86-91 ~ cR2e50R fIMPORTANT SAFETY NOTICE FEMININE) rcticzes srone posits of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. His important to note that this manual contains some warnings and cations against some specific service methods which ‘could cause PERSONAL INJURY to service personnel or could damage a vehicie or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda ‘might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all ‘such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly ‘that neither parsonal safety nor vehicie safety will be jeopardized by the service methods or tools selected §HOW TO USE THIS MANUAL Follow the Competition Maintenance Schedule recommendations (page 3-2) to en: sure that the vehicle is always in peak operating condition. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 15 describe parts of the motorcycle, grouped ac- cording to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration and specifications, torque values, general instructions, tools and troubleshooting for the section. The subse- quent pages give detailed procedures for the section, If you are not familiar with this motorcycle, tead Section 16, Technical features. It you don't know the source of the trouble, see section 17, Troubleshooting. CONTENTS GENERAL INFORMATION LUBRICATION ee | FUEL SYSTEM iz ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDERI/PISTON Ea H.P.P (Honda Power Port) is, | GEUTCHIGEARSHIFT LINKAGE Ea KICK STARTER TRANSMISSION/CRANKSHAFT/ | 9 | FRONT WHEEL/SUSPENSION/ STEERING |_ MAINTENANCE ENGINE @ | pean wi $ REAR WHEEL/BRAKE/SUSPENSION READ We EEE 5 | HYDRAULIC BRAKE ‘SUB FRAME/EXHAUST PIPE/ REAR FEN! - 23) IGnrtion system ‘TECHNICAL FEATURES ‘TROUBLESHOOTING1, GENERAL INFORMATION GENERAL SAFETY WW SERVICE RULES oe MODEL IDENTIFICATION 12 SPECIFICATIONS 14 TORQUE VALUES 16 TOOLS 18 CABLE AND HARNESS ROUTING 11 OPTIONAL PARTS LIST 1-22 GENERAL SAFETY rom {Ifthe engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that ‘may cause loss of consclousness and lead to death, Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard! caused by airborne asbestos fibers. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in your working area or where gasoline ls stored, SERVICE RULES The shock absorber has a gas-filled reservolr. + Use only nitrogen to pressurise the shock absorber. The use ‘of anstable gas can cause a fire or explosion resulting in serious injury. + The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. + Before disposal of the shock absorber, release the nitrogen bby pressing the valve core, Then remove the valve from the ‘shock absorber. CAUTION Used transmission oil may cause skin cancer if repeatedly left {in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daly ‘basis, it i still advisable 10 thoroughty wash your hands with soap and water as soon as possible after handling used oil. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA‘s design specifications may damage the motorcycle. Use the special tools designed for this product. 2 3. Install new gaskets, O-rings, cotter pins, lock plates, ete, when reassembling. ‘4. When torquing bolts or nuts, begin with larger-diameter or inner bolt first, and tighten to the specified torque, diagonally, in incremental steps unless a particular sequence is specified 5. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricste any sliding surfaces before reassembly, 6. When installing a new oil seal, make sure that the sealing lip is lubricated with grease. If an oil seal and related parts have bbeen washed, apply proper grease to the lip of the oil seal . After reassembly, check all parts for proper installation and operation. - Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with any other type of fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 1-1GENERAL INFORMATION MODEL IDENTIFICATION "86: 87; "90: After ‘90) 1-2GENERAL INFORMATION ‘The frame serial number is stamped on the right side of the The engine serial number is stamped on the lower left side steering head. of the crankcase, ['3) CARBURETOR IDENTIFICATION NUMBER ‘The carburetor identification number is on the left (After "88: right) side of the carburetor. 1-3GENERAL INFORMATION SPECIFICATIONS Tew - ‘SPECIFICATIONS Dimension | Overall lenath 86,87. 68 | 2,180 mmia5a im “99: | 2.195 mm (86.4 in) ‘Aiter"69: | 2,188 mmm (86.1 in) (Overall wie "86, 87, 68 825 mm (32.5 in), Alter 8: 1835 mm (92.9 in) Overall height 86, 87,88] 1.215 mm (47.8 in} “8; | 1,253 mm (49.3 in) ‘After 88: | 1,255 mm (49.4 in) Wheeiba "86,87, "88:_| 1,480 mm 68.3 in| - "ao:_| 1,895 mm (68.9 in) ‘After "89: | 1,488 mm (68.6 in) height _ "86: ‘960 mm (37.8 i) - “97, 88: 950 mm (37-4 in) ‘itor 88: 1970 mm (98.2 in) Foot pea height "86,87, 88 440 mm 117.3 in) ‘Attar 88: 45 mm (17.5 in) (Ground clearance 36, 87, 88) 340 mm (13.4 i) — ‘Ar 88: ‘350 mm (13.8) Dry weight 186,707: | 97.5 kg (214.9 B) ‘After 87;_| 97.0 kg (213.8 1) Frame Type. ‘Semi double cradle F. suspension, wavel Telescopic fork, 305 mm (12.0 ia) Ri. suspension, travel Pro-Link, 330 mm (13.0 in) F. tre size, pressure '80/100—21 51M, 15 psi (100 KPa, 1.0 Kalemtl tre size, pressure 110/100— 18 64M, 15 psi [100 KPa, 1.0 kgiem F. brake, swept ares 186: _| Single aise, 329 em (51.0 sa:n) ai ‘86: _| "Single disc, 306 em* (47.3 sain) brake, lining ae ‘86: | Internal expanding shoes, 102.1 en? (16.8 sain) R. broke, swept area ‘Alter 86: | Single dso, 303 em? (47.0 sani Fuel capacity 86 | 7.01 1.8US. gal, 1.6 mp. gal Aftor'86: | 7.50 (2.0US. gal, 1.6 imp. gal) Caster angle "86,87. 