Honda CR85 2006 Owner's Manual
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Honda CR85 2006 Owner's Manual

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2006
Honda CR85/85RB EXPERT
OWNER'S MANUAL & COMPETITION HANDBOOK

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Summary of Contents for Honda CR85 2006

  • Page 1 2006 Honda CR85/85RB EXPERT OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 CR and how it works. To protect your Please report any change of address or ownership investment, we urge you to take responsibility for to your Honda dealer so we will be able to keeping your CR well maintained. Scheduled contact you concerning important production service is a must, of course.
  • Page 3 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.

  • Page 4: Table Of Contents

    Contacting Honda..........121 Flooded Engine ..........13 Suspension............52 Your Honda Dealer...........122 How to Stop the Engine........14 Brakes..............57 The Honda Rider’s Club (USA only) ....123 Shifting Gears.............15 Wheels ..............61 Break-in Guidelines ...........16 Tires & Tubes .............62 TABLE OF CONTENTS .......124 Drive Chain ............64 SERVICING YOUR HONDA......17...

  • Page 5: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Information.......2 information and recommendations to help you Important Safety Precautions......2 ride your CR safely. Please take a few moments Important Message to Parents ......2 to read these pages. This section also includes Accessories &...

  • Page 6: Important Safety Information

    Your CR can provide many years of pleasure, if Your child's safely is very important to Honda. Keep Your Honda in Safe Condition. you take responsibility for your own safety and...

  • Page 7: Accessories & Modifications

    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.

  • Page 8: Safety Label

    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. Motorcycle Safety...

  • Page 9: Operating Controls

    Operating Controls Read this section carefully before you ride. It Operation Component Locations ......6 presents the location of the basic controls on your Operating Controls...

  • Page 10: Operation Component Locations

    Operation Component Locations clutch lever front brake lever engine stop button throttle grip choke knob kickstarter rear brake pedal fuel valve shift lever Operating Controls...

  • Page 11: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....9 you prepared, this section discusses how to Pre-ride Inspection ..........9...

  • Page 12: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CR for the first time,we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 13: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection 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 Check the following before each ride: right): •...
  • Page 14 Before Riding...

  • Page 15: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions ........12 start and stop your engine as well as break-in Starting & Stopping the Engine ......13 guidelines. Preparation ............13 Starting Procedure ........13 Flooded Engine ..........13 How to Stop the Engine........14 Shifting Gears.............15 Break-in Guidelines ...........16 Basic Operating Instructions...

  • Page 16: Safe Riding Precautions

    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. Your CR’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 17: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Check the transmission oil and coolant levels Flooded Engine described below. before starting the engine (page 37, 38). Your CR can be kickstarted with the transmission Cold Engine Starting in gear by pulling in the clutch lever before 1.

  • Page 18: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine (1) throttle (2) engine stop button 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.

  • Page 19: Shifting Gears

    Shifting Gears NOTICE Downshifting can help slow your motorcycle, especially on downhills. However, downshifting when engine rpm is too high can cause engine damage. NOTICE To prevent transmission damage, do not coast or tow the motorcycle for long distances with the engine off.

  • Page 20: Break-In Guidelines

    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: •...

  • Page 21: Servicing Your Honda

    You’ll also find Appearance Care ..........69 important safety precautions, information on oils, Service Preparations and tips for keeping your Honda looking good. Maintenance Component Locations....28 Seat Removal .............29 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30 used on this motorcycle;...

  • Page 22: The Importance Of Maintenance

    Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda Servicing Your Honda...

  • Page 23: Maintenance Safety

    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. Servicing Your Honda Servicing Your Honda...

  • Page 24: Maintenance Schedule

    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...
  • Page 25 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.

  • Page 26: General Competition Maintenance

    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.
  • Page 27 Follow the servicing instructions in possibility of them loosening. Position the twisted the Maintenance section. Use Pro Honda Foam Filter Oil or wire ends away from your palms and be sure to bend an equivalent. Be sure to grease the air cleaner flange the wire ends well into the grip rubber so they will not where it contacts the air cleaner housing.
  • Page 28 Honda Thread compensate to maintain the ignition curve. Cleaning dirt Lock or an equivalent prior to torquing the nuts.
  • Page 29 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. Servicing Your Honda...

