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Honda CR250R Owner's Manual & Competition Handbook

2007 honda cr250r owner's manual & competition handbook
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FOR COMPETITION USE ONLY
This motorcycle is designed and manufactured for closed-course competition conducted under the
auspices of a recognized body or by permit. It does not conform to federal motor vehicle standards,
and operation on public streets, roads, or highways is illegal. This vehicle is sold "as is" with no
warranties.
FOR EXPERIENCED RIDERS, NO PASSENGERS
This motorcycle is designed as an operator-only vehicle and for use by experienced riders only. The
load limit and seating configuration do not safely permit the carrying of a passenger.
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold.
All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor
Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
The vehicle pictured on the front cover may not match your vehicle.
©Honda Motor Co., Ltd., 2006
IMPORTANT NOTICES

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Table of Contents
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  Summary of Contents for Honda CR250R

  • Page 1 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 2 2007 Honda CR250R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 3 Please report any change of address or ownership keeping your CR well maintained. Scheduled to your Honda dealer so we will be able to service is a must, of course. But it’s just as contact you concerning important production important to observe the break-in guidelines, and information.
  • Page 4 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 5: Table Of Contents

    Authorized Manuals .........136 Reed Valve............58 Contacting Honda..........137 BASIC OPERATING INSTRUCTIONS..11 Your Honda Dealer...........138 Safe Riding Precautions ........12 Chassis The Honda Rider’s Club (USA only) ....139 Starting & Stopping the Engine ......13 Suspension............60 Preparation ............13 Brakes..............65 TABLE OF CONTENTS .......140 Starting Procedure ........13 Wheels ..............69...
  • Page 6: 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 Accessories & Modifications .......3 to read these pages. This section also includes Safety Labels ............4 information about the location of safety labels on your CR.
  • Page 7: Important Safety Information

    Keep Your Honda in Safe Condition. As an experienced rider, you know there is much you can do to protect yourself when you ride. Maintaining your CR properly is critical to your The following are a few precautions we consider safety.
  • Page 8: Accessories & Modifications

    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. WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed.
  • Page 9: Safety Labels

    Safety Labels Read these labels carefully and don’t remove them. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. Motorcycle Safety Motorcycle Safety...
  • Page 10: 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 11: Operation Component Locations

    Operation Component Locations front brake lever clutch lever engine stop button throttle grip choke knob kickstarter fuel valve shift lever rear brake pedal Operating Controls...
  • Page 12: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your CR are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? .....9 prepared, this section discusses how to evaluate Pre-ride Inspection ..........9 your riding readiness, and what items you should check on your CR.
  • Page 13: 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 14: 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 15 Before Riding...
  • Page 16: 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 Break-in Guidelines ...........15 Basic Operating Instructions Basic Operating Instructions...
  • Page 17: Safe Riding Precautions

    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 18: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Cold Engine Starting Flooded Engine described below. 1. Turn the fuel valve (1) ON. 2. Shift the transmission into neutral. Your CR can be kickstarted with the transmission 3. Pull the choke knob (2) up. If the engine fails to start after repeated attempts, in gear by pulling in the clutch lever before 4.
  • Page 19: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine (1) throttle grip (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle grip (1) two or three times, and then close it.
  • 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 Basic Operating Instructions...
  • Page 22: Servicing Your Honda

    Fuel Tank Removal ..........30 this motorcycle; consequently, routine ignition Subframe Removal ..........32 timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Procedures Service Manual (page 136). Fluids & Filters Fuel System ............34 An optional tool kit may be avaiable.
  • Page 23: 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 24: Maintenance Safety

    • 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. Servicing Your Honda Servicing Your Honda...
  • Page 25: 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 26 This maintenance schedule is based upon average riding condition. Machines subjected to severe use require more frequent servicing. NOTE: 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. Servicing Your Honda Servicing Your Honda...
  • Page 27: General Competition Maintenance

    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 28 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. Pro Honda White...
  • Page 29 For added peace of mind, and the flywheel makes the ignition control module remove the nuts, clean the threads, and apply Pro Honda compensate to maintain the ignition curve. Cleaning dirt Hondalock or an equivalent prior to torquing the nuts.
  • Page 30 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 Pro Honda Hondalock or an equivalent and tighten to the specified torque.
  • Page 31: Before & After Competition Maintenance

