Honda CR500R Manuals

Manuals and User Guides for Honda CR500R. We have 2 Honda CR500R manuals available for free PDF download: Service Manual

Honda CR500R Service Manual (223 pages)

Brand: Honda | Category: Motorcycle | Size: 18.19 MB

Contents
1
Symbols
2
General Information
3
General Safety
3
Carbon Monoxide
3
Gasoline
3
Coolant
4
Nitrogen Pressure
4
Model Identification
5
Specifications
6
Lubrication System
8
Fuel System
8
Cooling System
8
Clutch System
8
Torque Values
15
Tools
18
Lubrication & Seal Points
20
Cable & Harness Routing
22
Optional Parts
25
Frame/Body Panels/Exhaust System Service Information
29
Frame/Body Panels/Exhaust System Troubleshooting
29
Seat Removal
30
Seat Installation
30
Side Covers Removal/Installation
30
Fuel Tank Removal/Installation
30
Fuel Tank Disassembly/Assembly
31
Silencer Removal/Installation
31
Expansion Chamber Removal/Installation
31
Sub-Frame Removal
32
Sub-Frame Installation
32
Maintenance Service Information
33
Maintenance Specifications
33
Maintenance Special Tools
33
Service Access Guide
34
Competition Maintenance Schedule
36
Additional Items Requiring Frequent Replacement
37
Throttle Operation
38
Air Cleaner
38
Spark Plug
40
Radiator Coolant
40
Cooling System
40
Inspecting & Adding Transmission Oil
40
Replacing Transmission Oil
41
Drive Chain
42
Drive Chain Adjustment
42
Drive Chain Sliders
43
Drive Chain Rollers
43
Drive/Driven Sprocket
43
Brake Pads Wear
44
Front Brake Fluid
44
Rear Brake Fluid
44
Brake System Maintenance
45
Clutch System Maintenance
45
Brake Lever Adjustment
45
Brake Pedal Adjustment
45
Control Cables
46
Expansion Chamber/Silencer
47
Control Cables Lubrication
47
Throttle Assembly
47
Silencer Glass Wool Replacement
48
Front Suspension
48
Swingarm/Shock Linkage
49
Rear Suspension
49
Nuts, Bolts, Fasteners
50
Wheels/Tires
50
Steering Head Bearings
50
Fuel System Service Information
53
Fuel System Specifications
53
Fuel System Troubleshooting
54
Minor Carburetor Adjustment
55
Major Carburetor Adjustment
55
Turning Information Chart
56
Turning for Special Conditions
57
Carburetor Removal
58
Carburetor Disassembly
58
Carburetor Assembly
59
Carburetor Installation
61
Reed Valve Removal
61
Air Cleaner Housing
62
Reed Valve Disassembly
62
Reed Valve Assembly
62
Reed Valve Installation
62
Air Cleaner Installation
63
Cooling System Service Information
65
Cooling System Specifications
65
Cooling System Tools
65
Cooling System Troubleshooting
66
Coolant Replacement
67
Radiator Removal
68
Radiator Installation
68
Water Pump Water Seal Inspection
69
Water Pump Disassembly
69
Water Pump Bearing Replacement
69
Water Seal/Oil Seal Replacement
70
Water Pump Assembly
71
Engine Removal/Installation Service Information
75
Engine Removal/Installation Specifications
75
Engine Removal
76
Engine Installation
77
Cylinder Head/Cylinder/Piston Exploded View
78
Cylinder Head/Cylinder/Piston Service Information
79
Cylinder Head/Cylinder/Piston Specifications
79
Cylinder Head/Cylinder/Piston Troubleshooting
80
Cylinder Head Removal
81
Cylinder Head Combustion Chamber Decarbonizing
81
Cylinder Head Inspection
81
Cylinder Head Installation
82
Cylinder Removal
83
Cylinder Inspection
83
Piston Removal
84
Piston/Piston Pin Inspection
85
Piston Ring Inspection
85
Connecting Rod Inspection
85
Piston Installation
86
Cylinder Installation
86
Clutch/Kickstarter/Gearshift Linkage Exploded View
88
Clutch/Kickstarter/Gearshift Linkage Service Information
89
Clutch/Kickstarter/Gearshift Linkage Specifications
89
Clutch/Kickstarter/Gearshift Linkage Tool
89
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
90
Right Crankcase Cover Removal
91
Right Crankcase Cover Installation
91
Clutch Removal
92
Clutch Lifter Lever Removal
93
Clutch Lifter Lever Installation
94
Clutch Installation
94
Kickstarter Disassembly
96