  • Page 30: Before & After Competition Maintenance

    • 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 Servicing Your Honda...

  • Page 31: After Competition Maintenance

    If you decide to wash your CR or use cleaners, refer to Appearance Care (page 69). lube. Take care to prevent catching your fingers between the chain and sprockets. Servicing Your Honda...

  • Page 32: Maintenance Component Locations

    Servicing Your Honda...

  • Page 33: Seat Removal

    2. Install the seat bolts (5) and tighten them to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat bolts (2) seat (1) seat front prong (2) seat bracket (3) seat rear prong (4) tab (5) seat bolts Servicing Your Honda...

  • Page 34: Fuel Tank Removal

    4. Remove the left side shroud bolts (3), collar (6) breather tube (4) and left side shroud (5). (7) fuel tank band (8) fuel line (9) right and left side fuel tank bolts/washers (3) left side shroud bolts (4) collar (5) left side shroud Servicing Your Honda...
  • Page 35 (1) right and left side fuel tank bolts/washers the fuel tank. (2) fuel line 9. Tighten the shroud bolts (11). (3) fuel tank band (4) breather tube (11) (10) (8) right side shroud (9) grommet (10) boss (11) shroud bolts Servicing Your Honda...

  • Page 36: Subframe Removal

    16 lbf·ft (22 N·m, 2.2 kgf·m) (7) lower subframe mounting bolts (8) upper subframe mounting bolt (3) bolt/washer (9) subframe (4) silencer (3) subframe (4) upper subframe mounting bolt (5) lower subframe mounting bolts Servicing Your Honda...
  • Page 37 7. Install and tighten the bolt/washer (9). (6) silencer (8) "FR" mark (7) rubber seal (9) bolt/washer 8. Install the right side cover (10) and bolt/collar (11). (11) (10) (10) right side cover (11) bolt/collar 9. Install the seat (page 29). Servicing Your Honda...

  • Page 38: Fuel System

    Prepare the fuel mixture in a clean container, and shake until thoroughly mixed before filling the Fuel Fuel Recommendation fuel tank. Gallons Liters Ounces USE Pro Honda HP2 2-stroke Oil Type Unleaded (32:1) OR AN EQUIVALENT. 1.89 Pump Octane Number 91 (or higher) 3.78 5.67...
  • Page 39 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. Servicing Your Honda...

  • Page 40: Transmission Oil

    NOT RECOMMENDED suggested oil* Pro Honda HP Trans oil, Pro Honda GN4 or HP4 Other viscosities shown in the following chart (without molybdenum may be used when the average temperature in additives) 4-stroke engine your riding area is within the indicated range.
  • Page 41 6. Repeat steps 1 - 4. 7. After inspecting the oil level or adding oil, tighten the oil check bolt and filler cap securely and oil check bolt to the specified torque: 6.6 lbf·ft (9 N·m, 0.9 kgf·m) (1) oil drain bolt Servicing Your Honda...

  • Page 42: Coolant

    Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is low. Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing.
  • Page 43 Refer to Safety Precautions on page 19. Honda Service Manual for troubleshooting of leaks). Coolant should be replaced by your Honda 2. Check water hoses (1) for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.

  • Page 44: Air Cleaner

    Service the air cleaner more frequently if you (1) air cleaner retaining bolt ride in unusually wet or dusty areas. Your Honda (3) air cleaner dealer can help you determine the correct service (4) air cleaner holder interval for your riding conditions.
  • Page 45 Air Cleaner 9. Apply a thin coat of Honda White Lithium NOTICE Grease, or an equivalent, to the sealing surface. Improper installation of the air cleaner assembly 10.Assemble the air cleaner and holder and put may allow dirt and dust to enter the engine and the air cleaner retaining bolt through the cause rapid wear of the piston rings and cylinder.

  • Page 46: Throttle

    5. Operate the throttle grip to ensure that it functions smoothly and returns completely. (–) If you can’t get the freeplay within the specified range, contact your Honda dealer. (2) rubber dust cover (+)increase (3) upper lock nut (–)decrease...
  • Page 47 If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commercially- available cable lubricant to prevent premature rust and corrosion. Servicing Your Honda...

