1984-2007 Maintenance Schedule/Checklist/Maintenance Intervals Download for CR80/CR85/CR125/CR250-R Motorcycles.


1984-2007 Honda CR-80/85/125/250-R Maintenance

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Always refer to a service manual before attempting to do any work on your motorcycle, important data including step-by-step procedures, diagrams, pictures, illistrations, specifications cleaning & maintenance information will help you care for and lower the chances of premature parts failurer. Below is a great reference source available for instant download straight to your computer in just seconds.
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All manuals are simple to use pdf downloads and are delivered straight to your computer in just seconds. Not sure what a pdf is? Here is a sample of what a  Service Manual looks like (sample is restricted to one page only).
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Service Manuals Downloads
 
HONDA CR125/CR125R
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HONDA CR250/250R
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HONDA CR80/85R
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MODEL/YEAR APPLICATION:

Honda CR125R, CR125-R, CR-125-R, CR125 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 & 2007 models.

Honda CR250R, CR250, CR-250R, CR250-R 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06 & 07 year CR250R models.

Honda  CR80R, CR85R, CR80, CR85, CR-80-R, CR-85-R 1984, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06 & 07 year CR-80/85-R models.


This CR80/85/125/250-R maintenance guide describes the Honda CR80R, CR85R, CR125R & CR250R procedures as general procedures for Honda CR80R / CR85R / CR125R & CR250R motorcycles. It is only recommended to follow the maintenance guide in the reference guide links listed above as they contain the same information mechanics and technicians use to service your bike.

Important information contained in this page like special notes, tips, proper procedures, complete specifications, torque specs and recommendations must be followed in the reference links to ensure that the task is performed in the proper flow and to manufacture specification recommendations.

 


The following is a basic maintenance overview of critical points of service to maximize the performance of your motorcycle and help prevent premature part or parts failure. Since every model & year CR80/85/125/250 differs you should always refer to the links provided for exact maintenance procedures and specifications related to your model and year. Below is a list of topics usually covered in a Honda manual.

MAINTENANCE CHECKLIST

  • Maintenance Schedule Chart/Interval Chart
  • Fuel Line
  • Throttle Operation
  • Air Cleaner
  • Crankcase Breather
  • Spark Plug
  • Valve Clearance
  • Engine Oil
  • Engine Oil Strainer Screen
  • Engine Oil Centrifugal Filter
  • Engine Idle Speed
  • Drive Chain
  • Drive Chain Slider
  • Brake Fluid
  • Brake Shoe/Pad Wear
  • Brake System
  • Clutch System
  • Sidestand
  • Suspension
  • Spark Arrester
  • Wheels/Tires
  • Steering Head Bearings

MAINTENANCE SCHEDULE

MAINTENANCE

Always service your motorcycle (dirt-bike) more frequently if the motorcycle is ridden in dusty areas, sand or snow. Also service your bike more frequently if the motorcycle is ridden in very wet or muddy conditions. For a detailed checklist and maintenance schedule chart see download manual links above for complete intervals guide.

Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. The maintenance guide is for easy to understand with abbreviations to help identify which part gets cleaned, replaced, adjusted or lubricated and at what mileage interval it should be done at. Remember, to service your motorcycle more frequently if operated in sand, snow or muddy and wet conditions.

I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean R: Replace A: Adjust L: Lubricate


PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

Tires - check condition and pressures
Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
All brakes - check operation (includes auxiliary brake)
Throttle - check for free operation
Engine stop switch - check for proper function
Wheels - check for loose wheel nuts
Air cleaner element - check for dirt or water; clean or replace
Steering - check for free operation, noting any unusual looseness in any area
Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
Engine coolant - check for proper level at the recovery bottle

FUEL LINES

1. Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.
3. Replace all fuel lines every two years.

VENT LINES

1. Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.
2. Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

FUEL FILTER

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel pump and carburetor.

1. Shut off fuel supply at fuel valve.
2. Remove line clamps at both ends of the filter.
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow.
5. Install clamps on fuel line.
6. Turn fuel valve ON.
7. Start engine and inspect for leaks.

CARBURETOR DRAINING

The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.

1. Turn fuel valve to the off position.
2. Place a clean container beneath the bowl drain spigot or bowl drain hose.
3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
6. Turn fuel valve to “ON”.
7. Start machine and check for leaks.

NOTE: If there is a tube attached, it must be reattached as this will effect engine performance.

SHIFT LINKAGE ADJUSTMENT

1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.
2. Place gear selector in neutral.
3. Loosen rod end adjuster jam nuts on both ends of linkage rod.

