CR250 88-91, CR500 88-01

Number M432-3,  English.

Extensive descriptions for repairs or maintenance. Covers the following models:

  CR250R (1988-1991),  CR500R (1988-2001)

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Reference to location / Service hints / Special tips / Safety first / Torque specifications / Parts replacement / Lubricants / Fasteners / Basic hand tools / Precision measuring tools / Special tools / Expendable supplies / Mechanic's tips

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Emergency troubleshooting / Troubleshooting / Engine performance / Engine noises / Excessive vibration / 2-stroke pressure testing / Clutch / Transmission / Ignition system / Front suspension and steering / Brake problems / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Service intervals / Periodic lubrication / Transmission/clutch oil change / Fork oil change / Drive chain lubrication / Periodic maintenance / Drive chain lubrication and adjustment / Clutch adjustment / Throttle adjustment / Air filter service / Fuel line inspection / Cooling system inspection / Coolant change / Tune-up / Spark plug / Ignition timing / Carburetor adjustment / Carbon removal / Specifications

CHAPTER FOUR / ENGINE
Engine operating principles / Engine lubrication / Servicing engine in frame / Engine removal/installation / Cylinder head / Cylinder / Engine decarbonizing / Exhaust valve decarbonization / Reed valve assembly / Piston, piston pin and piston rings / Right crankcase cover / Primary drive gear / Drive sprocket / Crankcase and crankshaft / Kickstarter/idler gear / Break-in procedure / Specifications

CHAPTER FIVE / CLUTCH AND TRANSIMISSION
Clutch / Clutch inspection / Clutch cable / External shift mechanism / 5-speed transmission and internal shift mechanism / Internal shift mechanism inspection / Specifications

CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Carburetor body / Carburetor adjustments / Optional Honda carburetor components / Throttle cable / Fuel shutoff valve and filter / Fuel tank / Fuel tank repair / Fuel filter / Exhaust system / HPP system (CR250R) / Specifications

CHAPTER SEVEN / ELECTRICAL SYSTEM
Alternator / Ignition system / CDI unit / Pulse generator / Ignition coil / Ignition timing / Engine kill switch / Specifications

CHAPTER EIGHT / LIQUID COOLING SYSTEM
Safety precautions / Cooling system check / Water pump (water seal and oil seal inspection) / Radiators / Water pump / Coolant hoses / Specifications

CHAPTER NINE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheel spokes / Tire changing / Tire repairs / Handlebar / Steering head / Front fork / Front fork adjustment / Specifications

CHAPTER TEN / REAR SUSPENSION
Rear wheel / Rear hub / Drive chain / Swing arm / Pro-Link system / Shock absorber / Pivot arm assembly / Pivot arm and shock link needle bearing replacement / Sub-frame / Specifications

CHAPTER ELEVEN / BRAKES
Hydraulic disc brake / Draining brake fluid / Front master cylinder / Rear master cylinder / Brake pad replacement / Front caliper / Rear caliper / Brake hose replacement / Brake disc / Bleeding the system / Rear brake pedal assembly / Specifications

SUPPLEMENT / 1992-2001 CR500R SERVICE INFORMATION
Periodic lubrication / Periodic maintenance / Right crankcase cover / Primary drive gear / 5-speed transmission and internal shift mechanism / Throttle cable / Front wheel (1992-on) / Front hub / Wheel spokes / Handlebar / Steering head / Front forks / Front fork adjustment / Swing arm / Shock absorber / Pivot arm assembly / Front master cylinder / Front brake hose replacement

INDEX

WIRING DIAGRAMS