and then close it.
4. Depress and hold the engine stop button (2) until the engine stops completely.
Failure to close the fuel valve may cause the carburetor to overflow, fill the crankcase with fuel and result in hard starting.
Emer
gency Engine Stop To stop the engine in an emergency, press the engine stop button.
(1) throttle (2) engine stop button
(1)
(2)
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Basic Operating Instructions 15
Shifting Gears
1. After the engine has been warmed up, the
motorcycle is ready for riding.
2. While the engine is idling, pull in the clutch
lever and depress the shift lever to shift into 1st (low) gear.
3. Slowly release the clutch lever and at the
same time gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start.
When moving off from a standing start, be careful not to use too much throttle. The motorcycle may "wheelie" over backwards.
4. When the motorcycle attains a moderate
speed, close the throttle, pull in the clutch lever and shift to 2nd gear by raising the shift lever.
5. This sequence is repeated to progressively
shift to 3rd, 4th, 5th, and 6th, (top) gear. Raise the shift lever to shift to a higher gear and depress it to downshift. Each stroke of the shift lever engages the next gear is sequence. The shift lever automatically returns to the horizontal position when released.
NOTICE
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16 Basic Operating Instructions
Break-in Guidelines
Help assure your CR’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration.
This same procedure should be followed each time when:
• piston is replaced
• rings are replaced
• cylinder is replaced
• crankshaft or crankshaft bearings are replaced
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Servicing Your Honda 17Servicing Your Honda 17
Servicing Your Honda
Keeping your CR well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun.
To help keep your CR in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good.
An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual (page 122).
Before You Service Your Honda
The Importance of Maintenance ........................18
Maintenance Safety............................................19
Important Safety Precautions........................19
Maintenance Schedule .......................................20
General Competition Maintenance ....................22
Before & After Competition Maintenance.........26
Between Motos & Practice Maintenance .....26
After Competition Maintenance ...................27
Service Preparations
Component Locations ........................................28
Seat Removal .....................................................29
Fuel Tank Removal ............................................30
Subframe Removal.............................................32
Service Procedures
Fluids & Filters
Fuel System........................................................34
Transmission Oil ................................................36
Coolant ...............................................................38
Air Cleaner .........................................................40
Engine
Throttle ...............................................................42
Clutch System ....................................................44
Spark Plug ..........................................................46
Cylinder System .................................................47
Chassis
Suspension..........................................................52
Brakes.................................................................57
Wheels................................................................61
Tires & Tubes .....................................................62
Drive Chain ........................................................64
Expansion Chamber ...........................................67
Additional Maintenance Procedures ..................68
Appearance Care ................................................69
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18 Servicing Your Honda18 Servicing Your Honda
WARNING
Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed.
Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.
The Importance of Maintenance
Keeping your CR well-maintained is absolutely essential to your safety. It’s also a good way to get maximum performance during each moto. Careful pre-ride inspections and good maintenance are especially important because your CR is designed to be ridden in off-road competition.
Remember, proper maintenance is your responsibility. Be sure to inspect your CR before each ride and follow the Maintenance Schedule in this section.
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Servicing Your Honda 19Servicing Your Honda 19
Maintenance Safety
This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.
Important Safety Precautions
• Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation
whenever you operate the engine.
Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching.
Injury from moving parts. Do not run the engine unless instructed to do so.
• Read the instructions before you begin, and make sure you have the tools and skills required.
•To help prevent the motorcycle from falling over, park it on a firm, level surface, using the optional work stand or a maintenance stand to provide support.
•To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a non-flammable (high flash point) solvent such as kerosene —not gasoline— to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.
WARNING
Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.
Always follow the procedures and precautions in this owner’s manual.
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20 Servicing Your Honda20 Servicing Your Honda
Maintenance Schedule
To maintain the safety and reliability of your CR, regular inspection and service is required as shown in the Maintenance Schedule that follows.
The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual.
The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment. Therefore, we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools. Procedures for items in this schedule are provided in a service manual available for purchase from your dealer (page 121).
Service intervals in the maintenance schedule are expressed in terms of races and riding hours. To avoid overlooking required service, we urge you to develop a convenient way to record the number of races and/or hours you ride.
If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CR best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability.
Perform the pre-ride inspection (page 9) at each scheduled maintenance period.
Summary of Maintenance Schedule Notes and Procedures:
Notes:
1. Clean after every moto for dusty riding conditions.
2. Replace every 2 years. Replacement requires mechanical skill.
3. Replace after the first break-in ride.
Maintenance Procedures: I: inspect and clean, adjust, lubricate, or replace,
if necessary
C: clean L: lubricate R: replace
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Servicing Your Honda 21Servicing Your Honda 21
Maintenance Schedule
All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools.
Damage from competition use is not covered by the Distributor's Limited Warranty on your Honda.
Perform the Pre-ride Inspection at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.
