Haynes Honda CR250/500R Owners Workshop Manual 1563922223, 9781563922220

Citation preview

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Honda CR250/500R

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1997

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CHICAGO, IL 60605

Honda CR250/500R Owners

Workshop Manual

by Alan Ahistrand and John H Haynes Member of the Guild of Motoring Writers

Models covered: CR250R, 1986 through 1997 CRS5OOR, 1986 through 1997

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Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

IND

Acknowledgments Our thanks to Honda of Milpitas, Milpitas, California, for providing the motorcycles used in these photographs. Thanks also to Pete Sirett, service manager at Honda of Milpitas, for arranging the facilities and fitting this complicated project into his shop’s busy schedule. Steve Van Horn, who did most of the mechanical

work, deserves special

mention for his unique contribution to the book.

© Haynes North America, Inc. 1997 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Owners Workshop Manual Series Printed in the U.S.A.

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 222 3 Library of Congress Catalog Card Number 97-70909 British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library We take great pride in the accuracy of information given in this manual,

but motorcycle

manufacturers

make

alterations

and

design changes during the production run of a particular motorcycle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

97-176

Fasad Goalad BUSINESSISCIENCE/TECHNGOLOGY DIV (SION CHICAGO PUBLIC LIBRARY 400 SOUTH STATE STREET CHICAGO, IL 60605

Contents Introductory pages About this manual Introduction to the Honda CR250R/500R Identification numbers Buying parts General specifications Maintenance techniques, tools and working facilities Safety first! Motorcycle chemicals and lubricants Troubleshooting

0-5 0-5 0-6 0-7 0-7 0-9 0-15 0-17 0-18

Chapter 1 Tune-up and routine maintenance

1 1-1

Chapter 2

2

Engine, clutch and transmission

2-1

Chapter 3 Cooling system

3-1

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5 Ignition system

5-1

Chapter 6 Steering, suspension and final drive

6-1

3

4

5

6

Chapter 7 Brakes, wheels and tires

7-1

7

Chapter 8 Frame and bodywork

8-1

8

Chapter 9 Wiring diagrams

9-1

9

Index

IND-1

IND

Honda CR500 R

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your motorcycle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs or steps.

At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word ‘Chapter’ apply to Sections and/or paragraphs in the same Chapter. For example, ‘see Section 8’ means in the same Chapter. References to the left or right side of the vehicle assume you are sitting on the seat, facing forward. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Even though we have prepared this manual with extreme care, neither the publisher nor the authors can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Honda CR250R/500R The CR250R and CRS5OOR are highly popular motocross bikes. The CR250R, with its technically advanced suspension and engine power valve systems, has been consistently successful in what is arguably the most competitive motocross class. The CRSOOR, with its light weight and powerful engine, offers high performance to skilled riders. The engine on all models is a liquid-cooled two-stroke single. CR250R models are equipped with the Honda Power Port (HPP) system or Composite Racing Valve (CRV), which regulates exhaust gas flow for efficient performance throughout the engine’s rpm range.

Power is transmitted through a five-speed transmission. All models use a wet multi-plate clutch and chain final drive. Fuel is delivered to the cylinder by a slide-type carburetor. The front suspension consists of telescopic forks mounted in upper and lower triple clamps. The rear suspension uses a single shock absorber/coil spring unit and Honda’s Pro-Link progressive rising rate suspension linkage. A disc brake is used at the front on all models. Early models used a drum brake at the rear; later models use a rear disc brake.

Identification numbers The frame serial number is stamped into the front of the frame

identification number should also be kept in a handy place (such as

and printed on a label affixed to the frame. The engine number is

with your driver’s license) so they are always available when purchas-

stamped into the right side of the crankcase.

ing or ordering parts for your machine.

Both of these numbers

should be recorded and kept in a safe place so they can be furnished to law enforcement officials in the event of a theft.