  • Page 48: Clutch System

    Improper freeplay adjustment can cause 3. Turn the lower clutch cable adjuster (5) to install the dust cover. premature clutch wear. obtain the specified freeplay. 4. Check the freeplay again. 4. Tighten the lock nut. Check the adjustment. Servicing Your Honda...
  • Page 49 • Lubricate the clutch cable with a commercially- or worn, or the clutch discs may be worn. See available cable lubricant to prevent premature your Honda dealer or refer to pages 121 - 122 or wear and corrosion. the official Honda Service Manual.

  • Page 50: Spark Plug

    If the electrodes appear burnt, or the insulator is white or light gray (lean) or the electrodes and insulator are black or fouled (rich), there is a problem elsewhere (page 94). Check the fuel/oil mixture, carburetor and fuel system, and ignition timing. Servicing Your Honda...

  • Page 51: Cylinder System

    (2) cylinder mounting nuts (3) cylinder (4) reed valve (1) carburetor insulator (4) clamp mounting bolts (5) gasket (2) insulator (3) reed valve (1) radiator hoses (4) cylinder head nuts (2) spark plug cap (5) cylinder head (3) spark plug Servicing Your Honda...
  • Page 52 Cylinder/Piston/Piston Pin/Piston Ring The piston rings may be damaged if their ends Inspection are spread too far. We recommend you consult the Service Manual or your Honda dealer for correct Service Limit measurements. (1) cylinder head (3) feeler gauge (2) straight edge...
  • Page 53 Take care so that the clips do not fall into the crankcase. (1) read value mounting screws (3) reed valve Do not align the piston pin clip end gap with (2) stopper (4) cut-out the piston cut-out. (cont’d) Servicing Your Honda...
  • Page 54 (3) piston ring 3. Place the cylinder base gasket (1) and dowel Before tightening the cylinder nuts, make sure pins (2) on the crankcase. that there is no clearance between the cylinder and crankcase mating surface. Servicing Your Honda...
  • Page 55 (page 38). 7. Start the engine and check for the following: – compression leaks (1) cylinder head gasket (3) tab (2) “UP” mark – abnormal engine noise – carburetor insulator air leaks – coolant leaks Servicing Your Honda...

  • Page 56: Suspension

    See page 72 for oil level (3) wear rings adjustment after changing the fork oil. • Use Pro Honda HP Fork Oil 5W or an 4. Make a quick check of fork operation by equivalent which contains special additives to...
  • Page 57 (page 84). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assembly only. • When your CR is new, break it in for 2.
  • Page 58 Repeat this procedure 3 times. viscosity (weight) 5 W suggested oil Pro Honda HP Fork Oil or equiva- lent Fork Oil Change 1. Remove the fork cap, and fork spring as described in Oil Level Adjustment (page 72).
  • Page 59 Slightly stiffer as level 93 mm it nears full [capacity] 12.2 US oz compression. (362 cm Minimum oil 4.1 in Slightly softer as level 104 mm it nears full [capacity] 12.0 US oz compression. (5) syringe (355 cm (cont’d) Servicing Your Honda...
  • Page 60 3.6 in Slightly stiffer as level 92 mm it nears full [capacity] 12.3 US oz compression. (362.8 cm Minimum oil 3.9 in Slightly softer as level 100 mm it nears full [capacity] 12.1 US oz compression. (358.5 cm Servicing Your Honda...

  • Page 61: Brakes

    (page adjuster and piston (3). 60), there is probably air in the brake system. Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system. (–)
  • Page 62 (30 mm), there is probably air in the brake for leaks. system and it must be bled. Refer to the Honda If the brake lever freeplay exceeds 0.8 in Service Manual or see your Honda motorcycle (20 mm), there is probably air in the brake dealer for brake bleeding.
  • Page 63 Adding Rear Brake Fluid Other Inspection • Make sure there are not fluid leaks. The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 • Check for deterioration or cracks in the hoses brake fluid from a sealed container, or an brake fluid from a sealed container, or an and fittings.
  • Page 64 Check that the front brake lever and rear brake pedal assemblies are positioned properly and the securing bolts are tight. Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. (1) brake pads (2) wear limits Servicing Your Honda...