88 | 27°50 "eo: | zat ‘After@s:_| 28°03" Trail "36: | t12mmiaa @7, 88: | 114 mm 14.5 ind | "69; | 123 mm 14.8 in) | aier99° [125.5 mm 14.94 Fork oll capacity "86,67, "88._| 664 00 119.1 08! (Standard) "eo: | 657 cc (22.2 on) "90: [ 640 ce (21.6 on) - ‘After'90;__ | 651 cc (22.0 on), Engine Tee Lui: cooied, 2-st0ke ‘Cylinder arrangement 7 Single 7° inclined from vertical Bove snd stoke - 66.4 x 72.0 mm (2.61 x 2.83 i), Displacement [249.3 em? (15.2 ewcin) Compression ratio E 8.011 att "aa; | 90:7 | 9; | agit ‘Aftor'89: [85:1 Tranamission oll capacity | "86, 67, 88, "69:_| 0.6¢ (OG9US. qt, 0.59 imp. at [let disassembly) ‘After 88: | 0.637 (0.67 US. at, 0.88 imp. at)GENERAL INFORMATION TEM ‘SPECIFICATIONS Carburetor | Type | Piston valve ‘Identification number "86. | Pu23A [ "7: | Ps26a ‘aa: | P2668 "a9; | P26 90: | Pu28A ‘Aitar90: | Pu28c Main et (standard) "W6, B7, Ater "89: | #175 "a8: | #185 “aa: | #178 ~ Tet needle aad clip “a6: | _RIGBGN Bed groove from top Dosition "E788: | RIG67N 4th groove from top *89:_| _R1369PS 4th groove from top. 790:_| _R1370NS 3rd groove trom top ‘Aftor'90: | _RY369NS 1d groove from too. Slow jot tandara) a6: | #60 a7: | #58 es: | #02 a9: | #5 ‘Aner's9: | #55 ‘ir serew intial opening ‘36: | 1-1/2 twins out ‘Avtor 86: | 2.0 wens out Float height 16 mm (0.63 1) Drive wain | Glutch type 7 Wer, multplate type “Transmission B.cpeod, constant mesh “Primary reduction 3.000: 1 (Gear ratio | 1.800 1 277181 Gear ratio 6,67: | 1.388: 1 25/18) Ater87; | 1.870: 1 25/17) Gear ratio Hr "86,87: | 1-150: 1 (23/20) ‘Atter 87: | 1.210: 123/18) Gear ratio WV 1.000 = 1(21/21) Gear ratio V [ 786.87, After 86: | 0.869: 1 20/23) as: | 0.833-1 20724) Final reduction "687, | 3786-1 ners? | 3.6431 Gear shit pattern Left foot operated return system, 1-N—2-3—4—5 Bacvical | nition cor ‘Starting eystem 7 Kick ater ‘Spark plug (Optional) ‘26; | (CHAMPION) GN-86_(NGK) BRBEG — (ND) W24ESR-V Attr 88: (QN-26) (BREEV) —_(W24ESR-G) "a7,"88: | (CHAMPION) QN84 —(NGK) BR9EG (ND) W27ESR.V (QN-59G)_(BASEV)__—__W27ESR-G) 1-5GENERAL INFORMATION TORQUE VALUES ENGINE ‘tom Thread dia Torque x pitch Nem kom felb Cylinder head out @x125 | 24-29 | 24-29 | 17-21 Cylinder nut 96, '87,'88: | 10x 1.25 38-48 | 38-48 | 27—35 ‘after ‘88: | 10x 1.28 36-45 | 35-45 | 25-33 Clutch center nut 18x10 55-65 | 58-66 | 40-47 80-84 | 80-84 | 58-61 Clutch spring bolt 6x10 8-12 | 08-12 | 6-8 Primary drive gear bolt 10x 1.28 40-50 | 40-50 | 29-36 “Gearshift drum center pin 8x 128 20-24 | 20-24 | 14-17 Transmission oil drain bolt 12x15 25-35 | 25-35 | 18-25 *Countershaft bearing set plate 6x10 8-12 | oO 6-3 Alternator cover screw 8x10 3-5 2-4 Flywhee! nut 12x 1.25 50-60 36-43 Drive sprocket bolt 8x 1.25 25-29 18-21 Water pump impeller 7x 1.28 10-14 =10 Fight crankease cover bolt | 6x10 a-12 6-3 Rocker arm holder screw | 5x10 6-8 46 Exhaust valve rack hole plug | Bx125 8-12 6-9 Exhaust valve adjusting screw lock nut | 5x10 6-8 4-6 (86, '87, After ‘89) | Gearshift drum stopper erm bolt 6x10 10-14 7-10 Cylinder stud bolt 10x 1.25 10-14 7-10 Cylinder coolant drain bolt 6x10 8-12 6-9 Water pump cover coolant drain bolt 6x10 8-12 6-3 Spark plug 141.25 15-20 1-14 Oil check bott 6x10 B12 6-3 Exhaust valve adjusting bolt lock nut 5x08 5-7 a5 Water pump cover bolt (After '88) 6x 1.0 10-14 7-10 Cylinder and exhaust valve cover bolt (After ‘88) 6x10 10-14 7-10 “Apply Honda Thread Lock or an equivalent. FRAME ea Thread dia Torque xpitch Nem kom | fel ‘Steering stem nut 86, '87, ‘88, After 89: | 24x18 95-140 | 98-140] 69-101 "9: 24x 1.0 95-140 | 9.6-14.0| 69-101 Steering head adjusting nut 86,87, "88: | 26x 115 1-2 | 01-02 | 07-14 "89: 26x 1.0, 1-2 | 01-02 | 07-14 After 89: | 26x 1.5 8-12 | 08-12 | 6-9 Fotk tube pinch bolt (Top) "96, '87,'88, '89:°" Bx 1.25 18-25 | 18-25 | 13-18 ‘after ‘89:** | 8x 1.28 30-34 | 30-34 | 22-25 (Bottom) ‘86, ‘87, "88, '89:* axi25 | te-25 | 18-25 | 13-18 After ‘89:°* | 8x 1.25 24-30 | 24-30 | 17-22 Handlebar upper holder 8x 1.25 19-25 | 18-25 | 13-18 Handlebar lower holder nut ‘96, '87, 88: | 10 1.25, 30-40 | 30-40 | 22-28 Front axle "96, 87, "88°89: | 12x 1.25 55-70 | 5.6-7.0 | 40-81 ‘after ‘89: | 16x 1.5 80-83 | 80-93 | 58-67 Front axle holder 6x10 0-12, | 10-12 | 7-9) Rear axle nut 18x15 85-105 | 85-105) 61-76 Engine hanger bolt (10 mm) 10x 1.25 38-43 | 38-48 | 27-35 (8 mm) 8x 1.25 24-29 | 24-29 | 17-21 Engine mounting bolt "86, ‘87, '88, ‘89: | 101.25 38-48 | 38-48 | 27-35 ‘after 88; | 10x1.25 | 60-70 | 60-70 | 43-51 Driven sprocket "86, '87, "88, ‘89: sxt2s | 32-37 | 32-37 | 23-27 set | axt25 | 25-31 | 26-31 | 18-22 **: Apply oil to the threads. 1-6GENERAL INFORMATION fiat Thread aia Torque x piteh Nem kom ie ‘Shock absorber (upper 10x 1.28 40-80 | 40-50 | 29-a6 (lower 1031.25 seas | 3e-ae | 2735 Frontirear spoke BC. 3.6/8. 4.0 25-080 | 18-36 ‘Swingarm pivot bolt tex1.8 80-100 | 58-72 16x15 80-100 | 58-72 Fork boot clamp scrow ('86, ‘87, 88) 35x08 080.18 | 06-12 Fork cap bot 6,87, "88: | 39x 1.0 ts-30 | 11-22 ‘Attar ‘88: 50x15 30-20 | 22-28 Fork drain bolt ('86, '87, 88) ex1.0. os-09 47 Shock arm (swingarm side) 1241.25 55-70 | 40-51 (shock link side) 10% 1.25 40-50 | 29-36 | 121.28 55-70 | 40-51 ‘Shock link (frame side! 96."87,"88: | 10x 1.25, 40-50 | 29-36 12% 1.25 55-70 | 40-51 Fork corter bolt 14x10 30-60 | 22-29 "a: | 22x10 40-45 | 29-33, "90:| 22x1.0 50-55 | 36-40 Atter'90:| 18x 1.0 40-50 | 29-35 Shock absorber lock nut 56x 1:5 go-100 | 58-72 Fork cap lock nut ‘ge: | 10x10 12-18 "87,88, 99,'90: | 1021.0 175-225 ‘attor's0: | 12x 1.0 20-24 Fork piston retainer (88, '87. ‘88) 22x10 3-068 Fork protector bott (After ’88) 6x10 1218 FFrontrear re lock 8x 1.25 10-15 Fromtirear brake disc retaining bolt "86, '87, '88, "89: 8x10 14-16 ‘after “89: Bx1.25 40-45 Front wheel hub cover ('86, ‘87, ‘88, '90) 4x07 01-02 Ater90 4x07 005-01 ‘Brake hose joint (master cylinder side) 101.25 3,040 Brake hose joint rut (brake hose side) 1051.25 12-15 ‘Brake hose bolt (caliper) "96,89, Atter's9: | 101.25 30-40 a7."68: | 10x 1.25 25-35 8x10 og-1.2 8x10 o8—1:2 6x10 oa—12 Brake lever adjuster lock nut 5x05 05-07 ‘Clutch lever pivot bolt 8x10 01-03 {Clutch lever pvat lock nut 8x10 oB-12 Throttle housing cover screw 4x07 01-012 Gearshift pedal pinci bolt 8x10 10-14 Kickstarter peda bott 8x 1.25 24-30 Seat mounting bot 8x12 18-26 Sub-frame mounting bolt 8x 1.25 18-25 Alter ‘90, 8x12 24-30 ‘Shock absorbor banjo bolt (86) 10x10 27.5~32.8 | 2.75-3.25 [Bake caliper bloed valve Bx 1.25 4-7 04-07, ‘Clutch lever holder bolt 8x10 B12 | 08-12 ‘Throttie housing bolt 8x10 B12 | 08-12 Fear brake torque atm bolt ('86) 8x1.25 16-25 | 18-25 Rear brake master cylinder mounting bolt (After “86) 8x10 aie | 14-16 ‘Brake pedal pivot bolt "86: 8x 1.25 18-25 | 18-25 Attor "86: 8x1.25 2-28 | 24-28 Siloncor caso bolt (After “86), 5x08 45-60 | 045-060 | 33-43 ad pin pug (After 8) 10x1.0 2-3 02-03 | 14-22 Rear ise guard screw (After 86) 8x10 a8 06-08 yar Front brake caliper mounting bolt "36, '87, "88: 8x 1.25 20-30 | 20-30 | 14-22 ‘39: Bx 1.25 s2—3s | 32-36 | 23-26 “90: 8x 1.25 20-30 | 24-30 | 17-22 Attar ‘90:"* 8x1.25 esa | 2e-a4 | 20-26 Front caliper pin bolt ('86): upper Bx1125 20-25 | 20-25 | i418 lower 8x1.25 15-20 | 15-20 | 11-18 (ater ‘86): upper 8x1.25 20-25 | 20-25 | 14-18 ton 8x1.25 ton-is, | 10-15 740 Fear caliper pin bolt ('87, 88, '89): ront side* 8x1.25 20-25 | 20-25 | 14-18 (after '89): front side 12x 1.25 25-30 | 25-30 | 18-22 tear side 8x 1.25 to-15 | 10-15 71 Brake caliper pad pin 10x10 ts-20_ | is-20 | oe +: Apply Honda Thread Lock or an equi (cont'd “+: Apply oil to the threads.GENERAL INFORMATION dards given on this page. STANDARD TORQUE VALUES Theoad dia | item " X pitch Nem fee Shack absorber drain bot (87) 8x10 12-15 a1 ‘Shock absorber compression damping valve 22x1.0 15-20 ) 1-14 Atter'90: | 24x 1.0 18-22 | 13-16 Drive chain tensioner roller bolt "86 | Bx 125 2430 17-22 Atter’B6: | 8x 125 | 18-25 13-18 Rear damper rod nut 312x125 | 35-40 25-28 Atter’90: | 12x 1.5 24-30 17-21 Chain guide slider "96, '87,'88,'89: | Bx 10 | 2-3 14-22 ‘after 89: | 6x 1.0 10-14 7-10 Engine stop switch screw 4x07 1-2 7-14 Front brake hose guide bolt (After '87) 6x10 | 45-6 33-43 The torque values listed above are for the most important tightening points. Ifa torque specification isnot listed, use the stan SH TYPE: 6mm flange bolt with & mm head Ta Tea oe E see : wa [ tem ten [kom | Tombs edan [es-6 Joas-08 | 3-43] Sam acew a5-5 [oas—08 [25-28 6 mm bolt and nut | 8-12) 0.8-1.2 | 6-9 6 mm screw and flange. Sina ondnut | 828 | 48-28 | 3-18 | porlSh whe! 7-11 7-11) 5-78 Ommbos ang nt | 20-40 | 20-40 | 22-28 Smmtange tard nx | 10-14 | 10-4 | 7-10 WGiwmbottand nt |80-€0| 80-60 | 36-43 Smmianaetatand mt | 24-20 | 24-29 | 17-24 | 1mm tangent dns |35=48 | 38248 | 25-00 TOOLS ‘SPECIAL Bescon Toole, Aionaive | TooiWo, | Ra poe Universal bearing puller 07631—0010000 Equivalent cammercially | 98 sep ag ere Srois—sa20001 (Tavalsbain USA 139, 14,18 Stening tm socket Grai6easoroo 185 ide merger S7ase 2710309 aio Remover handle | 07936~3710100 910 forever wotht Orrat 01020" | Sider weight 079262710200 | 8.19 Bong oore set, 12 mm | o7aae—teo0001 | Nov avails in USA ‘es | “Rover angi Srret—oor0201 | Shaer weight 07936-s710200 |1o8 Romever ssoy,12mm | 079861660101 Remover fondle sexy [078361600100 | 10-6 Tfarover head 12mm | Bygne—vesoiso toe =Farover drat o7ase— 1680129 toe Biochem, 38% 20mm | 07848187000 08,7 | 12-52 Uni‘ Crartest pt 07937 £30000 sf Wate iver 67845 KAS0000 | Mechanical sal istler GILAK-OG5-415 107 Reningrace remover (86,87) | 07858—s280002 | ooagraceramowst"” /o9S6MsTa0OA| 11-40 Usa ent steering stam aver 072464200101 | stesing sem diver [073461400000 1-48 acinar hanee Ua: ony Nan ating vse 07848 Kas0000 12.48, 45,52 ('86, ‘87, After ‘88) | | Fort sel aver sachnent | 07947—Kaso200 28 (36,"87. "281 Font setaiver 88,87, 88) | 07947—KasO100 nae taney bo raes — 1660200 aati Atzombl cola | bys63—res0901 ra Threaded apt 7868 -KAs0000 | a3 1-8GENERAL INFORMATION Description Tool No. Alternative Too! No. Slider guide, 14 mm (07974 —KA40001 1231 07974—KASO101 | Not available in U.S.A, 12-24 (079883000000 12-25 07974~KA30201 12-24 Bearing remover, 7 mm (97931 KA30000 106 Bearing driver, 7'mm (07948—KA30100 10-6 Spherical bearing driver, 14 mm | 07946—KA30200 12-50, 51, (88, '87, "88) | 52, 53 Bearing retainer wrench (87, '88) | 07MA—KS70100 12-40, 13 Spherical bearing driver ('86, '87, After ‘88) | 07GMF-KS70100 | Not available in U.S.A. |O7HMF—KS60100| 12-40, 54 Retainer wrench ('86, ’87, BB) | O7GMA—KS70100 11-18, 27 Pin spanner A | 89201~KS8—810 } [Use two pin spanners 12.19, 39 for After ‘86: Pin spanner B ('86) | 89202—KS6—810 12-19, 39 Driver head After ‘87) | 07846—KM40701 | Driver head '07946—KM40700 | 12-45, 52 Driver shaft (after '87) | 07946—-MJ00100 | 12-45, 50, 52 Bearing race remover (After ‘B7) | 079484630100 11-46 Bearing remover set (After ‘BB) | 079363710001 12-52 Remover handle 079363710100 12.52 = Bearing remover 079363710600 | 12-52 Remover weight 077410010201 | Slider weight 07936-3710200 | 12-52 il seal driver O7KMD-—kZ30100 | *Fork seal diver ‘O7KMD—K23010A] 11-32 Fork slider spacer O7KMZ—K230101 | “Fork slider spacer O7KMZ—KZ3010A) 11-18, 21, 33, 39 ‘Seal case holder 07KMB~KZ30200 | Attachment 07965~MA60000 11:23, 32, 37, 38 Cylinder holder O7KMB-KZ30100___*Cylinder holder (O7KMB—K23010A] 11-19, 33, The tools marked “*”: U.S.A. only COMMON Description Tool No. ‘Alternative Tool