    Lubricate and sea level will increase as elevation increases.) adjust the chain as necessary. Do not perform maintenance while engine is running. Injury to your fingers or hands may result. (2) pressure release screws Servicing Your Honda...
  • Page 32: After Competition Maintenance

    (page 73). Be sure the chain is wiped clean and If you decide to wash your CR or use cleaners, is dry before lubricating the chain. refer to Appearance Care (page 78). Take care to prevent catching your fingers between the chain and sprockets. Servicing Your Honda...
  • Page 33: Maintenance Component Locations

    Servicing Your Honda...
  • Page 34: Seat Removal

    2. Install the collars and tighten the seat bolts to the specified torque: 20 lbf·ft (27 N·m, 2.8 kgf·m) (1) seat bolts (3) seat (2) collars (4) seat front prong (5) seat bracket (6) seat rear prong (7) tabs Servicing Your Honda...
  • Page 35: Fuel Tank Removal

    3. Remove the shroud A bolts/collars (2). (7) fuel tank band (8) fuel tank bolt 4. Remove the shroud B bolts/collars (3) and shrouds (4). (1) fuel valve (9) fuel line (2) shroud A bolts/collars (3) shroud B bolts/collars (4) shroud Servicing Your Honda...
  • Page 36 4. Hook the fuel tank band (4). 5. Hook the air cleaner case cover (5). 6. Put the breather tube (6) in the steering stem nut. (3) fuel tank bolt (4) fuel tank band (5) air cleaner case cover (6) breather tube Servicing Your Honda...
  • Page 37: Subframe Removal

    6. Remove the subframe (9) by pulling it straight (2) bolt/collar (1) screw backward. (2) connecting tube clamp 3. Remove the bolt/washer (3) and silencer (4). (7) lower subframe mounting bolts (3) bolt/washer (8) upper subframe mounting bolt (4) silencer (9) subframe Servicing Your Honda...
  • Page 38 (6) silencer (7) bolt/washer 8. Install the right side cover (8) and bolt/collar (9). (3) subframe (4) upper subframe mounting bolt (5) lower subframe mounting bolts (8) right side cover (9) bolt/collar 9. Install the seat (page 29). Servicing Your Honda...
  • Page 39: 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) 3.79 5.68...
  • Page 40 Attach the fuel line and turn the fuel valve to ON; check for leaks. • Stop the engine and keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Servicing Your Honda...
  • Page 41: Transmission Oil

    Pro Honda HP Trans oil, NOT RECOMMENDED Pro Honda GN4 4–stroke engine oil or an equivalent Other viscosities shown in the following chart * Suggested 4–stroke engine oils are equal...
  • Page 42: Replacing Transmission Oil

    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: 7 lbf·ft (10 N·m, 1.0 kgf·m) (1) oil drain bolt Servicing Your Honda...
  • Page 43: 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 44 3. Check the radiator mount for looseness. Refer to the official Honda Service Manual (page 4. Make sure the overflow tube (2) is connected 136). and not clogged.
  • Page 45: Air Cleaner

    Service the air cleaner more frequently if you saturate the air cleaner with oil. Squeeze out ride in unusually wet or dusty areas. Your Honda excess oil. dealer can help you determine the correct service interval for your riding conditions.
  • Page 46 Air Cleaner 8. Apply a thin coat of Pro Honda White 10. Insert the pin in the air cleaner housing hole 11. Reinstall the seat (page 29), making sure it is Lithium Grease or an equivalent, to the (7) and install the assembly into the air securely attached.
  • Page 47: Throttle

    If you can’t get the freeplay within the specified turn. Tighten the lock nut, install the dust range, contact your Honda dealer. cover and make the adjustment with the lower adjuster.
  • Page 48 2. Check for smooth rotation of the throttle grip (1) from fully open to fully closed in all steering positions. If there is a problem, see your Honda dealer. 3. Inspect the condition of the throttle cable from the throttle grip down to the carburetor. If the cable is kinked or chafed, have it replaced.
  • Page 49: Clutch System

