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Honda CR125R 2006 Owner's Manual

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2006
Honda CR125R
OWNER'S MANUAL & COMPETITION HANDBOOK

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  Summary of Contents for Honda CR125R 2006

  • Page 1 2006 Honda CR125R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 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 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

    Reed Valve............58 Contacting Honda..........133 BASIC OPERATING INSTRUCTIONS ..11 Your Honda Dealer...........134 Safe Riding Precautions ........12 Chassis The Honda Rider’s Club (USA only) ....135 Starting & Stopping the Engine ......13 Suspension............60 Preparation ............13 Brakes..............65 TABLE OF CONTENTS .......136 Starting Procedure ........13 Wheels ..............69...
  • 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 Precaution ......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 6: Important Safety Information

    Important Safety Precautions either. Your CR can provide many years of pleasure, if Keep Your Honda in Safe Condition. Maintaining your CR properly is critical to your you take responsibility for your own safety and safety. A loose bolt, for example, can cause a...
  • Page 7: 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 8: 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 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 front brake lever clutch lever engine stop button throttle grip choke knob kickstarter fuel valve rear brake pedal 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 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 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 Break-in Guidelines ...........15 Basic Operating Instructions Basic Operating Instructions...
  • Page 16: 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 17: 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 18: 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) 2 – 3 times, and then close it.
  • Page 19: 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 20 Basic Operating Instructions...
  • Page 21: Servicing Your Honda

    Servicing Your Honda Keeping your CR well maintained is absolutely Before You Service Your Honda Chassis essential to your safety. It’s also a good way to The Importance of Maintenance ......18 Suspension............60 protect your investment, get maximum Maintenance Safety ..........19 Brakes..............65...
  • 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

    • 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 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 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 26: 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 27 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...
  • Page 28 For added peace of mind, and the flywheel makes the ignition control module remove the nuts, clean the threads, and apply 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

    (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. Servicing Your Honda...
  • Page 31: After Competition Maintenance

    If you decide to wash your CR or use cleaners, lube. refer to Appearance Care (page 78). 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 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 34: 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) shrouds Servicing Your Honda...
  • Page 35 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 36: Subframe Removal

    6. Remove the subframe (9) by pulling it (2) bolt/collar (1) screw straight 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 37 (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 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) 3.79 5.68...
  • 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

    (4–stroke engine oil only) others without friction modifiers as molybdenum additives suggested oil* Pro Honda HP Trans oil, Pro NOT RECOMMENDED Honda GN4 or HP4 (without molybdenum additives) 4–stroke engine Other viscosities shown in the following chart oil or an equivalent may be used when the average temperature in * Suggested 4–stroke engine oils are equal...
  • Page 41: Checking & Adding 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 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 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 45 Air Cleaner 8. Apply a thin coat of Honda White Lithium 10. Insert the pin in the air cleaner housing hole 11. Reinstall the seat (page 29), making sure it is Grease or an equivalent, to the sealing (7) and install the assembly into the air securely attached.
  • Page 46: 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 47 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 48: 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 49 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 50 Loosen the bolts in a crisscross pattern in 2 or Replace the clutch springs as a set if any one of 3 progressive steps. them is beyond the service limit or if the clutch plates have been burnt/heat discolored. Servicing Your Honda...
  • Page 51 11. Lubricate the rear brake pedal pivot (9) and Clutch Disc/Plate/Cover Installation 7. Install the five clutch springs and bolts (6). pivot bolt (10) with Honda Lithium Grease or 8. Tighten the bolts in a crisscross pattern in 2 an equivalent and install the pivot bolt.
  • Page 52: 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 106). Check the fuel/oil mixture, carburetor and fuel system, and ignition timing. Servicing Your Honda...
  • Page 53: Cylinder System

    (7). 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 (7) cylinder head Servicing Your Honda...
  • Page 54 (3) bolts (7) B-clip (13) screw (16) upper mounting bolt (4) screw (8) setting collar (14) radiator hose (17) lower mounting bolt (5) right RC cover (9) valve rod (15) radiator shroud (18) radiator grill (6) grommet Servicing Your Honda...
  • Page 55 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 56 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 57 9 lbf·ft (12 N·m, 1.2 kgf·m) (12) (19) (22) (10) (13) (21) (5) flange nuts (20) (10) right RC valve cover (13) screw (19) gasket (21) clamp (cont’d) (12) bolts (20) left RC valve cover (22) bolts Servicing Your Honda...
  • Page 58 2 or 3 steps: 9. Start the engine and check for the following: 20 lbf·ft (27 N·m, 2.8 kgf·m) – compression leaks – abnormal engine noise – secondary air leaks – coolant leaks (5) cylinder head (6) cylinder head nuts Servicing Your Honda...
  • Page 59: Rc Valve