No. Ref. page Float level gauge (074010010000 an Spoke wrench C, 5.8 x 6.1 mm | 07701—0020300 + Equivalent commercially Spoke wrench, 6.5 mm 07701~0020400 Tavailable in U.S.A, Bearing retainer wrench B 077100010200 12:10, 13 ('86, After '88) Retainer wrench body 07710~0010401 12-40, 13 Socket wrench, 30x 32mm | 077160020400 | Equivalent 11-48, 47 Extension bar 077160020500 | }commercially 34.45, 47 Universal holder 07728-00300 | available in U.S.A 93,13 15-3, 4 Clutch center holder 077240050001 85,9 Gear holder 077240010100 | Equivalent commercially 19314 ‘available in U.S.A. Flywheel pull 07733-00100 | Flywheel puller (07833-00100 | 15-3 Attachment, 07746-0010200 sat Pilot, 17 mm’ 077460040400 9:11, 11-12, 12-81 Pilot, 25 mm, 077460040800 ean Pilot, 20 mm. 077460040500 12-12, 45, 52 Attachment, 42 x 47 mm 077460010300 9-11, 11-46, 12-12 Pilot, 22 mm 07746 —0041000 sat (186, 87), { 12-46, 52 (cont'd)GENERAL INFORMATION COMMON (CONT'D) Description Tool No. Alternative Tool No. | Ref. page fstachment, 62x 65 mm | 07746 -0010400 oi, 11-28 37.8 Awtachment, 6268 mm | 077480010500 eo Plot 28 mn 07746 0041 100 310 Div 07749 0010000 810,11, 105.6 1912046, 12542, 48, 46 30. bi. 82 Bearing remover shaft 07748-05010 + Eauivatont 1810, 1210 Bearing remover head, 17 mm | 07746 -0060500, =feommeriay 1110 Bearing remover heed, 20 mm | 077460980600 [1 evelable n U.S.A 1210 Prat 12 mm 07746 0040200 Tose 07746 0020100 1230 17 mm 1.0, 86) | 07746 -0020900 1330 Attachment, 20 mn Lb 7746 0020800 12.30 (nite 86) Actachment, 24x28 mm | 077480010700 120,61. 62| Attachment, 22xa5mm | 077460010100 Hag, ) [1248 46 | 1-10CABLE AND HARNESS ROUTING Note the following when routing cable and wire harnesses. © Aloose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure itis secure. © Do not squeeze wires against the weld or end of its clamp when a weld-on clamp is used © Secure wires and wire harnesses to the feame with their respective wire bands at the designated locations. Tighten ‘the bands so that only the insulated surfaces contact the wires or wire harnesses. '@ Route harnesses so they are neither pulled taut nor have ex cossive slack © Route wire hamesses to avold sharp edges or corners. Also avoid the projected ends of bolts and screws, © Proctect wires and harnesses with electrical tape or tubes if they do contact a sharp edge or comer. Clean the attaching surface thoroughly before applying tape. © Do not use wires or harnesses with broken insulators Repair by wrapping them with protective tape, or replace them, ‘© Keep wire harnesses away from the exhaust pipes and other hot parts. © Be sure grommets are seated in their grooves properly, © After clamping, check each harness to be certain that it is not interfering with any moving or sliding parts. © Wire harnesses routed along the handlebar should not be Pulled taut, have excessive slack, be pinched, or interfere ‘with adjacent or surrounding parts in all steering positions, © After routing, check that the wire harnesses are not twisted or kinked © Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. GENERAL INFORMATION x ) Fad) r —Aiaa_ O i x Sante (a) cures east 12) aLréawaton (10) ALTERNATOR ‘ RE WIRE (rn wire aan (RADIATOR iaewaedane (Secure SvenrLow WE BAND gy THROTTLE overt SURE (Secures tne, (COLE and alter wire) CDI unit wires) 1-20GENERAL INFORMATION After '90: (2) RADIATOR CONNECTING (1) RADIATOR OVERFLOW TUBE (3) IGNITION COIL WIRE (4) BAND (Secures the clutch cable) (©) wine BAND (5) THROTTLE CABLE jecures the overflow tube and alternator wire) CLAMP (8) CARBURETOR (Secures the AIR VENT TUBES: (9) CRANKCASE BREATHER, TUBE (10) CARBURETOR OVERFLOW TUBE (71) cLame (13) cLuTcH (Secures the carburetor ‘overtiow tube and crankcase (12) CLAMP breather tube.) 1-21GENERAL INFORMATION OPTIONAL PARTS LIST TEM REMARKS FRAME + Driven sprockets + Drive chains + Shock spring Identification mark "86, ‘87 ‘Aluminum 817 and 58T Stool 53T (mud/sand) (Standard: 537) 114 links: RKS2OKZ (After 88: RK52OKZ3} 114 links: 01D52005 (Standard: 116 links: DID520DS8, RK520KZ3) After ‘87 ‘Aluminum 497 and 537 Steel §1T {mud/sand) (Standard: 617) ‘26: [__Twe | Spring rate Isentification mark ght 4.4 kg/mm (246.4 Tein) | Brown Mark Standard | 4.8 kg/mm (268.8 Ib/n) | Pink Mark heavy 5.2 kgm (291.2 lin) | Black Mark 87 Tyee Spring vate Identication mark Light 4.8 kg/mm (268.8 bin) | White Mark Standard | 6.2 kglmm (291.2 fin) | Pink Mark Heavy 5.6 kg/mm (313.6 bin) | Green Mark "28: Type Spring rate Identification mark Lighe 5.2 kgm (291.2 Win) | Pink Mark Standard | 5.6 kgimm (313.6 bin) | Yellow Mark | Heavy 8.0 kg/mm (336.0 bin) | Brown Mark | 89: Type Spring vate ‘Wentiicaton mark ght 4.8 kgimm (268.8 in) | Pink Mark Standard | 6.2 kglmm (291.2 t/in) | Nothing Heavy 5.6 kgimm (313.6 tin) | Yellow Mark Type Spring vata Identification mark ane 4.8 kgimm (268.8 Win) | Pink Mark Stenderd | 6.2 komm (291.2 bin) | Nothing Heavy 5.6 kg/mm (313.6 Ib/in) Green Mark _| ‘tor ‘90: Type Spring rate Identification mark ght 4.8 Kgimm (257.6 in) | Black Mark Standard | 5.0 kg/mm (200.0 tin) | Nothing | Heavy 5:4 kgimm (302.4 fvn) | Yellow Mark 1-22GENERAL INFORMATION eM REMARKS * Fork spring "36 87 sdeerttficaton [ Type Spring rate Identification mark Light 0.336 kg/mm (18.76 Ibjin) | 3 coils + coi Standard | _0.355 kgimm (19.86 Ibiin) | 1 coil Heavy 0.375 kgimm (21.00 iin) | 2 cots "88: Type Spring rate Identification mark ate [0.346 kaimm (19.38 Ibn) | 1 coil 2 colle Standard 0.370 kg/mm (20.72 Ib/in) 2 coils Heavy 10.380 kgimm (21.84 Ibn) | 3 els ‘90; a Type Spring rate Identification mark Boole: Light 0.36 kg/mm (20.16 Ib/in) 3 coils Standard | _0.38 kg/mm (21.28 1b/in) | 