NOTE: The jam nut closest to the knurled end is Left Hand thread.

4. Turn linkage rod to shorten or lengthen rod until the shift lever is centered on hole in the fender.
5. Hold rod end parallel to mounting surface and tighten jam nuts securely.

THROTTLE OPERATION

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.

CHOKE (ENRICHER) ADJUSTMENT

If the choke knob does not stay out when pulled, adjust the choke tension by tightening the tensioner located under the rubber boot between the choke knob and nut. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled. Verify free play of (see reference manual links) and smooth operation of choke cable. If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.

PILOT SCREW

The pilot systemsupplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into themain bore through the pilot outlet.

PILOT SCREW ADJUSTMENT

1. Start engine and warm it up to operating temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns.

NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.

3. Connect an accurate tachometer that will read in increments of + or -- 50 RPM.
4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.
7. Center the pilot screw between the points in Step 5 and 6.
8. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (reference links).

NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

THROTTLE OPERATION

To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert blade into the pockets of the cover starting on the #1 position.
2. Twist screwdriver slightly while lifting on the cover to release snap.
3. Repeat procedure at the other five locations as shown.

NOTE: Do not attempt to remove cover until all latch points are released. Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. Replace the throttle cable if worn, kinked, or damaged.

SPARK PLUG


1. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed.
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.
4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.
5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side 0electrode carefully.
6. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.
7. Apply a small amount of anti-seize compound to the spark plug threads.
8. Install spark plug and torque to 9--11 ft. lbs (12--14 Nm).

NGK BR9EG-N8
NGK BR8EG
NGK BR8EIX
NGK Double Platinum Spark Plug
NGK honda spark plug

IGNITION TIMING

Refer to Electrical chapter for ignition timing procedure.

AIR FILTER/PRE-FILTER SERVICE

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. The pre filter should be cleaned before each ride using the following procedure:

1. Lift up on the rear of the seat.
2. Pull the seat back and free of the tabs. NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.
3. Remove clips from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.
4. Loosen clamp and remove air filter assembly

Cleaning:
5. Slip the pre-filter element off of main element. Clean the pre filter with hot soapy water.
6. Rinse and dry thoroughly.
7. Inspect element for tears or damage.
8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Installation:
9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.
10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.
NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.

ENGINE OIL LEVEL

To check the oil level:
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will return oil to its true level in the engine sump.
3. Stop engine, remove dipstick and wipe dry with a clean cloth.
4. Reinstall dipstick, screwing into place.
5. The dipstick must be screwed completely in to ensure accurate measurement.
6. Remove dipstick and check to see that the oil level is in the normal range. The oil should be between the top of the bottom crosshatched area and the bottomof the top crosshatched area. Add oil as indicated by the level on the dipstick. Do not overfill. NOTE: Do not fill the over the normal oil operating range. Filling over the normal operating range could cause a mist of oil to enter the air box. NOTE: Rising oil level between checks in cool weather driving, can indicatemoisture collecting in the oil reservoir. If the oil level is
over the full mark, change the oil.

VALVE CLEARANCE

Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke.

1. Remove the seat.
2. Remove body panels and fuel tank as necessary to gain access to valve cover.
3. Remove the spark plug high tension lead and remove the spark plug. CAUTION: Place a clean shop towel into the spark plug cavity to prevent dirt from entering.
4. Remove plastic valve plugs.
5. Remove timing inspection plug from recoil housing. CAUTION: Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjustment.
6. Rotate engine slowly with recoil rope, watching the intake valve(s) open and close. NOTE: Observe the intake valve closing and then start to open, continue to rotate until the “T” aligns with pointer. The camshaft lobes should be pointing downward.
7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves.


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Periodic Maintenance Chart . . . . . . . . . . . . . . . 2.2-2.3

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . 2.3

Recommended Maintenance Products . . . . . . 2.4

Lubricant and Maintenance Quick Reference 2.5-2.6

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

Transmission Lubrication . . . . . . . . . . . . . . . . . . 2.8

Transmission Linkage Adjustment . . . . . . . . . . 2.9

Throttle Operation / Choke Adjustment . . . . . . 2.10

Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 2.10-2.11

ETC Switch Adjustment . . . . . . . . . . . . . . . . . . . 2.11

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

Compression Test . . . . . . . . . . . . . . . . . . . . . . . . 2.13

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 2.13-2.14

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14-2.15

Oil Cooler Maintenance . . . . . . . . . . . . . . . . . . . 2.15

Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

Air Box Sediment Tube Service . . . . . . . . . . . . 2.16

Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Recoil Housing/PVT Drying . . . . . . . . . . . . . . . . 2.16-2.17