    To position the clutch lever closer to the handgrip, turn the adjuster (–) clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustment. Servicing Your Honda...
  • Page 50 If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the official Honda Service Manual (page 134). Servicing Your Honda...
  • Page 51 4. Remove the six clutch spring bolts (6) and clutch springs. (8) clutch lifter (10) clutch discs and plates Loosen the bolts in a crisscross pattern in 2 or 3 (9) clutch lifter rod (2)clutch plate progressive steps. Servicing Your Honda...
  • Page 52 11. Lubricate the rear brake pedal pivot (10) and them is beyond the service limit or if the clutch 8. Tighten the bolts in a crisscross pattern in 2 pivot bolt (11) with Pro Honda White plates have been burnt/heat discolored. or 3 steps to the specified torque: Lithium Grease or an equivalent and install 7 lbf·ft (10 N·m, 1.0 kgf·m)
  • Page 53: 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 109). Check the fuel/oil mixture, carburetor and fuel system, and ignition timing. Servicing Your Honda...
  • Page 54: Cylinder System

    To avoid warping the cylinder head, use a crisscross pattern to loosen each nut about 1/4, then remove the nuts. (1) water hose (2) spark plug cap (6) cylinder head nuts A (8) cylinder head (7) cylinder head nuts B/washers Servicing Your Honda...
  • Page 55 (14) (18) (2) bolts (4) RC cover (17) gasket (18) dowel pins (3) clamp (5) gasket (10) (11) (13) (9) screw (12) upper mounting bolt (10) radiator hose (13) lower mounting bolt (11) radiator grill (14) radiator Servicing Your Honda...
  • Page 56 We recommend you consult the Service Manual needle-nose pliers. Press the piston pin (2) Take care to avoid scratching the cylinder or your Honda dealer for correct Service Limit out of the piston (3), and remove the piston. head piston dome, or the head gasket surface.
  • Page 57 Do not rotate the cylinder, since this may cause the piston ring to snag a cylinder port and break. (1) piston pin (3) hole (2) “IN” mark (4) piston pin clip (1) cylinder head (3) feeler gauge (2) straight edge Servicing Your Honda...
  • Page 58 11. Install the RC valve cover and clamp (13), tighten the bolts (14) to the specified torque: 3.7 lbf·ft (5 N·m, 0.5 kgf·m) (11) (14) (13) (5) flange nuts (12) (11) gasket (13) clamp (12) RC valve cover (14) bolts (cont’d) Servicing Your Honda...
  • Page 59 2 or 3 steps: – compression leaks 20 lbf·ft (27 N·m, 2.8 kgf·m) – abnormal engine noise – secondary air leaks – coolant leaks (5) cylinder head (7) cylinder head nuts B/ (6) cylinder head nuts A washers Servicing Your Honda...
  • Page 60: Rc Valve

    5. Increase the engine speed until about 8,000 recommend you consult the service manual or rpm and check that the RC valve pulley turns your Honda dealer. Mismatching of parts on to the fully open position. reassembly can measurably affect engine performance.
  • Page 61 RC valve and valve shaft. 3. Apply silicone sealer (Three Bond 1207B or equivalent) (1) to the mating surface of the cylinder as shown. (2) RC valve (5) bolts A (6) bolts B (1) silicone sealer Servicing Your Honda...
  • Page 62 (4) RC valve pulley (2) adjuster (5) inner lock nut (2) pin (7) adjuster (3) inner lock nut (8) cylinder (3) rear RC valve cable (6) cylinder (4) front RC valve cable (9) outer lock nut (5) seat Servicing Your Honda...
  • Page 63: Reed Valve

    (5) on one side of the reed valve. 2. Align the cut-outs (6) between the reed valves and stoppers, then install them onto the cage. (1) reed valve mounting screws (4) reed valve (2) stopper (5) spacer (3) sub-reed valve (6) cut-out Servicing Your Honda...
  • Page 64 4. Install the carburetor (page 107). (1) gasket (3) reed valve assembly (2) crankcase 3. Install the insulator (4), six carburetor insulator mounting bolts (5) and tighten to the specified torque in a crisscross pattern: 9 lbf·ft (12 N·m, 1.2 kgf·m) Servicing Your Honda...
  • Page 65: Suspension

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CR’s front suspension.
  • Page 66 (page 99). 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.
  • Page 67 (weight) 5 W when the fork damper is removed. To avoid damage, hold both the outer tube and slider when suggested oil Pro Honda HP Fork Oil or equivalent removing the fork damper. Fork Oil Change NO GOOD Refer to Suspension Removal on page 83.
  • Page 68 13.5 US oz capacity (399 cm Maximum oil 14.7 US oz Slightly stiffer as it capacity (435 cm nears full compression. Minimum oil 11.4 US oz Slightly softer as it capacity (336 cm nears full compression. (cont’d) Servicing Your Honda...
  • Page 69 (2) is in good condition. Apply the recommended fork oil to the O-ring. (2) fork damper (9) o-ring 7. Tighten the fork damper using the special tool, to the specified torque: 25 lb·ft (34 N·m, 3.5 kgf·m) Servicing Your Honda...
  • Page 70: Brakes