1 ell Heavy 0.40 kg/mm (22.40 Ib/in) 2 coils - After “90: Type Soring rate Identification mark Uae 0.38 kgimm (21.28 iin) | 3 cols Standard | 0.40 kgimm (22.40 tin) | _1 col Heavy [0.42 kg/mm (23.52 tbvim_| 2 coils + Air pressure gauge + Pin spanner + Seat = For maintenance/service For fork air pressure adjustment For shock absorber spring length (preload) adjustment |two required) Pin spanner A, B '86. Pin spanner A (two) After "86 "86, '87: ® osm Se For optional height riding position ry [ef "20: Seat A: Standard: 122 mm (4.8 in) — Seat 8 : 96 mm (3.9 in) YX Seat C : 82 mm (3.2 in n ITF © Se Seat A: Standard: 117 mm (4.6 in) A Seat B : 93 mm (3.7 in) ©: 80. mm (3.1 in) Seat A: Standard: 117 mm (4.6 in) Seat B : 85 mm (3.3 in} Seat A: Standard: 117 mm (4.6 in) Seat B = 90 mm (3.5 in} After ‘89: Seat A: Standard: 113 mm (4.4 in) Seat_B : 96 mm (3.8 in) 1-23GENERAL INFORMATION i REMARKS ‘Carburetor tuning parts = Main jote . #160~ #190 {in increments of 2 or 3} — Standard: #175 75 \ ia ‘88: —, #170~#200 (in increments of 2 of 3) Mark Standard: #186 ‘eo #168 — #188 tn increments of 2 of 3) Standard: #178 Aor 89: #165 ~ #185 (in increments of 2 or 3) Stonderd: #175, Jet oaedles Standard: $6, “87: R136BN (92.685 mm -1°30") “88: R1387N (62.678 mm—1°30) "9: R1360PS (62.605 mm —1°30") *90; R1370NS (62.708 mm ~1°80) Atter ‘90; RIGEONS (62.698 mm 1°30) NEEDLE NUMBER lb. Teper angle Yean | SENERALFLOW | JETNEEDLE [6.5 am | TAPER | SPECIFIC FLOW chaRacrenisrics | NUMBER ANGLE | CHARACTERISTICS Leener than the stock 299° | Leaner only at 178 t0 RI36BN nesdle RUSTON | 2-705 | 1°30" | ya throttle Richer than the stock cao" | Richer only at 178 10 R1368N needle _IRISBON. 2.665 | 1°90 | 1/4 throttle Leaner than the stock ago" | Leaner only at 178 to ven |_RIOMN needle | BIseSN 2.698 1°30" | 1/4 throttle Richer than the stock ca" | Bicher only at 178 to R1367N needle dail E665 1°30" | 1/4 throttle | Leaner thon the stock | ATS7OPS | 2.708 | yagy) | Leaner oniy at 18 to vga |_RISOSPS noodie Riaies | 2.718 1a throttle Richer than the stock | R1367PS. 2.675 4°30" Richer only at 1/8 to R1369PS needle fizees | 2.685 a tht Leaner than the Too" | Leaner only at 178 to R1371NS needle: RiB72N8 om 1°30" 1/4 throttle Leaner than the stock cap” | Leaner only at 1/8 t0 go __RIS7ONS needle RIS7INS 278 1°30" 14 throttle Richer than the stock yao" | Richer only at 178 to RI370NS needle Alaeans 2608 130 1/4 throttle, 7 Rienor than the a0" | Richer only at 178 to RI369NS needle AISGBNS 2.686 1°30" | 1/4 throttle Leaner than the cao" | Leaner only at 178 to RIS7ONS needle Rus7ins | 2.716 130" | 4/4 throttle Lisaner than the stock cao" | Leaner only at 178 To ‘atter ‘90 -_RISE9NS needle RIaZONS: ara 1°30" | 1/4 throttle Richer than the stock nie Richer only at 1/8 to | R1369NS needle RISCBNS Bes ey 1/4 throttle Richer than the cag | Richer only t 178 to R1368NS needle RIge7Ns zens me 1/4 throttle Meaning of the jet needle number 1-24GENERAL INFORMATION TEM REMARKS, Slow jets NoTE +The evlinder cannot be bored or honed and only standard size pistons/rings are available. Ifthe cylind be replaced. "86: #55 —#65 (in increments of 2 or 3) Standard: #60 87, ‘89: +#52—#62 (in increments of 2 oF 3) Standard: #58 Fast #58 #68 lin increments of 2 oF 3) ‘Standard: #62 After '89: #50—#60 in increments of 2 o 3) Standard: #55 is damaged it must 1-25MEMO2. LUBRICATION SERVICE INFORMATION 2-1 TRANSMISSION OIL TROUBLESHOOTING 2-1 LUBRICATION POINTS 22 23 SERVICE INFORMATION GENERAL © This section describes inspection and replacement of transmission oll, and lubrication points © The Honda CR25OR has a two-stroke engine that requires a pre-mixed gasoline-oil mixture, SPECIFICATIONS Recommended engine pre-mix oil Honda 2-stroke oll or equivalent. ‘Mixing ratio (Fuel: Oi) 20:1 Transmission oil capacity ‘86, "87, "88, “89: 0.6 lit (0.63 US at, 0.63 Imp qt) at disassembly 0.56 lit (0.58 US gt, 0.48 Imp qt) at oll change After ‘89: 0.63 lit (0.67 US qt, 0.56 Imp qt) at disassembly 0.7 lit (0.74 US gt, 0.62 Imp qt) at oil change Recommended transmission oll Honda 4-stroke Oil SAE 10W-40 or equivalent. API Service Classification: SF or SG. NOTE + Viscosity selection should be based on the average atmo- spheric temperature in your riding area. Change to the proper viscosity oil whenever the average atmospheric tem ly, TORQUE VALUES Recommended transmission oil viscosity: Oil drain bolt 25-36 Nem (2.63.6 kg-m, 18—25 fr-ib) ‘SAE 10W-40 Oil check bolt 8=12 Nem (0.8—1.2kg-m, 6-9 feb) TROUBLESHOOTING Engine does not have sufficient power + Deteriorated gasoline-oil mixture Engine stalls frequently + Deteriorated gasoline-coil mixture ‘Spark plug fouled + Incorrect gasoline-oil mixture ratio + Deteriorated gasoline-oil mixture ratio ‘Transmission Oil Level Too Low + Worn right crankshaft sei (transmission oil drawn into crankcase) *+ External oll leaksLUBRICATION TRANSMISSION OIL LEVEL CHECK Place the motorcycle on a box or workstand so it is level and both wheels are an equal distance from the ground. Oil should flow out of the check bolt hole. If the oil does not flow out, add cil slowly through the oil filer hole until the oil starts to flow out of the check hole. Once it begins to flow out, stop adding oll and install the oll check bolt. TORQUE: 8— 12 N-m (0.8—1.2 kg-m, 6-9 ftlb) After checking oil level, install the oil filer cap and be sure that the cap and the oil check bolt are tightened securely. Install the oil filler cap. OIL CHANGE NOTE + Transmission oil should be changed at least every 3 races or 7.5 hours of running to ensure consistant performance and maximum service life of both transmission and clutch com: ponents + Warm-up the engine before d completa and rapid draining, ining the oil, This ensures Remove the oll filer cap {rom the right crankcase cover. Place an oil drain pan under the engine to catch the oil, then remove the drain bolt CAUTION + Used transmission oi may cause skin cancer if repeatedly left in contact with the skin for protonged periods. Although this is unlikely uniess you handle used oil on daily basis, its stil ad: visable to choroughly wash your hands with soap and water as soon as possible after handling used oil. {After the oll has been completely drained, check that the drain bolt sealing washer is in good condition and install the drain bolt TORQUE: 25—35 Nem (2.5—3.5 kg-m, 18-25 fib} CAPACITY: '86, ‘87, '88, ‘89: 0.55 lit (0.58 US qt. 0.48 Imp at) at oil change After ‘89: 0.7 lit (0.74 US at, 0.62 Imp at) at oil change RECOMMENDED OIL: Honda 4-Stroke SAE 10W-40 oF equivalent NOTE + Use this specified capacity only as a guide: add oil until it flows out of the oil check bolt hole, allow it to stop flowing out, then reinstall and tighten the oil check bolt Use only high detergent, premium quality motor oil certified to meet or exceed USA automobile manufacturer's requirements for Service Classification SF or SG Reinstall the ol filler cap. Start the engine and check for leaks. Stop the engine and re check the oil level. = = + Uf the engine must be running to do some work, make sure the ‘reais well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. 2-2 (1) DRAIN BOLT Mi) Of FILLER CAPLUBRICATION LUBRICATION POINTS Unless otherwise specified, use general purpose grease. Apply oll or grease to the other sliding surfaces not shown here. CONTROL CABLE LUBRICATION Periodically, disconnect the throttle, and clutch control cables at their upper ends. ‘Thoroughly lubricate their pivot points with a commercially available cable lubricant. lis not necessary to oil the cables. If clutch lever or throt tle operation is not smooth, replace the cable. WHEEL BEARINGS Grease new wheel bearings and dust seals before installa tion. Do not reinstall used wheel bearings or seals. "86: Shown, After ‘86: Similar (2) *#SHOCK LINKAGE PivoT DUST SEALS) MOUNT NEEDLE BEARINGS! 1 SPHERICAL BEARING (CuBRI a) (CANT) IVE CHAIN Sm 1 (13) BRAKE CAM | (36:) a | (32) WHEEL BEARINGS (863) Dust SEALs ai ‘ARM PIVOT (3) *SHOCK ABSORBER BRAKE PEDAL PIVOT) ('86:) BRAKE TORQUE Apply @ paste grease with 40% or more molybdenum di: sulfide to the * mark components (2, 3 and 10 below). NOTE 2e with 40% or more Some sources of MoS? paste gr molybdenum are: ‘© Molykote® G-n Paste manufactured by Dow Coming, USA ‘+ Honda Moly 45 or 60 (U.S.A. only) + Rocol ASP manufactured by Rocol Limited, U.K. ‘+ Rocol Paste manufactured by Sumico Lubricant, Japan. Any other manufacturer's paste grease equivalent to the above may also be used. (4) THROTTLE/CLUTCH CABLE PIVOTS a (6) THROTTLE GRIP a (6) BRAKE/CLUTCH LEVER PIVOT BOLTS ao (7) STEERING STEM BEARINGS) a DUST SEAL, \ (9) KICKSTARTER (8) WHEEL ARM JOINT BEARINGS! \ DUST SEALS (10) * SWINGARM PIVOT! DUST SEALSICOLLARS) NEEDLE BEARINGSMEMO3. MAINTENANCE SERVICE INFORMATION COMPETITION MAINTENANCE SCHEDULE THROTTLE OPERATION AIR CLEANER (AIR FILTER) SPARK PLUG DRIVE SPROCKET RADIATOR COOLANT COOLING SYSTEM DRIVE CHAIN DRIVE CHAIN SLIDER DRIVE CHAIN TENSIONER ROLLERS 3-1 FRONT BRAKE 39 REAR BRAKE 3-10 32 cLuTcH system 342 3-5 EXPANSION CHAMBER/SILENCER 3-13 38 EXHAUST VALVE DECARBONIZING 3-14 36 — susPENSION 314 3-7 TIRES/WHEELS/SPOKES 3-16 3-7 STEERING HEAD BEARINGS 316 | 37 CONTROL CABLES 3-16 $7 NUTS, BOLTS, FASTENERS 3-16 38 39 SERVICE INFORMATION SPECIFICATIONS TEM ‘Transmission al capacity] 86. ‘87, Atter 89: ‘STANDARD 0.55 lit (0.58 US at, 0.48 Imp at at oil change (0.7 lit (0.74 US at, 0.62 Imp qt) st oll change | SERVICE LIMIT Recommended tronsmission oil ‘Gluten lever free play Honda 4 Stroke Oi, SAE 10 W—40 or equivalent API Service Classification: SF of SG 1020 mm (3183/8 nl “Throttle grip fee play 3-5 mm (1/8 1/4 in} Recommended "36, spark plug | atter es: (optional ‘Spark plug ga. “CHAMPION: ON-86 (QN-26) GK: BROEG (BREEV! — No: W24ESR.V (W24ESR-G) ‘CHAMPION: ON 84 (QN-69G) NGK BA9EG (BRSEV) = ND: W27ESA |W27ESA-G) (0.5—06 mm (0.020~ 0.024 inl = Tew STANDARD ‘SERVICE LT Fork air pressure Drive chain slack Fear brake pedal fee play (86) (Chain tensioner roller 0.0. "0 KPa (0 Kaien? O psi ‘Maximum pressure 39 KPs (0.4 kglem. 6 psi 3640 mm (1918-1-9/76 in) 26.0 mm 0.88 in) Chain sider I 86: irom upper surface) | —ajaor 29g, Front Tire sizes Tie pressure 8.0 mm (0.38 in) ‘5.0 rom (0.20 in)MAINTENANCE TORQUE VALUES ear axle nut 85—105 Nem (8.5— 10.5 kg-m, 61—76 ft-b) Throttle housing cover screw 1=2Nem (0.1~0.2 kg-m, 0.71.4 ftlb} Rim lock 10-16 Nem (1.01.5 kg-m, 7—11 ft-lb) Silencer case bolt (After '86:) 4,5—6.0 Nem (0.45-0.60 kg-m, 3.34.3 ft-lb) COMPETITION MAINTENANCE SCHEDULE This maintenance schedule is designed to keep the CR250R in top running condition when used in motocross competition, Because the CR250R has no odometer, the replacement intervals for lubricants and parts is determined by “hours of sunning.”* Keep an accurate log of how long the engine runs each time you practice or race, |: Inspect and clean, adjust, lubricate or replace if necessary. R: Replace, C: Clean, L: Lubricate "86, ‘87. ‘88, ‘89: FREQUENCY aan | Baws Eve | every atte, | cmeet. | net pane ew 25hews | i'shows | _228hours “THROTTLE OPERATION o a8 TAR CLEANER c as SPARK PLUG — 1 ® 38 TRANSMISSION Ow ® 32 RADIATOR COOLANT ZVEARER i aT ‘COOLING SYSTEM 1 37 ‘CYLINDER HEAD DECARBOWZNG e = [EXHAUST VALVE DECARBONTNG € STs PISTON AND PISTON RINGS R es STON PR AND COMRECTING ROD ; a “DRIVE CHAIN oy 7 a7 ‘DRIVE CHAIN SLIDERS a i 38 DRIVE CHAIN ROLLERS 1 39 DRIVE SPROCKET T 1 [3 DDAIVEN SPROCKET 1 1 138 BRAKE FLU TSR =— 39,10 BRAKE SHOEIPAD WEAR TSB] 1 310 RAKE PAD WEAR afer @6: I 7 31017 BRAKE SYSTEM 7 39,10. 