  • Page 65: Wheels

    During the first 100 miles (150 km), 3. Check wheel rim runout. If runout is spokes will loosen more rapidly due to the initial noticeable, see the Honda Service Manual for seating of the parts. Excessively loose spokes inspection instructions.

  • Page 66: Tires & Tubes

    Overinflated tires make your motorcycle ride harshly, are more prone to dam- age from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 67 • Use a replacement tire equivalent to the original. • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 68: Drive Chain

    Lubricate any kinked or binding links and work them free. Adjust chain slack if needed. 5. Check the chain slider (4) for wear. If the wear is 0.16 in (4 mm) or more, replace Servicing Your Honda...
  • Page 69 8. Check the driven sprocket nut torque values should be used in preference to motor oil. Pro after each race. Honda Chain Lube or an equivalent, or SAE 80 24 lbf·ft (32 N·m, 3.3 kgf·m) or 90 gear oil is recommended.
  • Page 70 Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. 8. Recheck chain slack and adjust as necessary. Servicing Your Honda...

  • Page 71: Expansion Chamber

    Tighten the front and rear mounting bolts to the specified torque: 6.5 lbf·ft (8.8 N·m, 0.9 kgf·m) (1) spring (2) mounting bolts (1) O-rings (4) expansion chamber (2) washer spring (3) expansion chamber (5) mounting bolts Servicing Your Honda...

  • Page 72: Additional Maintenance Procedures

    Check and tighten nuts, bolts, and fasteners not see any movement in the steering head, before every outing. the fork bushings may be worn. Refer to the Honda Service Manual for replacement or Torque adjustment procedures, or see your Honda Item Remarks dealer.

  • Page 73: Appearance Care

    This will help and steering head bearings-driving dirt inside dry the brakes and restore normal braking You may use Pro Honda Hondabrite, a and needed lubrication out. performance. multi-surface cleaner/degreaser, to remove both dirt and petroleum-based grime from paint, alloy, plastic, and rubber surfaces.
  • Page 74 This is natural and manual for lubricating items such as the brake just one more reason why you should change the and clutch lever pivot points and footpeg pivot transmission oil often. pins. (1) alternator cover Servicing Your Honda...

  • Page 75: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CR Front Suspension Adjustments......72 for maximum competition performance. Rear Suspension Adjustments ......80 Suspension Adjustments for Track Conditions ..84 Initial suspension adjustments should be Suspension Adjustments Guidelines ....85 performed after a minimum of two hours of easy Carburetor Adjustments &...

  • Page 76: Front Suspension Adjustments

    See the Service Manual or compression damping screw adjusts how 3. Check that the O-ring (2) is in good condition. your Honda dealer for this service. quickly the fork compresses. 4. Install and tighten the pressure release screw •...
  • Page 77 Front Suspension Adjustments 4. Remove the axle nut (3). 7. Loosen the fork leg lower pinch bolts (7), 10.Hold the fork tube (10), then remove the fork 5. Pull the front axle shaft (4) out of the wheel then pull the fork legs down and out. cap (2), from the fork tube.
  • Page 78 Front Suspension Adjustments 13.Pour the recommended fork oil into the piston Fork Oil Level (CR85R) Optional Stiffer (0.30 kgf/mm) Fork Spring rod (15) until a little oil flows out of the top   2-coils at one end; Standard (0.28 kgf/mm) Fork Spring of the piston rod.
  • Page 79 Front Suspension Adjustments Fork Oil Level (CR85RB) Optional Stiffer (0.30 kgf/mm) Fork Spring 16.Inspect both ends of the fork spring. If you find any roughness or burred edge on the end   Standard (0.28 kgf/mm) Fork Spring of either spring, smooth the roughness with a ...
  • Page 80 Front Suspension Adjustments 17.Clean the spring and spring seat thoroughly 22.Install the fork spring (17) as follows: 24.Install the fork cap assembly into piston rod. with a high flash point solvent to remove all – With the fork spring held upright on its metal particles and dirt.
  • Page 81 Front Suspension Adjustments 28.Align the groove (23) in the fork tube (10) 33.Clean the threads of the fork protector bolts 40.Align the brake caliper (6) and hose with the with the top surface of the upper fork clamps and axle holder thoroughly. left fork leg, making sure that the brake hose (24).
  • Page 82 Front Suspension Adjustments 44.With the front brake applied, pump the fork Rebound Damping Front Suspension Damping up and down several times to seat the axle and Rebound damping effects how quickly the fork check front brake operation. rebounds. Compression Damping The rebound damping adjuster has 3 turns or Compression damping affects how quickly the less.
  • Page 83 Front Suspension Adjustments When adjusting oil levels, bear in mind that the Fork Springs air in the fork will increase in pressure while riding; therefore, the higher the oil level, the The fork springs in CR’s are about right for higher the eventual pressure of any air in the fork.

