Honda CR 125R 2003 Manuals

Manuals and User Guides for Honda CR 125R 2003. We have 1 Honda CR 125R 2003 manual available for free PDF download: Sevice Manual

Honda CR 125R 2003 Sevice Manual

Honda CR 125R 2003 Sevice Manual (294 pages)

Brand: Honda | Category: Motorcycle | Size: 39 MB

Table of Contents

Important Safety Notice
2
Contents
3
Symbols
4
General Information
5
General Safety
5
Carbon Monoxide
5
Gasoline
5
Service Rules
6
Coolant
6
Nitrogen Pressure
6
Model Identification
7
Frame Serial Number
7
Carburetor Identification Number
7
Engine Serial Number
7
Specifications
8
Torque Values
17
Lubrication & Seal Points
22
Cable & Harness Routing
24
Optional Parts
30
Frame/Body Panels/Exhaust/System Service Information
37
Frame/Body Panels/Exhaust/System Troubleshooting
37
Frame/Body Panels/Exhaust/System Torque Values
37
Seat Removal
38
Seat Installation
38
Side Covers Removal/Installation
38
Radiator Shroud Removal/Installation
39
Number Plate Removal/Installation
39
Sub-Frame Removal
40
Sub-Frame Installation
40
Fuel Tank Fuel Filter Maintenance
41
Fuel Tank Removal/Installation
41
Exhaust Pipe Silencer Removal/Installation
42
Exhaust Pipe Expansion Chamber Removal/Installation
43
Maintenance
45
Service Information
45
Maintenance Schedule
47
Additional Items Requiring Frequent Replacement
48
Throttle Operation
49
Air Cleaner
49
Spark Plug
50
Radiator Coolant
52
Cooling System
52
Cylinder Head Decarbonizing
52
Exhaust Valve Decarbonizing
53
Transmission Oil Level Inspection
53
Transmission Oil Change
53
Drive Chain
54
Drive Chain Adjustment
55
Drive Chain Sliders
56
Drive Chain Rollers
56
Drive/Driven Sprockets
57
Brake Fluid Level Inspection
57
Brake Pad Wear
58
Brake System Lever Position Inspection
58
Clutch System
59
Brake System Brake Pedal Height
59
Control Cables
60
Expansion Chamber/Silencer Glass Wool Replacement
60
Front Suspension Inspection
61
Swingarm/Shock Linkage
62
Rear Suspension Inspection
62
Nuts, Bolts, Fasteners
63
Wheels/Tires
63
Steering Head Bearings
63
Table of Contents
65
Fuel System
65
Fuel System Service Information
66
Fuel System Specifications
66
Fuel System Tool
67
Fuel System Torque Values
67
Fuel System Troubleshooting
67
Idle Mixture and Idle Speed
68
Carburetor Adjustment, Minor
68
Carburetor Adjustment, Major
69
Tuning Information Chart
70
Tuning for Special Conditions
72
Carburetor Removal/Disassembly
73
Fuel System
73
Carburetor Assembly/Installation
78
Installation
84
- Reed Valve Removal
  85
- Reed Valve Disassembly/Assembly
  86
- Reed Valve Installation
  87
- Air Cleaner Housing Removal
  87
- Air Cleaner Housing Installation
  88
- Cooling System Torque Values
  91
- Cooling System Specifications
  91
- Cooling System Service Information
  91
- Cooling System Troubleshooting
  92
- Cooling System Tools
  92
- System Testing Coolant (Hydrometer Test)
  93
- Specific Gravity Chart
  93
- System Testing Radiator Cap/System Pressure Inspection
  94
- Coolant Replacement Preparation
  94
- Radiator Removal
  95
- Coolant Replacement/Air Bleeding
  95
- Radiator Installation
  96
- Water Pump Mechanical Seal Inspection
  97
- Water Pump Removal
  97
- Water Pump Bearing Replacement
  99
- Water Pump Water/Oil Seal Replacement
  100
- Water Pump Installation
  101
- Engine Removal/Installation
  104
- Engine Removal/Installation Torque Values
  105