Frequency
Item Throttle Operation Air Cleaner Spark Plug Radiator Coolant Cooling System Cylinder Head Decarbonizing Piston and Piston Rings Piston Pin and Connecting Rod Small End Bearing Reed Valve Transmission Oil Drive Chain Drive Chain Sliders Drive Chain Rollers Drive Sprocket Driven Sprocket Brake Fluid Brake Pad Wear Brake System Clutch System Control Cables Expansion Chamber/Silencer Suspension Swingarm/Shock Linkage Fork Oil Wheels/Tires Nuts, Bolts, Fasteners Steering Head Bearing
This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1. Clean after every moto (heat) for dusty riding conditions.
2. Replace every 2 years. Replacement requires mechanical skill.
3. Replace after the first break-in ride.
Ref. page
42 40 46 38 39 48 48 48 49 37
64 – 66
64 65 66 66
58, 59
60 57 44 68
67 52, 53 25, 53
54
61, 62, 63
68, 109, 110
68
Every 9 races
or about
22.5 hours
R
I
Every 3 races
or about
7.5 hours
R
C R
R R R
L R
Each race
or about
2.5 hours I
C
I I I
I, L
I I I I I I I I
I,L
I I
I I
Note
Note 1
Note 2
Note 2
Note 3
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22 Servicing Your Honda22 Servicing Your Honda
General Competition Maintenance
Perform maintenance on firm, level ground using the optional workstand, or equivalent support.
Use genuine Honda parts or their equivalent when servicing your CR.
Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling. Lubricate any sliding surface, O-rings, and seals before reassembling. Grease parts by coating or filling where specified.
After any engine disassembly, always install new gaskets, O-rings, cotter pins, piston pin clips, snap rings, etc. when reassembling. After reassembly, check all parts for proper installation and operation.
All Pre-ride Inspection Items
Refer to Pre-ride Inspection in your Owner’s Manual, page 9.
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Servicing Your Honda 23
Handgrips
Always use Honda Hand Grip Cement (U.S.A only) or Honda Bond A when replacing handgrips.
Throttle Grip
Align the “∆” mark on the throttle grip with the hole of the throttle cable guide. Left handlebar grip: Align the top of the waffle pattern on the grip with the clutch lever as shown in the illustration. Refer to the Service Manual for installation instructions.
For added security, you may choose to safety wire the hand grips to the handlebar and throttle to prevent the possibility of them loosening. Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the grip rubber so they will not snag your glove.
Servicing Your Honda 23
General Competition Maintenance
Air Cleaner
Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance. Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass. Inspect the air cleaner closely each time it’s serviced for evidence of small tears or seam separation. Keep a spare air cleaner oiled and ready to install, sealed in a plastic bag. Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre-serviced air cleaner between motos. Be careful not to over oil the air cleaner. While it is important to oil the air cleaner thoroughly, over oiling will cause an overall rich running condition, probably more noticeable off idle and in low rpm performance. Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium Base Grease, or an equivalent, is handy for this because any dirt that penetrates this sealing area will show up clearly (page 40). Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model. Using the wrong Honda air cleaner or a non-Honda air cleaner which is not of equivalent quality may cause
Transmission Oil
Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch. Frequent oil changes will also assure consistent performance of both shifting and clutch action (page 36).
Air Cleaner Housing Sealing
Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with silicone sealer if there is any doubt to its sealing integrity. Use Honda Thread Lock or an equivalent on the attaching studs. Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration.
Throttle Control
Remove the throttle control every few rides, clean the inside of the drum and the handlebar thoroughly, and apply a light coating of silicone lubricant. Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way. Move the handlebar from lock to lock to be sure there is no cable interference. Check to be sure the top of the carburetor is screwed on tight. Make certain the throttle operation is perfect after servicing and inspecting.
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Fuel Filter
Periodically drain the fuel from the tank, remove and clean the fuel valve/filter. Replace the fuel valve O-ring if there are any signs of damage or deterioration (page 35).
Fuel Contamination
Periodically drain the float bowl and inspect the carburetor for contamination from dirt (page 35).
Inlet Tract Sealing
Air leaks around the carburetor insulator and reed valve assembly should be cured by disassembling, cleaning and resealing with new gaskets and some sealing agent. Be careful not to overtighten the mounting bolts — this is the most common cause for leaks here. Inspect the mating surfaces, for warpage due to over-torquing.
Pressure/Vacuum Leak-Down Test
Perform this test at regular intervals to minimize the possibility of engine damage from air leaks.
24 Servicing Your Honda
General Competition Maintenance
Electrical Connectors
Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections, water shorts or corrosion. Additional corrosion protection is offered by using Honda Dielectric Grease on all electrical connections.
Engine Mounting Bolts
Make sure the engine mounting bolts are tightened to the proper torque specification. For added peace of mind, remove the nuts, clean the threads, and apply Honda Thread Lock or an equivalent prior to torquing the nuts.
Gaskets
Always use new gaskets when reassembling components.
Cylinder Removal
Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals. The tolerances are quite tight, so it’s important to keep these dowels absolutely clean (page 47).