    2. Check that the exhaust valve (4) turns Before attempting complete disassembly, we recommend you consult the Honda Service Manual or your smoothly. If the exhaust valve turns Honda dealer. Mismatching of parts on reassembly can measurably affect fully engine performance.
  • Page 60 (3) nut (2) stopper plate (4) washer 4. Remove the valve shaft assembly (5), collar (1) valve shaft assembly (6) and RC valves (7) from cylinder. (2) RC valves (5) valve shaft assembly (7) RC valves (6) collar Servicing Your Honda...
  • Page 61 8. Install the cylinder (page 52). (1) RC valves (3) collar (2) valve shaft assembly 5. Make sure that the cut-outs of the valve shaft (4) and collar (5) are aligned. (4) cut-out of the valve shaft (5) cut-out of the collar Servicing Your Honda...
  • Page 62: Reed Valve

    2. Align the cut-outs (5) between the reed valves valve assembly (5). and stoppers, then install them onto the cage. (1) reed valve mounting screws (4) reed valve (2) stopper (5) cut-out (4) reed valve inner (3) sub-reed valve (5) reed valve assembly Servicing Your Honda...
  • Page 63 7 lbf·ft (10 N·m, 1.0 kgf·m) After installation, check for secondary air leaks around the reed cage and insulator. (1) reed valve inner (3) cut-outs (2) reed valve assembly (4) insulator (5) carburetor insulator mounting bolts 5. Install the carburetor (page 104). Servicing Your Honda...
  • Page 64: Suspension

    See page 62 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 locking the front brake and pushing down on assure maximum performance of your CR’s...
  • Page 65 (page 96). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. The instructions found in this owner’s manual are 2. Remove the subframe (page 32).
  • Page 66 Before pouring the fork oil, make sure that the viscosity (weight) 5 W partition plate is removed. suggested oil Pro Honda HP Fork Oil or equivalent Fork Oil Change 1. Remove the fork cap, spring seat and fork spring as described in Front Suspension Oil...
  • Page 67 33 mm it nears full [capacity] 17.1 US oz compression. (505 cm Minimum oil 4.3 in Slightly softer as level 108 mm it nears full [capacity] 14.4 US oz compression. (425 cm (9) oil level (cont’d) Servicing Your Honda...
  • Page 68 (2) lock nut (3) spring guide 15. Install the fork spring, spring seat and fork cap as described in Front Suspension Oil Level Adjustment (page 84-91). Servicing Your Honda...
  • Page 69: 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 70 (23 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 71 Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 • Make sure there are no fluid leaks. brake fluid from a sealed container, or an brake fluid from a sealed container, or an •...
  • Page 72 0.04 in (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 73: 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 74: Tires & Tubes

    • Check the position of both valve stems. A particular riding condition, make changes a little tilted valve stem indicates the tube is slipping at a time. inside the tire or the tire is slipping on the rim. Servicing Your Honda...
  • Page 75 • 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 76: 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 77 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 78 If the measurement exceeds the service limit, master link and pulling the old chain to replace the chain. After the chain is position the new chain on the sprockets. measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...
  • Page 79: Expansion Chamber

    3. Check the expansion chamber for cracks or Front: 9 lbf·ft (12 N·m, 1.2 kgf·m) deformation. Rear: 7 lbf·ft (10 N·m, 1.0 kgf·m) A damaged chamber may decrease engine performance. (1) springs (2) bolts Servicing Your Honda...
  • Page 80: 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 81 (4) clutch cover bolt 6 Right RC cover bolt (5) water pump cover bolt 7 Right RC cover screw LEFT SIDE 8 Alternator cover bolt 9 Left RC cover bolt (8) alternator cover bolt (9) left RC cover bolt Servicing Your Honda...
  • Page 82: 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-driving dirt inside multi-surface cleaner/degreaser, to remove both and needed lubrication out.
  • Page 83 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 84 Servicing Your Honda...
  • Page 85: 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 ......92 Suspension Adjustments for Track Conditions ..96 Initial suspension adjustments should be Suspension Adjustments Guidelines ....97 performed after a minimum of two hours of easy Carburetor Adjustments &...
  • Page 86: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the The air pressure should be adjusted according to Front Suspension Air Pressure rider’s weight and riding conditions by using one the altitude and outside temperature. or more of the following methods: •...
  • Page 87: Front Suspension Adjustment