Kickstarter Assembly
96
Gearshift Linkage Removal
97
Gearshift Linkage Installation
98
Crankcase/Crankshaft/Transmission Exploded View
102
Crankcase/Crankshaft/Transmission Service Information
103
Crankcase/Crankshaft/Transmission Specifications
103
Crankcase/Crankshaft/Transmission Troubleshooting
104
Crankcase/Crankshaft/Transmission Tools
104
Crankcase Separation
105
Transmission Disassembly
106
Transmission Assembly
107
Crankshaft Removal
108
Crankcase Bearing/Oil Seal Locations
109
Crankshaft Bearings
109
Transmission Bearings
110
Crankshaft Installation
111
Right Crankcase Bearings
111
Crankcase Assembly
112
Front Wheel/Suspension/Steering Exploded View
117
Front Wheel/Suspension/Steering Service Information
119
Front Wheel/Suspension/Steering Specifications
119
Front Wheel/Suspension/Steering Tools
120
Front Wheel/Suspension/Steering Troubleshooting
121
Front Wheel Removal
122
Front Wheel Disassembly
122
Front Wheel Inspection
123
Front Wheel Bearings
123
Front Wheel Rim
123
Front Wheel Assembly
124
Front Wheel Installation
128
Fork Removal
129
Fork Disassembly
129
Fork Inspection
132
Fork Assembly
133
Fork Installation
136
Handlebar Removal
147
Handlebar Installation
147
Steering Stem Removal
149
Steering Stem Bearing Replacement
150
Steering Stem Installation
151
Rear Wheel/Suspension Exploded View
154
Rear Wheel/Suspension Service Information
156
Rear Wheel/Suspension Specifications
156
Rear Wheel/Suspension Tools
157
Rear Wheel/Suspension Troubleshooting
158
Rear Wheel Removal
159
Rear Wheel Disassembly
159
Rear Wheel Inspection
159
Rear Wheel Bearings
159
Rear Wheel Rim
160
Rear Wheel Assembly
161
Rear Wheel Installation
163
Shock Absorber Removal
165
Shock Absorber Spring Removal
165
Shock Absorber Bladder Replacement
165
Shock Absorber Damper Disassembly
169
Piston Ring Replacement
170
Damper Rod Disassembly
171
Rod Guide Inspection
173
Rod Guide Assembly
174
Spherical Bearing Replacement
181
Shock Absorber Installation
183
Shock Linkage Removal
183
Shock Linkage Inspection
183
Needle Bearing Replacement
184
Swingarm Removal
186
Swingarm Replacement
187
Swingarm Assembly
188
Swingarm Installation
189
Brake System Exploded View
190
Brake System Service Information
191
Brake System Specifications
191
Brake System Troubleshooting
192
Brake System Tools
192
Brake Fluid Draining
193
Brake Fluid Filling/Air Bleeding
193
Brake Pad Replacement
195
Front Master Cylinder Disassembly
195
Front Master Cylinder Assembly
196
Rear Master Cylinder Removal
197
Rear Master Cylinder Disassembly
197
Rear Master Cylinder Assembly
198
Rear Master Cylinder Installation
198
Front Brake Caliper Removal
199
Front Brake Caliper Disassembly
199
Front Brake Caliper Assembly
200
Front Brake Caliper Installation
201
Rear Brake Caliper Removal
201
Rear Brake Caliper Disassembly
201
Rear Brake Caliper Assembly
202
Rear Brake Caliper Installation
203
Electrical System Service Information
205
Electrical System Specifications
205
Electrical System Tools
205
Electrical System Location
206
Electrical System Troubleshooting
207
Ignition Control Module (ICM) System Inspection
208
Ignition Control Module Removal/Installation
208
Alternator
209
Exciter Coil Inspection
209
Ignition Pulse Generator Inspection
209
Alternator Removal
209
Alternator Installation
210
Ignition Coil Inspection
211
Ignition Timing
211
Engine Stop Button
212
Wiring Diagram
213
Troubleshooting
215
Engine Does Not Start or Is Hard to Start
215
Engine Lacks Power
216
Poor Performance at Low and Idle Speed
217
Poor Performance at High Speed
218
Poor Handling
218
Index
221

Honda CR500R Service Manual (30 pages)

Brand: Honda | Category: Engine | Size: 7.6 MB

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Honda CR500R Service Manual (223 pages)

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