Honda 1988-1991 CR250R, 1988-2001 CR500R Motorcycle Repair Manual

Description

This Clymer Honda 1988-1991 CR250R and 1988-2001 CR500R Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1988 1989 1990 1991 Honda CR250R and 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 Honda CR500R motorcycles.

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, cooling system, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 310 illustrated pages.

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

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks, Service intervals, Periodic lubrication, Periodic maintenance, Tune-up

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

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

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)

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

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

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

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

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

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