Oil Level/Change/Filter . . . . . . . . . . . . . . . . . . . . 2.17-2.18

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 2.19-2.20

Steering and Toe Alignment . . . . . . . . . . . . . . . 2.20-2.22

Exhaust System Maintenance . . . . . . . . . . . . . 2.22

Brake System Service . . . . . . . . . . . . . . . . . . . . 2.23-2.24

Drive Chain and Sprocket Service . . . . . . . . . . 2.24-2.26

Suspension Service / Controls . . . . . . . . . . . . . 2.26-2.27

Wheel Removal / Installation . . . . . . . . . . . . . . . 2.27

Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28


E

Engine Oil - Level/Change 100 hrs 6 months 1000 (1600) Check Level Daily; Break In service at 1 month

E

Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change

E

Air Filter - Foam Pre-Cleaner Daily Daily Inspect-Clean & oil more often in dirty conditions.

E

Air Filter - Main Element Weekly Weekly Inspect - Replace if necessary

Air Box Sediment Tube - Daily Drain deposits whenever visible

 

Engine Breather Filter 20 hrs Monthly 200 (320) Inspect and replace if necessary

 

Oil Tank Vent Hose 100 hrs 12 months 1000 (1600) Inspect hose routing /hose condition  Valve Clearance 100 hrs 12 months 1000 (1600) Inspect/Adjust

E

Idle Speed As required As required Adjust



Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary

Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage

Carburetor Air Intake Ducts/Flange 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/air leaks

Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary

E

pump & carburetor. Replace lines every 2 years.

 Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,

E

Coolant/Level Inspection Daily Daily Replace engine coolant every 2 years

Coolant Strength / Pressure Test

System

100 hrs 6 months 1000 (1600) Inspect strength seasonally; Pressure test system

annually

Radiator 100 hrs 12 months 1000 (1600) Inspect / Clean external surface

Cooling System Hoses 100 hrs 12 months 1000 (1600) Inspect

Engine Mounts 100 hrs 12 months 1000 (1600) Inspect

Drain Recoil Housing Weekly Weekly More often if operating in wet environment

Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600)

 Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually

ELECTRICAL

E

Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security

Ignition Timing 100 hrs 12 months 1000 (1600) Inspect

Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level

Headlight Aim As required As required Adjust if Necessary

Headlamp Inspection Daily Daily Check operation daily; Apply Nyogel

to connector when lamp is replaced

Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Nyogel

to socket when lamp is replaced

Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary Grease Grease

 

E


General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc.

Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly

 

Front Hubs/Fluid Change 100 hrs 12 months 1000 (1600) Check monthly Front Wheel Bearings (2x4) Annually 12 months Inspect and replace if necessary



(AWD Models)

Annually 12 months Inspect Torque and Locking Fastener and replace

if necessary

Drive Belt 50 hrs 6 months 500 (800) Inspect - Adjust, Replace if Necessary

Clutches (Drive And Driven) 100 hrs 12 months 1000 (1600) Inspect, Clean

Front Hub Spindle Nut Torque

Transmission Oil Level 25 hrs Monthly 250 (400) Inspect Monthly; Change Annually Steering 50 hrs 6 months 500 (800) Inspect Daily, Lubricate



Toe Adjustment As required As required Periodic Inspection, Adjust When Parts are Replaced

Rear Axle 50 hrs 6 months 500 (800) Inspect Bearings, Grease Fitting

 

Front Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate

 

Rear Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate Brake Fluid 200 hrs 24 months 2000 (3200) Change Every Two Years

Brake Fluid Level Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

 

Brake Lever Travel Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item Brake Pad Wear 10 hrs Monthly 100 (160) Inspect Periodically

 



Auxiliary Brake Adjustment As required As required Inspect Deflection Daily; Adjust

Output Shaft Bearing Monthly Monthly Grease Monthly

Brake System Pre-ride Pre-ride Pre-Ride Inspection Item

Wheels Pre-ride Pre-ride Pre-Ride Inspection Item

Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride Pre-Ride Inspection Item

 

Drive Chain 50 hrs 6 months 500 (800) Inspect Daily, Adjust and Lubricate if Needed

Tires Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item



 

Shift Linkage 50 hrs 6 months 500 (800) Inspect,Lubricate, Adjust