    Front Suspension Adjustment Rebound Damping Front Suspension Damping Fork Springs Rebound damping effects how quickly the fork rebounds. Compression Damping The fork springs in CR’s are about right for The rebound damping adjuster has 18 positions Compression damping affects how quickly the riders weighing between 150 and 160 lbs (less or more.
  • Page 88 See the Service Manual or your Honda dealer for this service. 1. Place your CR on the optional workstand or equivalent support with the front wheel off the ground.
  • Page 89 Front Suspension Adjustments 6. Remove the disc cover (7) by removing the 9. Remove the fork protector bolts (12), brake 11. Loosen the fork leg lower pinch bolts (17), two bolts (8). hose clamp bolts (13) and fork protectors then pull the fork legs down and out. (14).
  • Page 90 Front Suspension Adjustments 13. Record the rebound damping adjuster 17. Pour the recommended fork oil into the fork position and turn the adjuster screw (22) tube (20) until a little oil flows out of the top counterclockwise until it stops. of the damper rod.
  • Page 91 Front Suspension Adjustments Fork Oil Level Optional Stiffer (0.46 kgf/mm) Fork Spring 20. Inspect both ends of the fork spring. If you find any roughness or burred edge on the   2 separate scribe marks   Standard (0.44 kgf/mm) Fork Spring end of either spring, smooth the roughness with a file and some emery cloth.
  • Page 92 Front Suspension Adjustments 24. Loosen the lock nut (25) slightly. 28. Place the spring seat (26) on the fork spring 29. Screw the fork cap (6) on the damper rod. 25. Attach a two-foot length of mechanic’s wire (27) with its flat side facing up. 30.
  • Page 93 Front Suspension Adjustments 33. Align the groove in the fork tube (20) with 39. Clean the threads of the fork protector bolts NOTICE the top surface of the upper fork clamps (12) and axle holder thoroughly. (32). Over-tightening the pinch bolts can deform the Apply locking agent to the bolt threads.
  • Page 94 Front Suspension Adjustments 40. Clean the surfaces where the front axle shaft 44. Align the brake caliper (16) and hose with 48. Install the handlebar (4) mounting rubbers and axle clamps contact each other. the left fork leg, making sure that the brake (34), washers and handlebar holder nuts (3) 41.
  • Page 95 Front Suspension Adjustments 50. Install and tighten the number plate bolt (1). 53. Tighten the left axle pinch bolts (38) 54. Clean the threads of the bolts and axle holder 51. Install the handlebar pad (37). alternately first. thoroughly. While keeping the forks parallel, alternately 55.
  • Page 96: Rear Suspension Adjustments

    Min. : 10.0 in (254 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring preload length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 4.4 kgf/mm): 10.0 in (254 mm) limited to adjustments of the shock assembly Min.
  • Page 97 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. Compression Damping adjuster.
  • Page 98 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 Setting the proper race sag (ride height) is very dimension (step 2). UNLOADED MEASUREMENT important for competition use.
  • Page 99 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 100: 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 101: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CR, using the methods described on pages 82 - 96. 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 102 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 103 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 104: 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 105 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 106 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 107 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 (–) • Stop the engine and keep heat, sparks equivalent, sea level altitude, and 68 °F (20 and flame away.
  • Page 108 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 109 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 110 Carburetor Adjustments & Tuning Tips NOTICE NOTICE Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may be damaged.
  • Page 111: 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 112: 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 113: 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 114: 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 115: Tips