1112 CLUTCH SYSTEM 1 3 CONTROL CABLES ne 316 EXPANSION CHAMBERSIENCER - i 33 SUSPENSION - T i 34 'SWINGARM!SHOGK UNKAGE — 1246 TIRES WHEELSTSPORES 7 36 [srenins HEAD BEARINGS z 316 NOTE: The maintenance echeauae based upon average rig conditions Machines svppetesta savers ee requre more equent Seung 3-2MAINTENANCE “901 FREGUENGY laan | eens Tan nore creo | items, | imcee fet. sooe ew 26rous | Tsou | 22 Shure | THeoTTie oPeRaTION i t = ‘AIR FTER NOTED c 35 SPARK PLUG a a 36 RADIATOR COOLANT Nowa i 37 | EKHAUST VALVE DECAREONZING é _ - 373 PISTON ANO PISTON RINGS: z ee PISTON PW ANO CONNECTING ROD ; Gi SMALLEND BEARING TRANSMISSION OF I z [ae DRIVE CRA 7 ® : 37 DRIVE CRAIN SLOERS 7 38 DRIVE CHAN ROLLERS t — 39 ~onive sPAocKET —T— Cs a7 DRIVEN SPROCKET 1 co 128 BRAKE FLUID [wore i 39.70 BRAKE PAD WEAR 1 ~ 30.17 BRAKE SYSTEM 1 — 39,10, 11.12 (CLUTCH SYSTEM 1 a ‘CONTROL CABLES i ne EXPANSION GHAMGERSUENGER i 2a SUSPENSION — i ae 'SWINGARM SHOCK LINEAGE i t 12-46 FORK OL - ® 123 NUTS, BOLTS, FASTENERS i - 316 WHEELSITIRES i ~ 316 STEERING HEAD BEARINGS, 1 T_T si6 ‘Th mantnance sehen is based upon average ring condition. Wachne subjected fa severe ue Yequre more equa See 2 Replace every 2 year. Replacement aqures mechanical ski 3-3MAINTENANCE a] After 90: FREQUENCY Soon raw Evey eve note seman | oe 7 ot. ae vem ‘Tsroue | 22s hors THROTTLE OPERATION t ss AIR FILTER OTe € 35 ‘SPARK PLUG r 7 “36 RADIATOR COOLANT wore a, r 37 ‘GOOUNG sysTEM r 37, (CYLINDER HEAD OFCARBONTZNG € 63 {EXHAUST VALVE DECARBONZING € 31873 PISTON AN PISTON RINGS a 56 PISTON PIN AND CONNECTING ROD a oo. SWALLEND BEARING TRANSMISSION Ol, a 2 ‘DRIVE CHAIN 1 R 37 ‘DRIVE CHAIN SLIDERS t 38 DDRIVE CHAIN ROLLERS t 39 [ORWE SPROCKET r 37 [DRIVEN SPROCKET T t 128 ‘BRAKE FLUID (NOTE a r 39.10 |“ srake pAos WEAR t 310.17 [RAKE SYSTEM r 39.10.1112 CLUTCH SYSTEM r 312 CONTROL CABLES te 316 EXPANSION CHAMBERISILENCER 313 SUSPENSION o - a4 'SWINGARMUSHOGK UNKAGE v 1208 FORK On. NOTES. a 1123 NUTS, GOLTS, FASTENERS 7 316 | ‘WHEELSITIRES r a6 ‘STEERING HEAD BEARINGS L i 316 ‘This maintenance sched is based uaon average ing condlion Machine Subj To severe use requ mee Feaut aes. NOTE" Cian after avery moto fr aust rig condivon 2, Rapce every 2 yous. Replacement requires mechanic! sil 5 Replace ster te retook Hae ADDITIONAL ITEMS REQUIRING FREQUENT REPLACEMENT rem Case Ramat fg| Cylinder hen gasket Compression ask Tiplace wherever assembled B) Read waive Damage or fatigue B) Catch cs ‘Waar o dlaolrntan Z| Grier bese gasket Ueatage Replace whenever sererbled S| lam cranteace cover socks Damage Replace wharaverseseembleg Foner tre Wear Front broke pd (6) West Minmum thickness 1.0 mm 0.08 in) Frontiear rake oad Attar "86 Wiest imam tiskness 1.9m 0.08 ia Feo brave tring (88) Wiest Mansmum tines: 2.0 mm 0.08 in) ear brake torque am bushing (863) Wiese Bear brace panel uenng 880, Wiese San Fatigue oF damage Chain guise score ‘Wer or domege jus) Sie cover Bamoae FZ Fron number plore Damage }| Fronuren fern Damage IE) Chtchlevesmoider Pray or damage fae lever Pray or dames endsba Bore or erctod ‘Throttle Nosing Damage ip rater Damage Seas peas! Damage Brake pada Damage Chain Santer Samage Sir closer element Domoge {shows chabar sng hook Fagunor domage [NOTE: The pars replacerentntrvale showin the above schedule ae bused ups average ia Condos: Macines sjetedo severe ure eg ore re 3-4MAINTENANCE THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. 3-5 mm J j1/8—174 in Inspect the throttle cable for deterioration, damage or kinks. Replace the cable as required. Measure throttle grip free play at the throttle grip flange. ‘THROTTLE GRIP FREE PLAY: 3-5 mm (1/8~1/4 in) (1) THROTTLE GRIP Minor adjustments can be made with the adjuster at the (2) ADJUSTER (3) LOCK NUT housing. Slide the rubber protector down end loosen the lock \ rut, then turn the adjuster (1) DECREASE Tighten the lock nut. PLAY y After ‘86: Remove the fuel tank (page 4-14) "86 and AFTER (2) RUBBER CAP Major adjustments can be made at the carburetor end of the cable. ‘Turn the adjuster at the throttle grip in all the way. : (1) INCREASE PLAY Pull the rubber cap up, loosen the lock nut, and turn the adjuster. Tighten the lock nut and reinstall the rubber cap. Check that the throttle grip turns smoothly and retums completely AIR CLEANER (AIR FILTER) Remove the seat, unscrew the element set bolt and air cleaner assembly, (3) DECREASE PLAY eh (4) ADJUSTER (5) LOCK NUT (2) "UP" MARK (3) ELEMENT HOLDER, f NOTE + Use air filter oil, instead of 2-stroke oll, when riding on a dusty track. Apply air filter oll to whole surface of the telement and rub it with both hands to saturate the element. Squeeze out excess ail and wipe oil off the element surface with a dey cloth, (5) TAB —— fy (4) GROOVEMAINTENANCE Apply a thin coat of grease to the sealing surface of the ele- ment and reinstall Install the air cleaner element with the “"UP" mark facing up. "87: Position the element's tab so it aligns with the groove in the holder Install the element with the “UP” mark facing up on the air cloaner case. Aftor 87: Install the element holder, aligning the pin on the holder with the hole in the element. Install the element into the air cleaner case with the tab of the clement facing up. After ‘88: Install the element into the air cleaner case aligning the tab of ‘the element with the °*" mark of the case Tighten the set bolt securely. "86 and AFTER Install the