Ignition
Remove the alternator cover and keep it off for a few hours after each washing to let condensation evaporate. Pull the flywheel rotor every few rides and clean it and its crankshaft mounting surface, the alternator stator, the ignition pulse generator pickup and the entire ignition cavity thoroughly. The presence of dirt between the ignition pulse generator and the flywheel makes the ignition control module compensate to maintain the ignition curve. Cleaning dirt from the ignition side main seal helps to prevent premature seal wear. Close inspection of this seal can reveal a leakage problem before engine damage occurs.
Spark Plug
Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range. Replace periodically as specified in the Maintenance Schedule (page 21).
Spark Plug Cap
Install a small plastic tie-wrap around the spark plug cap to reduce any possibility of it loosening or of water penetration.
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Servicing Your Honda 25
Brake Fluid Replacement
Refer to Brake Pad Wear in your Owner’s Manual, page 60. Brake Caliper Inspection: Be sure both the front and rear calipers are able to move freely on the caliper bracket pins. Check pad thickness periodically and replace when minimum thickness is reached. If the brakes fade when they are hot, inspect the pads for glazing or damage, and replace if necessary. Brake Fluid Replacement: Replace the hydraulic fluid in the brake system every two years. Replace the fluid more frequently if you subject your brakes to severe use. Heavy braking heats the brake fluid and it may deteriorate sooner than expected. Any type of riding, that requires frequent use of the brakes, such as in tight woods, can shorten the service life of brake fluid.
Water Pump Inspection Hole
After every race, check the inspection hole, located just below the water pump cover on the right crankcase cover. Clean away any clogged dirt or sand, if necessary. Look for coolant or oil leakage. Leaking coolant indicates a worn or damaged water seal. Leaking oil indicates a bad transmission oil seal. If replacement is necessary, both seals should be replaced.
General Competition Maintenance
Swingarm Pivot Lubrication
Clean, inspect and lubricate when servicing suspension linkage pivots. Be sure all of the suspension pivot seals are in good condition. Use Honda Moly 60 paste (U.S.A. only) or molybdenum disulfide paste (containing more than 40% molybdenum disulfide additive).
Suspension Linkage Lubrication
Disassemble, clean, inspect and lubricate all pivot bearings after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear. Use Honda Moly 60 paste (U.S.A. only) or molybdenum disulfide paste (containing more than 40% molybdenum disulfide additive).
Swingarm
Do not attempt to weld or otherwise repair a damaged swingarm. Welding will weaken the swingarm.
Footpegs
Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular-shaped file. Be aware that filing them too sharp will reduce boot sole lifespan. Sharpen only the points of the teeth. Filing the grooves deeper will weaken the footpegs. Be sure the pegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition.
Steering Head Bearings
Periodically clean, inspect and regrease the steering head bearings — especially if wet, muddy or extremely dusty courses are encountered often.
Fork Oil/Performance
Disassemble, clean and inspect the fork and replace the oil regularly. Contamination due to the tiny metal particles produced from the normal action of the fork, as well as normal oil breakdown, will deteriorate the performance of the suspension. Refer to the Honda Service Manual. Use only Pro Honda HP Fork Oil 5W (U.S.A. only) or equivalent which contains special additives to assure maximum performance of your CR’s front suspension.
Frame
Because your CR is a high-performance machine, the frame should not be overlooked as part of your overall competition maintenance program. Periodically inspect the frame closely for possible cracking or other damage. It makes good racing sense.
Spokes
Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact points seat-in, the spokes may need to be retightened. Once past this initial seating-in period, the spokes should hold their tension. Still, be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis (page 61).
Nuts, Bolts, Etc
Application of a thread locking agent to essential fasteners offers added assurance and security. Remove the nuts, clean the threads of both the nuts and bolts, apply Honda Thread Lock or an equivalent and tighten to the specified torque.
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Between Motos & Practice Maintenance
After practice or between motos you have a chance to make additional checks and adjustments.
• Clean accumulated dirt from under the fenders and off the wheels, suspension components, hand grips, controls, and footpegs. A stiff, nylon parts cleaning brush works well.
• Check tire air pressure.
•
Check spoke tension and rim lock nut security.
• Check sprocket bolt and nut security.
• Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary.
Do not perform maintenance while engine is running. Injury to your fingers or hands may result.
• After adjustment, check that the chain
adjuster index marks (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel
alignment will also extend brake pad wear.
(1) chain adjuster index marks
• Suspend the front wheel above the ground and use the pressure release screws (2) to release the built-up pressure (in excess of normal atmospheric pressure: 0 psi) in the fork tubes. This pressure is caused by normal fork action while riding. (If you are riding at altitude, remember that fork pressure of 0 at sea level will increase as elevation increases.)
(2) pressure release screws
• Be sure the fuel and oil is mixed well by agitating it thoroughly before pouring pre-mix into the fuel tank.
26 Servicing Your Honda
Before & After Competition Maintenance
(1)
(2)
WARNING
Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel.
• Stop the engine and keep heat, sparks
and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
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