    68), there is probably air in the brake system. (1) lock nut (3) piston (2) adjuster Refer to the Honda Service Manual or see your (–) Honda dealer to have the air bled from the 1. Loosen the lock nut (1).
  • Page 71 (20 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 dealer for (20 mm), there is probably air in the brake brake bleeding.
  • Page 72 Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Pro Honda DOT The recommended brake fluid is Pro Honda DOT • Make sure there are no fluid leaks. 4 brake fluid from a sealed container, or an 4 brake fluid from a sealed container, or an •...
  • Page 73 0.04 in replace (1 mm) (4) brake pads (6) brake disc (5) rear brake caliper replace wear indicator grooves 0.04 in (1 mm) replace (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...
  • Page 74: Wheels

    Axles & Wheel Bearings Maintenance of spoke tension and wheel trueness (roundness) is critical to safe motorcycle See the Honda Service Manual for inspection operation. During the first 100 miles (150 km), information: spokes will loosen more rapidly due to the initial seating of the parts.
  • Page 75: Tires & Tubes

    • Check the position of both valve stems. A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim. Servicing Your Honda...
  • Page 76 • 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 77: Drive Chain

    Lubricate the drive chain (page 73) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed. Servicing Your Honda...
  • Page 78 Pro decrease slack or clockwise to increase slack. Honda Chain Lube or an equivalent, or SAE 80 Align the index marks (4) of the axle plates or 90 gear oil is recommended.
  • Page 79 17 pins, from pin center to pin center. position the new chain on the sprockets. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...
  • Page 80: Expansion Chamber

    3. Check the expansion chamber for cracks or deformation. A damaged chamber may decrease engine performance. (1) springs (2) bolts 3. Remove carbon deposits from the head pipe of the expansion chamber. Check the O-rings (3) on the head pipe for wear. (3) O-rings Servicing Your Honda...
  • Page 81: Additional Maintenance Procedures

    If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to the Honda Service Manual for replacement or adjustment procedures, or see your Honda dealer.
  • Page 82 4 Clutch cover bolt (1) cylinder head nut (6) RC cover bolt 5 Water pump cover (2) cylinder mounting nut bolt (3) carburetor insulator bolt 6 RC cover bolt RIGHT SIDE (4) clutch cover bolt (5) water pump cover bolt Servicing Your Honda...
  • Page 83: Appearance Care

    CR. of water under extreme pressure can penetrate performance. the dust seals of the suspension pivot points You may use Pro Honda Hondabrite, a and steering head bearings- multi-surface cleaner/degreaser, to remove both driving dirt inside and needed lubrication out.
  • Page 84 Do not use steel wool to clean the frame as it could damage or discolor the frame surface. Muffler stain remover (Scotch-Brite Hand Pad #7447-maroon) is for removing stains on the non-coated aluminum frame only. (1) alternator cover Servicing Your Honda...
  • Page 85 Servicing Your Honda...
  • Page 86: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CR Front Suspension Adjustments......82 for maximum competition performance. Rear Suspension Adjustments ......95 Suspension Adjustments for Track Conditions ..99 Initial suspension adjustments should be Suspension Adjustments Guidelines ....100 performed after a minimum of two hours of easy Carburetor Adjustments &...
  • Page 87: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: • Oil volume — The effects of higher or lower Air is an unstable gas which builds up pressure Compression Damping fork oil level are only felt during the final 3.9...
  • Page 88: Front Suspension Adjustment