The frame serial number, engine serial number and carburetor

The models covered by this manual are as follows: CR250R, 1986 through 1997

CR500R, 1986 through 1997

aioe

The frame serial number is located at the front of the frame

Identifying models and years

The engine serial number is located on the left side of the crankcase

CR500R Engine code asctivcaicutntcncneat

PEO2E

Engine number range NG SCE, cocacy assecsheresdeestarersnane

5500036-5505153

2800040-2809499

VOB Reet eter oas ister eee

5600101-5604112

NOGTR ee eerste secretes NOOBS eee ee Oitcn cn caicare sere ILO YS Ee keg eet ene ei ke ree) Geet OMe 1 a RM

5900101-5906845 5000001-5009970 5100001-on 5200023-5208362

NIG Oar. crcetavecesrsacacensceteen seceeees TREE) stocensesocnecegancc cneeconoesscacart AGOO aa eet Retened co saraaneet eee TOOT Nave eatceote tat ceste eae tee

5700008-on 5800001-on 5900001-5904044 5000010-5003006

OO; ere eRe 1 OOD a Ra eA ewe Leek ae OOS Semen tte aie re a a

5300007-5308483 5400013-5408442 5500021-5507773

ISISAaa rere arr Ae nent 5100009-5102184 NOGSe, ccctccacanccoaee eens 5200006-5201031 199A. ote iceccatot nto eee eee 5300005-5301886

CR250R EMGiIMC\COUG)trrecrsscecess1itesrccutecssess Engine number range "KO }S{Sessa, eae

ee

eee

MEO3E

NODA ee ee eae nee. oretiecctte nays 560001 3-5608582 (OE ern aren SEE. eee 5700009-on O96 eetsee te eesr cen crteraares 5800009-on

NOG 7 rikasatageen aioe oanmeeens Brame Coder sescssateecestoeeness: Frame

number

NMOSOa.cccreas

5900001-on ME030

range

TIERSoNare croton coecenon nc costa hece 5400008-on 1996. avthbiceus. cheers 5500001-on ctor: 5600001-on QO 7 sete tents ecunte pctescreennenure

PEEIIVS COAG acc cctrerecer csteesoeces ree PE020 Frame number range OBO

Covet tes ee

aes estes

GC800021-808068

cute

ot

yaa

ere

eee

GC500018-505028

LSC Ceisxceccas tances creriet nenademee cad HC60014-604005

VOGZ.sasesccwess ecooneeee eee desc HC900016-905384

HOGS Be caseascararsttss caret thy ace JM700005-on

loko hire aban dinnhn treosetosecoosaaecern aietoto Nara alin Na WVe 8 SER ren Mes

JM000001-004826 KM100001-on

jjOOO eee

LM200013-203598

NOON eerie tener ietan tt ets MM300005-302994

ARSISI LOQOK TOG WOOO

Ik

kee toe ao

ee

croton tid son Geesreece inch cee yee ie wansdc peers een eee

KM800001-on LM900001-on eeseceereee tee tatters steerer MMO000006-001974 iecrrnccnurcencantataer svete orecen NM100006-101487

ee eae ee oe

NM400009-403206

1993 .....eecerseenees PReen

PM20005-201026

QOS Re eer cee eee TOO Aes eines erent eter coches

PM500015-504128 RM600010-604081

WO ae racesunte dues drcscavviewsoceeceseneed MOOS ook ve ceaccs te cua tee cncparesercccneeeaes

RM300005-301029 SM400001-on

NOOB ere ennrmenens sean. neers

SM700007-on

NWOOG

TM500001-on

ACISYS eee ar

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go 12 a REA re eRe

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Buying parts Once you have found all the identification numbers, record them for reference when buying parts. Since the manufacturers change specifications, parts and vendors (companies that manufacture various components on the machine), providing the ID numbers is the only way to be reasonably sure that you are buying the correct parts. Whenever possible, take the worn part to the dealer so direct comparison with the new component can be made. Along the trail from the manufacturer to the parts shelf, there are numerous places that the part can end up with the wrong number or be listed incorrectly. New motorcycle parts - original equipment or aftermarket - are available from franchised dealers and phone or mail order outlets that advertise in motorcycle magazines. Original equipment parts (also called genuine parts) are sold by the same company that built the motorcycle. Aftermarket parts are produced by independent manufac-