  • Page 84: Rear Suspension Adjustments

    Do not attempt to disassemble, service, or Spring preload length (Optional spring) Min. (Softer, 4.6 kgf/mm): 8.6 in (218 mm) dispose of the damper; see your Honda dealer. Min. (Softer, 4.8 kgf/mm): 8.7 in (222 mm) The instructions found in this owner’s manual are Min.
  • Page 85 Rear Suspension Adjustments Rebound Damping Rear Suspension Damping The rebound damping adjuster (4) is located at the lower end of the shock absorber. Compression Damping To increase damping, turn the adjuster screw Compression damping can be adjusted with the clockwise. adjuster located on the rear shock absorber's reservoir.
  • Page 86 Rear Suspension Adjustments 4. Calculate the race sag dimension. LAST CHAIN ADJUSTER Rear Suspension Race Sag MARK To do this, subtract the loaded with rider SEAT MOUNTING dimension (step 3) from the unloaded BOLT Setting the proper race sag (ride height) is very dimension (step 2).
  • Page 87 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CR’s suspension is dimension (step 2).

  • Page 88: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 89: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CR, using the methods described on pages 72 - 83. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 90 Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in 1/4 turn increments. •...
  • Page 91 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring preload). Example: –...

  • Page 92: Carburetor Adjustments & Tuning Tips

    (16) . throttle. The size should be reduced at higher altitudes. Honda carburetor jet sizes are numbered in increments of 2or3. When changing the main jet size, increase or decrease it gradually until the desired setting is obtained. Because your CR’s jet size numbers do not correspond with other carburetor manufacturer’s jet size numbers, use...
  • Page 93 Carburetor Adjustments & Tuning Tips Jet Needle All jetting is based on The jet needle controls fuel/air mixture over 1/16 • Standard Jetting to 3/4 throttle. The straight section (1) affects • 32:1 Fuel/Oil Ratio throttle response at smaller throttle openings. By •...
  • Page 94 Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Adjustments for Altitude & Temperature Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change All jetting recommendations are based on drastically. However, there are some unique Before adjusting carburetor settings, check the atmospheric conditions or race day situations that standard jetting with an unmodified engine.
  • Page 95 You can be burned or the following conditions: 32-to-1 premix ratio seriously injured when handling fuel. using Pro Honda HP2 2-stroke oil or its equivalent, sea level altitude, and 20 °C (68 • Stop the engine and keep heat, sparks °F) air temperature.
  • Page 96 Carburetor Adjustments & Tuning Tips 7. Change the jets as required. 4. Remove the carburetor to the left side. Carburetor Disassembly/Assembly Be careful not to damage around the throttle sensor. 1. Turn the fuel valve off. Do not assemble or move the carburetor while holding the throttle sensor lead.
  • Page 97 Carburetor Adjustments & Tuning Tips 6. Remove the throttle cable (5) and cable holder 9. Remove the float bowl screws (11) and float 11.To assemble, reverse the disassembly (6) from the throttle valve (7). bowl (12). procedures. 7. Remove the cable holder and throttle valve 12.To install the carburetor, reverse the removal spring (8) from the throttle cable.
  • Page 98 Pressure/vacuum testing your engine on a reading. A new plug will not color immediately. regular basis to detect air leaks is recommended. See your Honda dealer. The same simple throttle opening identification system used in the Break-in section of this manual can also be...