    See the Service Manual or If the fork is too hard on big bumps, turn the your Honda dealer for this service. damping adjuster counterclockwise 1-turn and lower the oil level in increments of 0.2oz (5 cm 1.
  • Page 89 Front Suspension Adjustments 3. Remove the handlebar pad. 6. Remove the disc cover (7) by removing the NOTICE Remove the washers/handlebar holder nuts disc cover bolts (8). (3), mounting rubbers and handlebar (4). Do not support the brake caliper by the brake hose.
  • Page 90 Front Suspension Adjustments 11. Clean the fork assembly, especially the sliding 14. Hold the outer tube (23), then remove the 16. Temporarily install the fork damper to the surface of the slider (18) and dust seal (19). fork damper (24) from the outer tube using a outer tube.
  • Page 91 Front Suspension Adjustments 21. Apply pressure to the fork damper and insert Damper Oil Change a special tool or mechanic’s stopper tool (27) (25) between the axle holder (25) and lock nut (28). (28) 22. Hold the lock nut and remove the fork center (29) bolt (26) from the fork damper.
  • Page 92 Recommended Oil: Oil Level: 1.65 – 1.85 in (42 – 47 mm) Do not disassemble the fork cap assembly. Pro Honda HP Fork oil 5 W or equivalent Replace the fork cap as an assembly if it is Recommended Amount: damaged.
  • Page 93 Front Suspension Adjustments 9. Tighten the fork cap (1) while holding the cut 11. Screw in the lock nut (6) to the fork damper 13. Drain the extra oil from the fork damper out of the fork damper (2) using the lock nut piston rod (5) fully.
  • Page 94: Fork Assembly

    Front Suspension Adjustments 2. Tighten the lock nut (2) fully by hand and Amount of fork oil left in the fork Fork Assembly (without damper and spring) unit: cm measure the thread length. Standard: 0.43 – 0.51 in (11 – 13 mm) minute 1.
  • Page 95 Front Suspension Adjustments 4. Set the lower end (axle holder) of the slider in 8. Make sure that there is clearance between the 10. Apply fork oil to the fork center bolt (9) O- a vise with a piece of wood or soft jaws to lock nut (2) and center bolt (9).
  • Page 96 Standard (0.44 kgf/mm) Fork Spring outer tube/slider (1). No mark Recommended Oil: (factory products) 2 scribe marks Pro Honda HP Fork Oil 5W or equivalent. 3 scribe marks (aftermarket parts) Standard oil 13.2 US oz Standard oil 13.3 US oz...
  • Page 97 Front Suspension Adjustments 14. Check that the O-ring (12) on the fork 15. Temporarily thread the fork damper (4) into 17. Tighten the fork lower pinch bolts (13) to the damper assembly (4) is in good condition. the outer tube (1). Insert both fork legs into specified torque: Apply the recommended fork oil to the O- the fork clamps.
  • Page 98 Front Suspension Adjustments 20. Clean the threads of the fork protector bolts 21. Clean the surfaces where the axle and axle 22. Align the brake caliper (20) and hose with (16) and axle holder thoroughly. clamps contact each other. the left fork leg, making sure that the brake Apply locking agent to the bolt threads.
  • Page 99 Front Suspension Adjustments 24. Install the handlebar (22) mounting rubbers 26. Install and tighten the number plate bolt (28). (23), washers and handlebar holder nuts (24) Install the handlebar pad (29). (30) and tighten the handlebar holder nuts to the (30) specified torque: 32 lbf·ft (44 N·m, 4.5 kgf·m)
  • Page 100: Rear Suspension Adjustments

    Min. : 9.9 in (252 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring preload length (Optional spring) Min. (Softer, 5.0 kgf/mm): 9.7 in (246 mm) The instructions found in this owner’s manual are limited to adjustments of the shock assembly Min.
  • Page 101 Rear Suspension Adjustments High Speed Damping: Rebound Damping Rear Suspension Damping The high speed damping can be adjusted by The rebound damping adjuster (3) is located at turning the hexagonal portion of the compression the lower end of the shock absorber. adjuster.
  • Page 102 Rear Suspension Adjustments 4. Calculate the race sag dimension. Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT important for competition use.
  • Page 103 Rear Suspension Adjustments 6. Calculate the free sag dimension. Spring Rates To do this, subtract the loaded without rider If you are lighter or heavier than the average dimension (step 5) from the unloaded rider and cannot set the proper ride height dimension (step 2).
  • Page 104: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface Hard Surface On soft ground, sand, and especially mud, For a fast, hard track with no large jumps, you consider increasing compression damping front can probably run the same spring as normal, but and rear.
  • Page 105: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CR, using the methods described on pages 82 - 99. 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 106 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 one-click increments. •...
  • Page 107 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 108: Carburetor Adjustments & Tuning Tips

    (11) (15) Optional main jets and slow jets are available for (10) (13) your CR. See your Honda dealer. (9) main jet (13) baffle plate Any engine or airbox modifications or the use of (10) jet needle (14) float...
  • Page 109: Standard Tuning Recommendations