turers. All franchised dealers, and some phone or mail order outlets, offer a complete range of original equipment parts. Franchised dealers usually also carry aftermarket high wear items such as chains, cables and brake pads, as well as accessories such as helmets and leathers. Dealers offer the advantage of face-to-face contact, so you can bring the used part in for comparison. Phone and mail order outlets may provide substantial discounts from original equipment prices, but it’s a good idea to shop around before you order. Used parts can be obtained for roughly half the price of new ones, but you can’t always be sure of what you’re getting. Once again, take your worn part to the salvage yard for direct comparison.

Whether buying new, used or rebuilt parts, the best course is to deal directly with someone who specializes in parts for your particular make.

General specifications 66.4 mm (2.61 inches) 89.0 mm (3.5 inches)

72.0 mm (2.83 inches) 79.0 mm (8.1 inches) 249.3 cc (15.2 cubic inches) 491.4 cc (29.9 cubic inches)

CR250R 9.0 9.1 9.0 8.8

to to to to

1 1 1 1

8.5 to 1 8.7 to 1 7.0 to 1

6.8 to 1 Wheelbase

CR250R

1480 1495 1488 1467 1471 1483 1483

mm mm mm mm mm mm mm

(58.3 (58.9 (58.6 (57.8 (57.9 (58.4 (58.4

inches) inches) inches) inches) inches) inches) inches)

1500 1495 1489 1491 1485

mm mm mm mm mm

(59.1 (58.9 (58.6 (58.7 (58.5

inches) inches) inches) inches) inches)

2180 2195 2188 2161 2165 2177 2182 2185

mm mm mm mm mm mm mm mm

(85.8 (86.4 (86.1 (85.1 (85.2 (85.7 (85.9 (86.0

inches) inches) inches) inches) inches) inches) inches) inches)

CR500R

Overall length

CR250R

0-8 eee

a

General specifications aM

SS

I

PSPS

RSE

A

ESE PSS

ST

SS

ET

Overall length (continued) CR500R WOSEsthrOU Gln sOOOe: sera tee tere oetre deans ciantctivaredsseueaviveressveceetee tame OO MUR

crete oe Sin Shake men

Sree

ely iss ans eee at

NEA ne

eee

TEN GAEL SOT

SE

AY

2200 mm (86.6 inches) 2195 mm (86.4 inches)

OG 2a GOS ese anata eeteae checks scsbebcrevvessCadescasesvaded evtacsaeunretves Syernmeyes HDOA ares axe aee teaser aCe aub riceshe kes csics'vaeableyySoomtest GE oawen ve eee gen

2183 mm (85.9 inches) 2185 mm (86.0 inches)

SOS; OM ett we eee Oe

2179 mm (85.8 inches)

ae Ee oa

a

ne

Overall width CR250R ileketovita) Colle |aldltlote bernrontce, coc SeecnecRe Re er ee eesoman: tie sel ra see ocean Aces

NOSE OUIG ROO aces teeter NGO ZarCliOOS erecta

ws sk Av vases

use tee

nea

allan

A

SE

825 mm (32.5 inches)

835 mm (32.9 inches)

exch vaswacis ean sm neatennuey aac eapaute sce Seaathasenee

825 mm (32.5 inches)

ARS ISVARAdeto1U(o| ALELIKC Xo)6)es aee sce eee nee Rae ey ee eee he nrg eA aricoenet sercooreacecortee Peer cue REPEC ECCe erher eh hereon ErC ioe METER crepe

835 mm (32.9 inches) 827 mm (32.6 inches)

CR500R OBS MOU OGG seen rece cet en cae neces cedars svaxe van ss ware meaner ts rae OSD panGlGOT es acc tires Saute ee anteeeeur rere ts ave nana sata. cated aniretmelees HOO Ar MOUCM MOOS wt. 2 neveeree tr eee ata, easier nega iece ne tar cat apart, BIO SyO ie cceees sree ce cs er Me on teee Ee cece res en ty Bian aa Woe neeors

