2004r.pdf

IMPORTANT NOTICE

THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR COMPETITION USE ONLY AND IS SOLD

“AS IS” WITH NO WARRANTY. IT DOES NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY

STANDARDS AND OPERATION ON PUBLIC STREETS, ROADS, OR HIGHWAYS IS ILLEGAL.

STATE LAWS PROHIBIT OPERATION OF THIS MOTORCYCLE EXCEPT IN AN ORGANIZED RACING OR

COMPETITIVE EVENT UPON A CLOSED COURSE WHICH IS CONDUCTED UNDER THE AUSPICES OF A

RECOGNIZED SANCTIONING BODY OR BY PERMIT ISSUED BY THE LOCAL GOVERNMENTAL

AUTHORITY HAVING JURISDICTION.

FIRST DETERMINE THAT OPERATION IS LEGAL.

OPERATOR ONLY, NO PASSENGERS.

This motorcycle is designed and constructed as an operator-only model. The motorcycle load limit and

seating configuration do not safely permit the carrying of a passenger.

READ THIS MANUAL CAREFULLY.

Pay special attention to statements preceded by the following words:

Indicates severe personal injury or death will result if instructions are not followed.

Indicates a strong possibility 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.

This manual should be considered a permanent part of the motorcycle and should remain with the

motorcycle when resold.

Honda CR250R

OWNER’S MANUAL

2004

All information in this publication is based on the latest product information available at the time of

approval for printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without

notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

Honda Motor Co., Ltd. 2003

TO THE NEW OWNER

By selecting a Honda motocross CR250R as your new

motorcycle, you have placed yourself in a distinguished

family of motorcycle owners and riders.

The purpose of this Owner’s Manual is to help ensure

that you obtain the greatest possible satisfaction from

your new CR motocrosser – satisfaction with the per-

formance of the motorcycle, and through success in

competition.

Read this WARNING LABEL before you ride.

• The CR is a high performance racing motorcycle

utilizing the latest motocross technology. This

motorcycle is intended for competition use by

experienced riders only.

This new motocross model was designed to be as

competitive as possible. But motocross is a physically

demanding sport that requires more than just a fine

motorcycle. To do well, you must be in excellent

physical condition and be a skillful rider. For the best

possible results, work diligently on your physical con-

ditioning and practice frequently.

The Service Manual for your CR is available from your

authorized Honda dealer. It is the same manual your

dealer uses. If you plan to do any service on your CR

beyond the standard maintenance procedures included

in this Owner’s Manual, you will find the Service Manual

an effective and worthwhile tool. If your dealer does not

have the Service Manual for your particular year and

model in stock, he can order it.

PROTECTIVE APPAREL

1. Most motorcycle accident fatalities are due to head

injuries: ALWAYS wear an approved motorcycle

helmet. You should also wear a face shield or

goggles, boots, gloves, and protective clothing.

2. The exhaust system becomes very hot during op-

eration, and it remains hot after operation. Never

touch any part of the hot exhaust system. Wear

clothing that fully covers your legs.

3. Do not wear loose clothing which could catch on the

control levers, kickstarter, footpegs, drive chain, or

wheels.

MODIFICATIONS

•

Modification of the motorcycle, or removal of

original equipment may render the vehicle unsafe

or illegal. Obey all federal, state, and local equip-

ment regulations.