    Carburetor Adjustments & Tuning Tips Jet Needle All jetting is based on The jet needle controls fuel/air mixture from • Standard Jetting fully closed to 3/4 throttle. The straight section • 32:1 Fuel/Oil Ratio (1) affects throttle response at smaller throttle •...
  • Page 110 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 drastically. However, there are some unique All jetting recommendations are based on Before adjusting carburetor settings, check the atmospheric conditions or race day situations that standard jetting with an unmodified engine.
  • Page 111 • The standard carburetor settings are ideal for seriously injured when handling fuel. the following conditions: 32-to-1 premix ratio using Pro Honda HP2 2-stroke oil or its equivalent, sea level altitude, and 68 °F (20 • Stop the engine and keep heat, sparks and flame away.
  • Page 112 Carburetor Adjustments & Tuning Tips 7. Change the main jet (5) and slow jet (6) as 5. Loosen the screws (5) and remove the Carburetor Disassembly/Assembly required. carburetor top (6). 1. Remove the fuel tank. (Page 30) 2. Remove the subframe. (Page 32) 3.
  • Page 113 Carburetor Adjustments & Tuning Tips 7. Remove the throttle cable (9) and collar (10) 10. Remove the carburetor to the left side. 12. Use a float level gauge (17) to measure the from the cable holder (11). float level (18) with the float tab just 8.
  • Page 114 Carburetor Adjustments & Tuning Tips After installing the carburetor, check the air vent NOTICE Spark Plug Reading hoses (20) and overflow hose (21) for kinking or pinching and correct routing as necessary. An improperly tightened spark plug can damage the engine. If a plug is too loose, a piston may Refer to Spark Plug, page 48.
  • Page 115: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CR’s wheelbase can offer subtle not adjustable. changes in overall handling.
  • Page 116: Gearing

    Unless you have the required mechanical Ideally, your gearing should be adjusted to suit gearing feels wrong. knowhow, tools, and an official Honda Service all these conditions. Manual, sprocket changing should be done by If you decide to try a gearing change, have your Honda dealer.
  • Page 117: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CR offer a “happy medium” for additional loads to the transmission because it the variety of soil conditions the majority of grips so well, especially when riding in situations...
  • Page 118: 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 Handlebar Position, Width & Shape the threads of these bolts prior to adjustment to help ensure the correct torque is retained.
  • Page 119 Adjustments for Competition...
  • Page 120: Tips

    Tips Here’s helpful advice on how to transport and Transporting Your Motorcycle ......116 store your Honda, as well as two troubleshooting Storing Your Honda..........117 flow charts. You & the Environment ........118 Troubleshooting..........119 Tips Tips...
  • Page 121: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CR, brace the front wheel against transport your Honda, we recommend that you the front of the truck bed or trailer rail. Attach follow these guidelines: the lower ends of two straps to the tie-down •...
  • Page 122: Storing Your Honda

    Removal from Storage such as during the winter, thoroughly inspect (1) at the water pump (2) to drain coolant. your Honda and correct any problem before After the coolant has been completely storing it. That way, needed repairs won’t be drained, ensure that the drain bolt sealing 1.
  • Page 123: 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 124: 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 (*) timing* •...
  • Page 125 Tips...
  • Page 126: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........122 other technical data. Specifications ...........123 Torque Specifications ........124 High Altitude Carburetor Adjustment ....127 Oxygenated Fuels..........128 Competition Logbook ........129 Optional Parts List..........131 Spare Parts & Equipment.........132 Wiring Diagram..........133 Technical Information...
  • Page 127: Vehicle Identification

    Vehicle Identification RIGHT SIDE Serial Numbers The VIN and engine serial numbers are required when you register your CR. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of this manual. The VIN (vehicle identification number) (1) is stamped on the right side of the steering head and also appears on the Safety Certification Label...
  • Page 128: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 86.0 in 2,185 mm Type Liquid cooled, 2-stroke Final reduction 3.769 Overall width 32.3 in 821 mm Cylinder arrangement Single 9° inclined from Left foot-operated return Gear shift pattern vertical system 1-N-2-3-4-5...
  • Page 129: Torque Specifications