air cleaner case cover {if riding in rain oF wet cond: tions Install the seat, checking to see that the front and lower tabs are securely engaged Tighten the mounting bolts, SPARK PLUG Remove the spark plug, then visually inspect it for damage, Discard it if the insulator is cracked or chipped. ‘ (1) "UP" MARK Pi mTAB—+O aay auion 5) SET BOLT \ (1) ELEMENT (2) “A” MARK (After ‘83 [(4)SET BOLT ia} TABI \ (4) ELEMENT (3) HOLOER Zz wee “39 CHAMPION) ON 86 (0N-26) an-88 (0N-59G) DiRT i t BRBEG (BRBEV) BRIEG (BRIEV) ane : anet ie WaT ETERS a ox indicat tional spark plugs, same maker. Cena (Thiet optional tbat pln, some ma SAuING carefully. then reinetal the spark plug 4) CHECK - foe ‘SPARK PLUG GAP: 0.5~0.6 mm (0.020—0.024 in) 3-6MAINTENANCE DRIVE SPROCKET Inspect the sprocket teeth for excessive wear or damage. Replace it necessary. (1) Damaged Sprocket “J (2) Worn Sprocket Teeth Teeth NOTE ~ Never install @ new drive chain on worn sprockote ora worn | REPLACE | | REPLACE ehnin an new sprockets, Both hain and sprocket must be | } Jn good condition, or the new replacement chain or sprock (3) Normal Sprocket Teeth ets will wear rapidly. RADIATOR COOLANT Check the coolant level with the engine col; it should be up to the filler neck. Add coolant as required (page 10-2), x +The engine must be cool before servicing the cooling system, or ‘you could be sealded. Check that all cooling system items are secure and not leaking. COOLING SYSTEM Remove the radiator shrouds, Inspect the hoses for cracks and deterioration, Use low pressure water and a soft brush to rinse off any dirt that may be stuck on the radiator core. Replace, if necessary. Check the tightness of the hose clamps and radiator mounting bolts. DRIVE CHAIN NOTE + For maximum service life, the drive chain should be ol and lubricated before each outing Stop the engine and shift to neutral Place the engine on a box or work stand Carefully remove the master link clip with pliers. Remove the master link and the drive chain. Clean the drive chain in high flash point solvent and wipe it Inspect the chain for possible wear or damage; replace any | —«(2) WIPEDRY _—_— | nstall the drive chain and lubricate with Honda chain tee (4) CHAIN | Note the direction of the master link clip. (Its epen end should ertbsaeate {ace in the opposite direction of whee! rotation.) 3-7MAINTENANCE ADJUSTMENT Raise the rear wheel off the ground by placing a box or work stand under the engine, Measure the chain slack in the upper run, mid-way between the sprockets, CHAIN SLACK: 35—40 mm (1-3/8~1-9)16 in} needs adjustment, loosen the axle nut and turn the adjusting nuts to increase or decrease slack Check that the chain adjuster index marks are in the same position on each side, then tighten the axle nut to 85-105 After “B6 shown: Nem (8.5—10.5 kg-m, 61—76 fb). a seer sere THADIUST BOLT Wiz) LOCK NUT A . -— \ rod (5) ADJUSTMENT PLATE If the chain needs adjustment, loosen the axle nut and lock ruts and turn the adjusting bolts to increase or decrease chain 7 ‘ slack. For the other drive chain service, see page 3-7, DRIVE CHAIN SLIDER Inspect the drive chain slider for excessive we SERVICE LIMIT: CHAIN SLIDER (from upper surface! 86: 9.0 mm (0.35 in} ‘After ‘86: 5.0 mm (0.20 in) Check the chain guide slider and chain guide for ws damage 86, After ‘89, Replace the chain quide slider if the chain is visible through the ‘wear inspection window. (2) WEAR INSPECTION WINDOWMAINTENANCE "87, '88, 89: "87, ‘88, ‘89: (1) UPPER HOLE NoTE + The chain guide slider is adjustable, For the 63 or 55 T sprockets, position the chain guide slider's rear mounting bolt in the lower hole (the upper hole is for the 49 T or 81 T sprockets.) (3) WEAR INSPECTION WINDOW (2) LOWER HOLE DRIVE CHAIN TENSIONER ROLLERS Inspect the drive chain tensioner rollers for excessive weer and smooth rolling, ‘SERVICE LIMIT: ‘MINIMUM ROLLER 0.D.: 25.0 mm (0.98 in} FRONT BRAKE Check the front brake fluid reservoir level. If the level is near ‘the lower level mark, remove the cover and diaphragm. (1) LOWER LeveL Fill the reservoir with DOT 3 or 4 brake fluid to below the casting edge level. (1) UPPER LEVEL If the level was low, check the entire system for leaks, CAUTION + Do not remove the cover until the handlebar has been turned so ‘that the reservoir is level. + Do not mis different types of fluid, as they are not compatible Wt with each other. + Avoid spilling fluid on painted, plastic or rubber parts Place a rag over these parts whenever the system is service. Rofer to section 18 for brake bleeding procedures. 3-9MAINTENANCE Inspect the brake hose and fittings for deterioration, cracks ‘and signs of leakage. Tighten any loose fittings. Replace hose and fittings as required PAD WEAR Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of the wear grooves. LEVER FREE PLAY (1) PISTON Free play must be adjusted to provide 0.1—1.4 mm (0.004 (0.085 in| clearance between the end of the adjuster and the front brake master cylinder piston. If the clearance is incorrect, loosen the lock nut and turn the adjuster CAUTION + Do not adjust distance “A” to below 0.1 mm (0.004 in) (3) Lock nur IH the brake lever free play exceeds 30 mm (1.25 in} with the clearance between the adjuster and the front brake master cy inder piston below 1.4 mm (0.06 in), there is probably air in the brake system and it must be bied (page 13-4) REAR BRAKE 86: First adjust the brake pedal to the desired height by loosening the lock nut and turning the pedal height adjuster. Tighten the lock nut. Ww ptoek Nur * x= Measure the brake pedal free play at the tip of the pedal. FREE PLAY: 20—30 mm (3/4~1-1/4 In) (2) PEDAL HEIGHT ADJUSTER 3-10