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CR500R
Service manual
Honda CR500R Service Manual
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Service manual
(30 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
Symbols
General Information
General Safety
Carbon Monoxide
Gasoline
Coolant
Nitrogen Pressure
Model Identification
Specifications
Lubrication System
Fuel System
Cooling System
Clutch System
Torque Values
Tools
Lubrication & Seal Points
Cable & Harness Routing
Optional Parts
Frame/Body Panels/Exhaust System Service Information
Frame/Body Panels/Exhaust System Troubleshooting
Seat Removal
Seat Installation
Side Covers Removal/Installation
Fuel Tank Removal/Installation
Fuel Tank Disassembly/Assembly
Silencer Removal/Installation
Expansion Chamber Removal/Installation
Sub-Frame Removal
Sub-Frame Installation
Maintenance Service Information
Maintenance Specifications
Maintenance Special Tools
Service Access Guide
Competition Maintenance Schedule
Additional Items Requiring Frequent Replacement
Throttle Operation
Air Cleaner
Spark Plug
Radiator Coolant
Cooling System
Inspecting & Adding Transmission Oil
Replacing Transmission Oil
Drive Chain
Drive Chain Adjustment
Drive Chain Sliders
Drive Chain Rollers
Drive/Driven Sprocket
Brake Pads Wear
Front Brake Fluid
Rear Brake Fluid
Brake System Maintenance
Clutch System Maintenance
Brake Lever Adjustment
Brake Pedal Adjustment
Control Cables
Expansion Chamber/Silencer
Control Cables Lubrication
Throttle Assembly
Silencer Glass Wool Replacement
Front Suspension
Swingarm/Shock Linkage
Rear Suspension
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Head Bearings
Fuel System Service Information
Fuel System Specifications
Fuel System Troubleshooting
Minor Carburetor Adjustment
Major Carburetor Adjustment
Turning Information Chart
Turning for Special Conditions
Carburetor Removal
Carburetor Disassembly
Carburetor Assembly
Carburetor Installation
Reed Valve Removal
Air Cleaner Housing
Reed Valve Disassembly
Reed Valve Assembly
Reed Valve Installation
Air Cleaner Installation
Cooling System Service Information
Cooling System Specifications
Cooling System Tools
Cooling System Troubleshooting
Coolant Replacement
Radiator Removal
Radiator Installation
Water Pump Water Seal Inspection
Water Pump Disassembly
Water Pump Bearing Replacement
Water Seal/Oil Seal Replacement
Water Pump Assembly
Engine Removal/Installation Service Information
Engine Removal/Installation Specifications
Engine Removal
Engine Installation
Cylinder Head/Cylinder/Piston Exploded View
Cylinder Head/Cylinder/Piston Service Information
Cylinder Head/Cylinder/Piston Specifications
Cylinder Head/Cylinder/Piston Troubleshooting
Cylinder Head Removal
Cylinder Head Combustion Chamber Decarbonizing
Cylinder Head Inspection
Cylinder Head Installation
Cylinder Removal
Cylinder Inspection
Piston Removal
Piston/Piston Pin Inspection
Piston Ring Inspection
Connecting Rod Inspection
Piston Installation
Cylinder Installation
Clutch/Kickstarter/Gearshift Linkage Exploded View
Clutch/Kickstarter/Gearshift Linkage Service Information
Clutch/Kickstarter/Gearshift Linkage Specifications
Clutch/Kickstarter/Gearshift Linkage Tool
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
Right Crankcase Cover Removal
Right Crankcase Cover Installation
Clutch Removal
Clutch Lifter Lever Removal
Clutch Lifter Lever Installation
Clutch Installation
Kickstarter Disassembly
Kickstarter Assembly
Gearshift Linkage Removal
Gearshift Linkage Installation
Crankcase/Crankshaft/Transmission Exploded View
Crankcase/Crankshaft/Transmission Service Information