    Torque Specifications Nuts, Bolts, Fasteners Torque Check and tighten nuts, bolts, fasteners before every outing. Item Remarks lbf·ft N·m kgf·m Engine ENGINE 1 Cylinder head nut 2 Cylinder mounting 3 Carburetor insulator bolt 4 Clutch cover bolt LEFT SIDE 5 Water pump cover bolt 6 RC cover bolt RIGHT SIDE...
  • Page 130 (11) Brake hose bolts (12) (18) (15) NOTES: 1. Apply Pro Honda Hondalock or an equivalent to the threads. 2. Apply oil to the threads and flange surface. 3. Stake. (14) 4. U-nut. 5. UBS nut. 6. SH bolt.
  • Page 131 (39) Upper chain roller NOTE 6 (22) Lower chain roller NOTE 4 NOTES: 1. Apply Pro Honda Hondalock or an equivalent to the (31) threads. 2. Apply oil to the threads and flange surface. 3. Stake. (35) 4. U-nut. (36) (34) 5.
  • Page 132: 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 133: 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 134: 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 135 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 136: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks Honda dealer. Driven sprocket < >: Drive chain links Shock spring Higher gearing 48 Teeth, Aluminum <114> Standard 291.2 lbf/in (5.2 kgf/mm) CARBURETOR Remarks...
  • Page 137: Spare Parts & Equipment

    In addition to the usual nuts and bolts, brake assemblies (front & rear) consider the following: wheels & tires (front & rear, mounted) Pro Honda HP Trans Oil or Pro Honda GN4 4- clutch plates & transmission oil stroke oil seat...
  • Page 138: Wiring Diagram

    Wiring Diagram Technical Information...
  • Page 139 Technical Information...
  • Page 140: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........136 contacting Honda and how to get an official Contacting Honda..........137 Honda service manual. Your Honda Dealer...........138 The Honda Rider’s Club (USA only) ....139 Consumer Information...
  • Page 141: Authorized Manuals

    Authorized Manuals The Service Manual used by your Honda dealer is available from Helm, Inc. NOTE: Dealers and Companies, please provide dealer or company name, and also the name of the person to whose attention the shipment should be sent. For purchases outside U.S.A., please write to the address shown below for a quotation.
  • Page 142: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.
  • Page 143: 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 144: The Honda Rider's Club (Usa Only)

    • 24-hour, toll-free roadside assistance for your new Honda (includes roadside assistance for your transport vehicle [up to one ton] as long as your Honda is aboard or in tow). For street- legal motorcycles and scooters only. • An exclusive HRCA website complete with...
  • Page 145: Table Of Contents

    Appearance Care ..........78 Contacting Honda..........137 Maintenance Schedule ........20 Your Honda Dealer...........138 General Competition Maintenance ....22 The Honda Rider’s Club (USA only) ....139 Before & After Competition Maintenance..26 Between Motos & Practice Maintenance ..26 TABLE OF CONTENTS .......140 After Competition Maintenance ....27 INDEX .............141...
  • Page 146: Index

    ..........82 component locations, fork, tires ..............70 maintenance..........28 front suspension adjustment ......82 operation ............6 front suspension inspection......60 American Honda, contacting ......137 apparel, protective ..........2 competition logbook........129 oil recommendation........62 coolant ..............38 consumer information ........135 front brake lever adjustment......65 appearance care ..........78 contacting Honda ..........137...
  • Page 147 ..........27 rear suspension maintenance......61 gearing ..............111 before & after competition......26 reed valve ............58 guidelines, suspension adjustment ....100 between motos & practice ......26 Rider’s Club Honda..........139 compornent locations ........28 riding, general competition ........22 apparel ............2 importance ............18 basic operation ..........11 handlebar inspection ..........76...
  • Page 148 Index suspension, front ..............60 rear ..............61 suspension adjustment, front ..............82 rear ..............95 for track conditions ........99 guidelines ............100 transmission oil ..........36 tuning tips ............103 throttle, freeplay............42 inspection ............43 tires, air pressure ............70 flat ..............70 selection ............112 tools ..............132 torque specifications ........124 transporting ............116 troubleshooting ..........119 tubes, replacing ..........71...
  • Page 149: Quick Reference

    91 or higher Premix: Pro Honda HP2 2-stroke oil (32 : 1) Tank: 2.0 US gal (7.7R) Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 4-stroke oil or an equivalent. Front: 80/100-21 51M, Rear: 110/90-19 62M Tires Type: bias-ply, tube Tire Pressure Front: 15 psi (100 kPa, 1.0kgf/cm...

This manual is also suitable for:

2007 cr250r