  • Page 99: Chassis Adjustments

    Chassis Adjustments Refer to Safety Precautions on page 19. Fork Height/Angle Wheelbase The following suggestions may improve a specific concern. Subtle changes in overall The position of the fork tubes in the clamps is Adjusting your CR’s wheelbase can offer subtle handling may also be noted.

  • Page 100: Gearing

    Unless you have the required mechanical If you decide to try a gearing change, have knowhow, tools, and an official Honda Service • Wet and slippery or sandy conditions: use a someone check your times with a stopwatch...

  • Page 101: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Refer to Safety Precautions on page 19. If you choose a tire with a sticky compound for added traction, remember that it may transfer Choosing the correct tire tread pattern and rubber additional loads to the transmission because it compound can affect your placing in competition.

  • Page 102: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to • Chamfer the edges to remove burrs and other help ensure the correct torque is retained.

  • Page 103: Tips

    Tips Here’s helpful advice on how to transport and Transporting Your Motorcycle ......100 store your Honda, as well as two troubleshooting Storing Your Motorcycle........101 flow charts. You & the Environment ........102 Troubleshooting..........103 Tips Tips...

  • Page 104: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda, we recommend that you follow these guidelines: • Use a loading ramp. • Make sure the fuel valve is off. • Secure the motorcycle in an upright position, using motorcycle tie-down straps.

  • Page 105: Storing Your Honda

    (2) and water pump (3) to drain plastic bag over the end of the muffler to your Honda and correct any problem before coolant. prevent moisture from entering. storing it. That way, needed repairs won’t be After the coolant has been completely 9.

  • Page 106: You & The Environment

    You & the Environment Owning and riding a motorcycle can be NOTICE enjoyable, but you must do your part to protect nature. When you show respect for the land, Improper disposal of drained fluids is harmful to wildlife, and other people, you also help preserve the environment.

  • Page 107: Troubleshooting

    The items that are serviceable using this Manual are Poor performance at high speed followed by the page number reference in parenthesis. The CHECK POSSIBLE CAUSES items that require use of the Honda Service Manual are 1. Check ignition • Faulty alternator* INCORRECT followed by an asterisk.
  • Page 108 Tips...

  • Page 109: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........106 other technical data. 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 Technical Information...

  • Page 110: Vehicle Identification

    Vehicle Identification The frame number (1) is stamped on the right Serial Numbers side of the steering head. RIGHT SIDE The VIN, frame and engine serial numbers are required when you register your CR. They may also be required when ordering replacement parts.

  • Page 111: Specifications

    Specifications CR85R Item English Metric Item English Metric Engine Drive train Item English Metric Type Liquid cooled, 2-stroke Final reduction 3.267 Dimension Cylinder arrangement Single 15° inclined from Left foot-operated return Overall length 71.0 in 1,803 mm Gear shift pattern vertical system 1-N-2-3-4-5-6 Overall width...
  • Page 112 Specifications CR85RB Item English Metric Item English Metric Engine Drive train Item English Metric Type Liquid cooled, 2-stroke Final reduction 3.667 Dimension Cylinder arrangement Single 15° inclined from Left foot-operated return Overall length 74.1 in 1,881 mm Gear shift pattern vertical system 1-N-2-3-4-5-6 Overall width...

  • Page 113: Torque Specifications

    NOTE 4 Rear shock link nuts (10) NOTE 4 (Frame side) Shock spring lock nut NOTES: 1. Apply Honda Thread Lock or an equivalent to the (17) threads. 2. Apply oil to the threads and flange surface. 3. Stake. 4. U-nut.
  • Page 114 (32) Seat mounting bolts Pressure release screw (28) (21) (32) NOTES: 1. Apply Honda thread Lock or an equivalent to the threads. 2. Apply oil to the threads and flange surface. 3. Stake. 4. U-nut. 5. UBS nut. 6. SH bolt.

  • Page 115: High Altitude Carburetor Adjustment

    However, the carburetor must be returned to standard factory specifications when lower altitude riding is desired. See your Honda dealer for high altitude modification. NOTICE Sustained operation at altitudes below 5,000 feet...

  • Page 116: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions.