825 835 825 835

mm mm mm mm

(32.5 (32.9 (32.5 (32.9

inches) inches) inches) inches)

Overall heigtt® CR250R TIS OsthnOuGhinl OSS cere wecerse scones ies -cc--cccnstustqeoeetuua re:Pocesseavcesureseaya-neasve OO nena Meetcents SAN nati Se, saan: Ata ara e meeee eaten TmURSL ar ci se raenceaienays TRSISTO MEAVoL ANSI |ss Gersceee sia 75058 cca pe eRe EPR Cee conn Eee eer mee Pea errr ASIS Ae he aired AF os ee ris8. as i meer a er pettyOeteiee eee mer ae eee NOOB eee tec pete a ees eee Ge Mca Nancy Oe ie ew aces Ova Marae aN hata i cn enids

OO A ieee etec seder

Ae LI

Fe Le PRM

TE

eee

1215 1253 1255 1262 1243

mm mm mm mm mm

(47.8 (49.3 (49.4 (49.7 (48.9

inches)=-._ inches) inches) inches) inches)

ERIE Se

1242 mm (48.9 inches)

OOS rat) WOOG eeteeses aes couse fon-t oe ved. c cheno eeslasspsnante donee 72 osaseetaatbeaee MOO etier iets on rcla ee nibecte sceic tae sa usa eeeonsett seen cut emabatawcutm Seven asteleds

1244 mm (40.0 inches) 1249 mm (49.1 inches)

“4

CR500R MOSES MOUGH MOSS recssereeseeccee aankesevoeceseas svicssavsuces onpiasnapevescesencesies

1200 mm (48.0 inches)

NOS Oe wee tecot sian erect er nat ast cos itoceaseere eae sitean dete cutiveapianccanateoes MOO OAM Oi hececaraus cect sce sskcrvs iesOssccnatas sateen cxstee acento een foun eee

1260 mm (49.6 inches) 1255 mm (49.4 inches)

NO O2 THKOUGM NO etic sae seen sce: wae noccead es RitiowahesevayienceecussHeste achceecntvesnaants MOO SiO Meratliohar snes caatveeeingasee scam cerietocieisdavsiucsctvraagatierssassucueceaseyetocutaays

1240 mm (48.8 inches) 1237 mm (48.7 inches)

Seat height CR250R DOGG werorane even csces sessensuccinie sateen vs xevs snes cczesduvaseusanins sucpaiascouaeaccesdsseescceeete> NOS TEANG MOSS erence ac th tvs stacey ey saciced fesaancaeasus se aetaladedistel vats stuaeeaeees OSOMMOUG hel GOD ieee acevececerpeasets coccvsxtsaseconcravespenves eanesheehsuneedvatsanes MOSSTANC OOS Ter azcnncensiervesscaeduvs enue tevcstanec saps rahsecevuencenaaeesextecagavates MOOR AMMOOG cert selt Ae ca tensy aca senasscotied «sb tes ionevig sed aeto ices tencescest nemeeene OD fieapeatrces caus. ox erty ene eaetaressiandexcatcpa etwas duty tapnostcvtvavesisvendanaserieatevenvecsaye CR500R NO SGIMMLOUGK LOSS Sec cviscewevrsarressnsesbeanecesapwdsvrssespeatitnesdivsosisertssscsqahes MOG OMMKOUCM LOO dia seuss sr vaacorcenncueiestscensa(esnPeenesvyauctitas nvaneasswieiuccates HOO ZFaI QOS ts ner ceteecst is hia cum cnn vest eterna atta cos fina aad OO ee sereeyte re merssete seas ar Marcy saga a naa desc Paik oatsOuan'Cos nepttda cute x aneerevneeeet oss OO OROM Geen sartyty Arnie a ectee ween creas cerary dhe samt Crdereagrt nate