- Engine Removal/Installation Specifications
  105
- Engine Removal/Installation Service Information
  105
- Engine Removal
  106
- Engine Installation
  108
- Cylinder Head/Cylinder/Piston
  110
- Cylinder Head/Cylinder/Piston Service Information
  111
- Cylinder Head/Cylinder/Piston Specifications
  111
- Cylinder Head/Cylinder/Piston Troubleshooting
  112
- Cylinder Head/Cylinder/Piston Torque Values
  112
- Cylinder Head Removal
  113
- Cylinder Head Inspection
  114
- Cylinder Head Installation
  114
- Cylinder Removal
  115
- Piston Removal
  116
- Cylinder Inspection
  117
- Piston Inspection
  118
- Cylinder/Piston Selection
  119
- Piston Installation
  120
- Connecting Rod Inspection
  120
- Cylinder Installation
  121
- RC Valve
  124
- RC Valve Service Information
  125
- RC Valve Troubleshooting
  125
- RC Valve Torque Values
  125
- RC Valve Tools
  125
- Exhaust Valve Decarbonizing/Inspection
  126
- Exhaust Valve Removal/Disassembly
  126
- Exhaust Deposit Draining
  126
- Flap Valve Drive Shaft Bearing Replacement
  127
- Exhaust Valve Assembly/Installation
  127
- Governor/Valve Linkage Removal
  129
- Governor/Valve Linkage Inspection
  129
- Governor Shaft Bearing Replacement
  129
- Clutch/Kickstarter/Gearshift Linkage
  132
- Clutch/Kickstarter/Gearshift Linkage Torque Values
  133
- Clutch/Kickstarter/Gearshift Linkage Tool
  133
- Clutch/Kickstarter/Gearshift Linkage Specifications
  133
- Clutch/Kickstarter/Gearshift Linkage Service Information
  133
- Clutch/Kickstarter/Gearshift Linkage Troubleshooting
  134
- Right Crankcase Cover Removal
  135
- Right Crankcase Cover Installation
  135
- Clutch Removal
  136
- Clutch Inspection
  138
- Kickstarter Removal
  144
- Kickstarter Disassembly
  144
- Kickstarter Inspection
  144
- Kickstarter Assembly
  145
- Gearshift Linkage Removal
  147
- Gearshift Linkage Inspection
  148
- Gearshift Linkage Installation
  149
- Crankcase/Crankshaft/Transmission
  152
- Crankcase/Crankshaft/Transmission Service Information
  153
- Crankcase/Crankshaft/Transmission Specifications
  154
- Crankcase/Crankshaft/Transmission Tools
  155
- Crankcase/Crankshaft/Transmission Troubleshooting
  155
- Crankcase/Crankshaft/Transmission Torque Values
  155
- Crankcase Separation
  156
- Transmission Disassembly
  158
- Crankshaft Removal
  160
- Crankshaft Inspection
  160
- Crankcase Bearing Replacement
  161
- Crankcase Bearing/Oil Seal Location
  161
- Crankshaft Bearing
  162
- Transmission Bearings
  162
- Crankshaft Installation
  165
- Transmission Assembly
  166
- Crankcase Assembly
  168
- Front Wheel/Suspension/Steering
  172
- Front Wheel/Suspension/Steering Service Information
  173
- Front Wheel/Suspension/Steering Specifications
  173
- Front Wheel/Suspension/Steering Tools
  174
- Front Wheel/Suspension/Steering Torque Values
  174
- Front Wheel/Suspension/Steering Troubleshooting
  175
- Front Wheel Removal
  176
- Front Wheel Inspection
  176
- Front Wheel Disassembly
  177
- Front Wheel Assembly
  178
- Front Wheel Installation
  180
- Fork Removal
  181
- Fork Disassembly
  182
- Fork Inspection
  185
- Fork Assembly
  188
- Fork Installation
  194
- Handlebar Removal
  196
- Handlebar Installation
  198
- Steering Stem Removal
  201
- Steering Stem Bearing Replacement
  202
- Steering Stem Installation
  204
- Rear Wheel/Suspension
  206