Crankcase/Crankshaft/Transmission Specifications
Crankcase/Crankshaft/Transmission Troubleshooting
Crankcase/Crankshaft/Transmission Tools
Crankcase Separation
Transmission Disassembly
Transmission Assembly
Crankshaft Removal
Crankcase Bearing/Oil Seal Locations
Crankshaft Bearings
Transmission Bearings
Crankshaft Installation
Right Crankcase Bearings
Crankcase Assembly
Front Wheel/Suspension/Steering Exploded View
Front Wheel/Suspension/Steering Service Information
Front Wheel/Suspension/Steering Specifications
Front Wheel/Suspension/Steering Tools
Front Wheel/Suspension/Steering Troubleshooting
Front Wheel Removal
Front Wheel Disassembly
Front Wheel Inspection
Front Wheel Bearings
Front Wheel Rim
Front Wheel Assembly
Front Wheel Installation
Fork Removal
Fork Disassembly
Fork Inspection
Fork Assembly
Fork Installation
Handlebar Removal
Handlebar Installation
Steering Stem Removal
Steering Stem Bearing Replacement
Steering Stem Installation
Rear Wheel/Suspension Exploded View
Rear Wheel/Suspension Service Information
Rear Wheel/Suspension Specifications
Rear Wheel/Suspension Tools
Rear Wheel/Suspension Troubleshooting
Rear Wheel Removal
Rear Wheel Disassembly
Rear Wheel Inspection
Rear Wheel Bearings
Rear Wheel Rim
Rear Wheel Assembly
Rear Wheel Installation
Shock Absorber Removal
Shock Absorber Spring Removal
Shock Absorber Bladder Replacement
Shock Absorber Damper Disassembly
Piston Ring Replacement
Damper Rod Disassembly
Rod Guide Inspection
Rod Guide Assembly
Spherical Bearing Replacement
Shock Absorber Installation
Shock Linkage Removal
Shock Linkage Inspection
Needle Bearing Replacement
Swingarm Removal
Swingarm Replacement
Swingarm Assembly
Swingarm Installation
Brake System Exploded View
Brake System Service Information
Brake System Specifications
Brake System Troubleshooting
Brake System Tools
Brake Fluid Draining
Brake Fluid Filling/Air Bleeding
Brake Pad Replacement
Front Master Cylinder Disassembly
Front Master Cylinder Assembly
Rear Master Cylinder Removal
Rear Master Cylinder Disassembly
Rear Master Cylinder Assembly
Rear Master Cylinder Installation
Front Brake Caliper Removal
Front Brake Caliper Disassembly
Front Brake Caliper Assembly
Front Brake Caliper Installation
Rear Brake Caliper Removal
Rear Brake Caliper Disassembly
Rear Brake Caliper Assembly
Rear Brake Caliper Installation
Electrical System Service Information
Electrical System Specifications
Electrical System Tools
Electrical System Location
Electrical System Troubleshooting
Ignition Control Module (ICM) System Inspection
Ignition Control Module Removal/Installation
Alternator
Exciter Coil Inspection
Ignition Pulse Generator Inspection
Alternator Removal
Alternator Installation
Ignition Coil Inspection
Ignition Timing
Engine Stop Button
Wiring Diagram
Troubleshooting
Engine Does Not Start or Is Hard to Start
Engine Lacks Power
Poor Performance at Low and Idle Speed
Poor Performance at High Speed
Poor Handling
Index
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Specifications
2
Wiring Diagram
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust System Service Information
29
Fuel System Troubleshooting
54
Cooling System Troubleshooting
66
Cylinder Head/Cylinder/Piston Troubleshooting
80
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
90
Crankcase/Crankshaft/Transmission Troubleshooting
104
Front Wheel/Suspension/Steering Troubleshooting
121
Rear Wheel/Suspension Troubleshooting
158
Brake System Troubleshooting
192
Electrical System Troubleshooting
207
Troubleshooting
215
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