    Tips Here’s helpful advice on how to transport and Transporting Your Motorcycle ......112 store your Honda, as well as two troubleshooting Storing Your Honda..........113 flow charts. You & the Environment ........114 Troubleshooting..........115 Tips Tips...
  • Page 116: 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 117: 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 118: 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 119: 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 120 Tips...
  • Page 121: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........118 other technical data. Specifications ...........119 Torque Specifications........120 High Altitude Carburetor Adjustment ....123 Oxygenated Fuels..........124 Competition Logbook ........125 Optional Parts List ...........127 Spare Parts & Equipment.........128 Wiring Diagram..........129 Technical Information...
  • Page 122: Vehicle Identification

    Vehicle Identification The frame number (2) 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 123: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85.2 in 2,163 mm Type Liquid cooled, 2-stroke Final reduction 4.000 Overall width 32.3 in 821 mm Cylinder arrangement Single 18.5° inclined from Left foot-operated return Gear shift pattern vertical system 1-N-2-3-4-5...
  • Page 124: 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 RIGHT SIDE 5 Water pump cover bolt 6 Right RC cover bolt 7 Right RC cover...
  • Page 125 Kickstarter arm bolt Front brake master cylinder holder (20) Brake hose bolts (19) NOTES: 1. Apply Honda Thread Lock or an equivalent to the (12) (11) (14) threads. (17) 2. Apply oil to the threads and flange surface. 3. Stake.
  • Page 126 Fork air plug Upper chain roller NOTE 6 Lower chain roller NOTE 4 (30) NOTES: 1. Apply Honda Thread Lock or an equivalent to the (35) threads. 2. Apply oil to the threads and flange surface. (36) (34) 3. Stake.
  • Page 127: 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 128: 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 129: 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 130 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 131: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring Higher gearing 51 Teeth, Aluminum <116> Softer 246.4 lbf/in (4.4 kgf/mm) CARBURETOR...
  • Page 132: Spare Parts & Equipment

    In addition to the usual nuts and bolts, rear brake assembly consider the following: wheels & tires (front & rear, mounted) Pro Honda HP Trans Oil or Pro Honda GN4 or clutch plates & transmission oil HP4 (without molybdenum additives only) seat...
  • Page 133: Wiring Diagram

    Wiring Diagram Technical Information...
  • Page 134 Technical Information...
  • Page 135: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........132 contacting Honda and how to get an official Contacting Honda..........133 Honda service manual. Your Honda Dealer...........134 The Honda Rider’s Club (USA only) ....135 Consumer Information...
  • Page 136: 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 137: 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 138: 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 139: 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 140: Table Of Contents

    Appearance Care ..........78 Contacting Honda..........133 Maintenance Schedule ........20 Your Honda Dealer...........134 General Competition Maintenance ....22 The Honda Rider’s Club (USA only) ....135 Before & After Competition Maintenance..26 Between Motos & Practice Maintenance ..26 TABLE OF CONTENTS .......136 After Competition Maintenance ....27 INDEX .............137...
  • Page 141: Index

    ........44 flooded engine, starting ........13 front suspension ..........82 component locations, fork, tires ..............70 maintenance..........28 front suspension adjustment ......82 American Honda, contacting ......133 operation ............6 front suspension inspection......60 apparel, protective ..........2 competition logbook........125 oil recommendation........62 coolant ..............38 consumer information ........131 frame number ..........118...
  • Page 142 ........76 rear suspension maintenance......61 gasoline ..............34 after competition ..........26 reed valve ............58 gearing ..............108 before & after competition......26 Rider’s Club Honda..........135 guidelines, suspension adjustment ....97 between motos & practice ......26 riding, component locations ........28 apparel ............2 general competition ........22 basic operation ..........11...
  • Page 143 Index suspension, front ..............60 rear ..............61 suspension adjustment, front ..............82 rear ..............92 for track conditions ........96 guidelines ............97 transmission oil ..........36 tuning tips ............100 throttle, freeplay............42 inspection ............43 tires, air pressure ............70 flat ..............70 selection ............109 tools ..............128 torque specifications ........120 transporting ............112 troubleshooting ..........115 tubes, replacing ..........70...
  • Page 144: Quick Reference

    Premix: Pro Honda HP2 2-stroke oil (32 : 1) Tank: 2.0 US gal (7.7 Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil, or an equivalent. Tires Front: 80/100-21 51M, Rear: 100/90-19 57M...

This manual is also suitable for:

2007 cr125rCr 125r