- Rear Wheel/Suspension Service Information
  207
- Rear Wheel/Suspension Specifications
  208
- Rear Wheel/Suspension Torque Values
  208
- Rear Wheel/Suspension Troubleshooting
  209
- Rear Wheel/Suspension Tools
  209
- Rear Wheel Removal
  210
- Rear Wheel Inspection
  210
- Rear Wheel Disassembly
  211
- Rear Wheel Assembly
  212
- Shock Absorber Removal
  216
- Shock Absorber Disassembly
  216
- Shock Absorber Bladder Replacement
  217
- Shock Absorber Damper Disassembly
  220
- Shock Absorber Piston Ring Replacement
  221
- Shock Absorber Damper Rod Disassembly
  222
- Shock Absorber Rod Guide Inspection
  223
- Shock Absorber Damper Rod Inspection
  224
- Shock Absorber Damper Assembly
  224
- Spherical Bearing Replacement
  230
- Shock Absorber Installation
  231
- Shock Linkage Removal
  232
- Shock Linkage Inspection
  233
- Shock Linkage Bearing Replacement
  234
- Shock Linkage Installation
  235
- Swingarm Removal
  237
- Swingarm Disassembly
  238
- Swingarm Bearing Replacement
  239
- Swingarm Assembly
  240
- Swingarm Installation
  241
- Brake System
  244
- Hydraulic Brake
  245
- Hydraulic Brake Service Information
  246
- Hydraulic Brake Specifications
  246
- Hydraulic Brake Troubleshooting
  247
- Hydraulic Brake Torque Values
  247
- Hydraulic Brake Tool
  247
- Brake Fluid Replacement/Air Bleeding
  248
- Brake Fluid Draining
  248
- Brake Fluid Filling/Air Bleeding
  249
- Brake Pad Replacement
  251
- Brake Disc Inspection
  253
- Front Master Cylinder Removal
  253
- Front Master Cylinder Disassembly
  254
- Front Master Cylinder Inspection
  254
- Front Master Cylinder Assembly
  255
- Front Master Cylinder Installation
  256
- Rear Master Cylinder Removal
  256
- Rear Master Cylinder Disassembly
  257
- Rear Master Cylinder Inspection
  257
- Rear Master Cylinder Assembly
  258
- Rear Master Cylinder Installation
  259
- Front Brake Caliper Removal
  260
- Front Brake Caliper Disassembly
  260
- Front Brake Caliper Inspection
  261
- Front Brake Caliper Assembly
  262
- Front Brake Caliper Installation
  262
- Rear Brake Caliper Removal
  263
- Rear Brake Caliper Disassembly
  263
- Rear Brake Caliper Inspection
  264
- Rear Brake Caliper Assembly
  265
- Rear Brake Caliper Installation
  266
- Brake Pedal Removal
  266
- Ignition System/Alternator
  268
- Ignition System/Alternator Service Information
  269
- Ignition System/Alternator Troubleshooting
  270
- Ignition System/Alternator Specifications
  270
- Ignition System/Alternator Torque Values
  270
- Ignition System/Alternator Tools
  270
- Ignition System Inspection
  272
- Ignition Coil Primary Peak Voltage
  272
- Exciter Coil Peak Voltage
  273
- Ignition Pulse Generator Peak Voltage
  274
- ICM (Ignition Control Module)
  274
- Ignition Coil Inspection
  275
- Ignition Coil Removal/Installation
  275
- Exciter Coil Inspection
  276
- Ignition Pulse General Inspection
  276
- Alternator Removal
  276
- Ignition Timing
  280
- Engine Stop Switch Inspection
  281
- Wiring Diagrams
  283
- Technical Features
  285
- RC (Radical Combustion) Valve
  285
- Troubleshooting
  287
- Engine Does Not Start or Is Hard to Start
  287
- Engine Lacks Power
  288
- Poor Performance at Low and Idle Speed
  289
- Poor Performance at High Speed
  290
- Poor Handling
  290
- Index
  293

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