CONTENTS

1. OPERATING INSTRUCTIONS ........................... 2

Fuel ................................................................. 2

Basic Operation ............................................. 3

• Starting The Engine ............................... 3

• Stopping The Engine ............................. 3

• Break-In Procedure ................................. 3

Controls .......................................................... 4

Control Adjustment ....................................... 5

• Clutch Lever Free Play ........................... 5

• Clutch Lever Position ............................. 5

• Throttle Grip ........................................... 6

• Front Brake Lever ................................... 7

• Brake Pedal Height ................................. 7

Adjustment For Personal Fit ......................... 7

• Control Positioning ................................ 7

• Handlebar Position, Width & Shape ..... 7

• Additional Individualized

Adjustments ............................................ 8

2. SPECIFICATIONS ............................................... 9

3. OPTIONAL PARTS ........................................... 10

4. SERVICE AND MAINTENANCE ....................... 11

Pre-ride Inspection Check List ..................... 11

Maintenance Schedule ................................. 11

General Service Information ....................... 12

Between Moto/Between Practice And Moto

Maintenance ................................................. 12

After Race Maintenance ............................... 13

• After Race Lubrication .......................... 13

• Routine Cleaning ................................... 13

• Pressurized Spray Washers .................. 13

• Condensation Control ........................... 13

• After Cleaning Lubrication .................... 13

General Maintenance ................................... 14

Maintenance Preparations ............................. 17

• Seat ........................................................... 17

• Fuel Tank .................................................. 17

• Subframe ................................................. 19

Maintenance Procedures ............................. 20

•

• Reed Valve ............................................. 28

• Cylinder Head/Cylinder/Piston ............. 29

• Nuts, Bolts, Fasteners ........................... 35

• Handlebar And Steering Head

Bearings ................................................. 35

• Throttle Grip .......................................... 35

• Fuel Line ................................................. 35

• Carburetor .............................................. 36

• Front And Rear Wheels And Tires ....... 36

• Front Suspension .................................. 37

• Rear Suspension ................................... 38

• Brakes ..................................................... 39

• Drive Chain ............................................ 41

• Drive Chain Sliders ................................ 43

• Drive Chain Rollers ................................ 43

• Driven Sprocket ..................................... 43

• Expansion Chamber .............................. 44

• Control Cables ....................................... 44

• Torque Table .......................................... 45

5. CARBURETOR ADJUSTMENT ........................ 46

• Carburetor .............................................. 46

• Tuning For Special Conditions ............. 51

• Spark Plug Coloring Indications ........... 51

6. SUSPENSION ADJUSTMENT ......................... 52

• Race Sag ................................................ 52

• Rear Suspension ................................... 53

• Front Suspension .................................. 55

• Suspension Adjustments Relating To

Specific Track Conditions ..................... 70

• Suspension Adjustment Guidelines .... 71

7. CHASSIS ADJUSTMENTS FOR TRACK

CONDITIONS .................................................... 74

• Rear End ................................................. 74

• Fork Height/Angle .................................. 74

• Wheelbase ............................................. 74

8. GEARING SELECTION ..................................... 74

9. TIRE SELECTION .............................................. 75

10. MAINTENANCE, TUNING & RACING

LOGBOOK ......................................................... 76

11. SPARE PARTS & EQUIPMENT ........................ 78

12. TROUBLESHOOTING ....................................... 79

•

13. CLEANING ........................................................ 80

14. STORAGE .......................................................... 81

• To Prepare The Motorcycle For

Storage ................................................... 81

• Removal From Storage ......................... 81

15. WIRING DIAGRAM ............................................. 82

16. INDEX .................................................................. 83

17. AUTHORIZED MANUALS .................................. 84

Transmission Oil ................................... 20

•

Coolant ................................................... 21

•

Spark Plug .............................................. 22

•

Ignition ................................................... 22

•

Air Cleaner ............................................. 23

•

Clutch ..................................................... 24

Poor Performance At Low And Idle

Speeds .................................................... 79

•

RC Valve ................................................. 25

•

Poor Performance At High Speed ........ 79

1. OPERATING INSTRUCTIONS

FUEL

Your CR has a two-stroke engine that requires a gaso-

line-oil mixture.

• Vegetable oils separate from gasoline more easily

than mineral oils, especially in cold weather. It is

advisable to use mineral oil when ambient tem-

peratures below 0 ° C (32 ° F) are expected.

• If the gasoline-oil mixture is left standing in a

container for a long period of time, lubricity will

deteriorate. Use the mixture within 24 hours-or the

time period recommended by the oil manufacturer.

• Once an oil container is opened, the oil must be

used within one month, since oxidation may occur.

CAUTION:

•

32:1 FUEL OIL MIXING CHART

Fuel

Oil

Fuel tank capacity: 2.0 US gal (7.7 liter, 1.7 Imp gal)

Gallons

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

Liters

1.89

3.79

5.68

7.57

9.46

11.36

13.24

15.14

17.03

18.92

20.81

22.71

Ounces

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

22.0

24.0

cm 3

118

177

237

296

355

414

473

532

591

651

710

To open the fuel fill cap, pull the breather tube out of the

steering stem nut. Then turn the fuel fill cap

counterclockwise.

• Use automobile gasoline with a pump octane

number of 92 or higher. If “knocking” or “pinging”

occurs, try a different brand of gasoline or a higher

octane grade.

• Premix gasoline and oil in a ratio of 32:1. Prepare

the fuel mixture in a clean container, and shake until

thoroughly mixed before filling the fuel tank.

USE PRO Honda HP2 2-STROKE OIL (32:1) OR AN

EQUIVALENT.

CAUTION:

•

Do not mix vegetable and mineral based oils.

•

Gasoline is extremely flammable and is explosive

under certain conditions. Perform this operation in

a well-ventilated area with the engine stopped. Do

not smoke or allow flames or sparks in the area

where gasoline is drained or stored and where the

fuel tank is refueled.

Too much oil will cause excessive smoking and

spark plug fouling. Too little oil will cause engine

damage or premature wear.

(1) FUEL FILL CAP

(2) BREATHER TUBE

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