  • Page 117: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.
  • Page 118 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 119: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your REMARKS REMARKS FRAME FRAME authorized Honda dealer. < >: Drive chain links Shock CR85R 48T, Aluminum <116> springs CARBURETOR Remarks CR85R 49T, Aluminum <116> (Standard) Brown mark Driven 50T, Aluminum <116>...
  • Page 120 Optional Parts List REMARKS REMARKS FRAME FRAME Shock CR85RB Fork CR85R springs springs 2-coils at Red mark Softer 4.8 kgf/mm Softer 0.26 kgf/mm both ends White mark 5.0 kgf/mm 1-coil at Standard 0.28 kgf/mm both ends No mark Standard 5.2 kgf/mm 2-coils at Stiffer 0.30 kgf/mm...

  • Page 121: Spare Parts & Equipment

    Honda Hand Grip Cement chain roller Honda Hondalock General Tools inner tubes (front & rear) Honda Moly 60 Paste (U.S.A. only) or fenders molybdenum disulfide paste (containing more footpegs sockets (3/8 in drive) than 40% molybdenum disulfide additive) front &...

  • Page 122: Wiring Diagram

    Wiring Diagram Technical Information...

  • Page 123: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........120 contacting Honda and how to get an official Contacting Honda..........121 Honda service manual. Your Honda Dealer...........122 The Honda Rider’s Club (USA only) ............123 Consumer Information...

  • Page 124: Authorized Manuals

    For purchases outside U.S.A., please write to the address shown below for a quotation. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service...

  • Page 125: Contacting Honda

    • product model, year, and frame/VIN serial If you wish to comment on your experiences with number your Honda or with your dealer, please send your • date of purchase comments to the following address (USA only): • dealer name and address We will likely ask your Honda dealer to respond, or possibly acknowledge your comments directly.

  • Page 126: Your Honda Dealer

    Your Honda Dealer Once you purchase your new Honda, get familiar Your dealer can inform you about competition with the organization of your Honda dealer so events in your area. You’ll also find that your you can utilize the full range of services dealer is a source of information (USA only) the available.

  • Page 127: The Honda Rider's Club (Usa Only)

    Safety Foundation training. Separate free training from the Specialty Vehicle Institute of America for ATV owners. • One full year of the Honda Red Rider magazine or Honda Red Rider ATV (for ATV purchasers). • Discounts from HRCA partners for experienced rider courses.

  • Page 128: Table Of Contents

    Table of Contents The following presents the contents for each SERVICING YOUR HONDA......17 Chassis section of your owner's manual. Before You Service Your Honda Suspension............52 The Importance of Maintenance ......18 Brakes..............57 MOTORCYCLE SAFETY........1 Maintenance Safety ..........19 Wheels ..............61 Important Safety Information.......2 Important Safety Precautions......19...
  • Page 129 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...

  • Page 130: Index

    Brakes, front ...............78 refueling ............35 rear..............80 system............34 fluid level ............58 lever, front adjustment ........57 dealer, your Honda ...........122 oxygenated ..........112 pad wear ............60 diagram, wiring ..........118 tank capacity ..........35 pedal height ...........57 drive chain ............64 valve ..............35 break-in guidelines ..........16...
  • Page 131 Index gap, spark maintenance, rear suspension maintenance......53 plug..............46 additional procedures ........68 Rider’s Club Honda..........123 gasohol ...............34 after competition ...........27 riding, gasoline...............34 before & after competition......26 apparel .............2 gearing ..............96 between motos & practice......26 basic operation ..........11 guidelines, suspension adjustment .....85 component locations ........28...
  • Page 132 Index suspension adjustment, front ...............72 rear..............80 for track conditions ........84 guidelines ............85 transmission oil ..........36 tuning tips............88 throttle, freeplay............42 inspection ............43 tires, air pressure ............62 flat ..............62 selection............63 tools ..............117 torque specifications.........109 transporting............100 troubleshooting..........103 tubes, replacing ..........62 valve, fuel ............34 vehicle identification ........106 washing your motorcycle ........69 wheels..............61...
  • Page 133 Memo...

  • Page 134: Quick Reference

    91 or higher Premix: Pro Honda HP2 2-stroke oil (32 : 1) Tank: 1.4 US gal (5.3 Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke engine oil, or an equivalent. Tires CR85R...

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85rb expert 2006

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