Honda CR 125R 2002 User Manual

Provides safety warnings and guidelines for handling gasoline, hot components, and used engine oil.

Lists tools mentioned in the general information section.

Details lubrication and seal points for various components.

Describes how to route cables and harnesses.

Lists optional parts available for the motorcycle.

Provides warnings and precautions regarding coolant, including flammability and toxicity.

Explains safety precautions related to nitrogen pressure in the shock absorber reservoir.

Outlines rules for servicing the motorcycle, including using genuine parts and metric tools.

Shows how to identify the motorcycle's frame and engine serial numbers and carburetor ID.

Lists dimensions, frame type, suspension, tire sizes, brake types, and fuel tank capacity.

Details engine bore/stroke, cooling, air filtration, crankshaft type, transmission, and ignition system specs.

Provides specifications for recommended engine oil, fuel/oil ratio, and transmission oil.

Lists carburetor identification, main jet, slow jet, jet needle, float level, and throttle grip free play specs.

Details coolant capacity, radiator cap relief pressure, and recommended antifreeze.

Specifies cylinder head warpage, cylinder I.D., piston O.D., clearances, and ring end gap.

Lists clutch lever free play, spring length, disc thickness, and kickstarter/gearshift component dimensions.

Provides specifications for crankshaft clearances, transmission gear/bushing I.D./O.D., and shift fork dimensions.

Lists front wheel specs, fork spring free length, fluid level, and damping adjuster settings.

Details tire pressure, axle/rim runout, drive chain slack, shock absorber specs, and suspension adjuster settings.

Lists brake fluid specs, pad/disc thickness, master cylinder/caliper dimensions for front and rear brakes.

Covers spark plug type, gap, coil resistance, pulse generator specs, and ignition timing.

Lists torque specifications for various engine fasteners and components.

Provides torque values for frame, engine mounting, front wheel, and steering stem components.

Lists torque values for clutch lever, rear suspension, hydraulic brake components.

Lists various tools and their part numbers for general service procedures.

Details lubrication materials and points for engine components.

Details lubrication materials and points for frame components.

Illustrates cable and harness routing for 2000-2001 models.

Illustrates cable and harness routing for models after 2001.

Provides detailed illustrations of cable and harness routing for 2000-2001 models.

Provides detailed illustrations of cable and harness routing for models after 2001.

Lists optional carburetor main jets and detailed specifications for jet needles.

Continues the listing of optional carburetor jet needles and their specifications.

Details specifications for optional carburetor main jets and jet needles, including flow characteristics.

Covers work stand, air pressure gauge, pin spanner, drive chain/sprocket, handlebar, and front wheel assembly.

Details fork spring types, rates, and oil capacities for 2000 models.

Provides specifications for fork springs (after 2001) and shock absorber springs.

General safety, removal/installation notes, and torque values for frame components.

Lists common problems like excessive noise and poor performance related to the exhaust system.

Details the procedure for removing and installing the motorcycle seat.

Explains how to remove and install the side covers.

Describes the process of removing and installing the radiator shrouds.

Details how to remove and install the front number plate.

Covers the removal and installation of the sub-frame assembly.

Explains fuel filter maintenance and the process for removing and installing the fuel tank.

Details the removal and installation of the silencer case, including glass wool packing.

Describes the removal and installation of the expansion chamber.

General safety warnings and specifications related to maintenance.

Lists specifications for throttle grip free play, spark plug, and transmission oil.

Details clutch lever play, chain slack, tire size, and tire air pressure.

Lists torque values for various maintenance items like oil bolts, spark plug, axle nuts, and chain adjusters.

Provides a detailed schedule for regular maintenance intervals and required service actions.

Lists engine and frame parts that may require frequent replacement due to wear or damage.

Explains how to check and adjust throttle grip free play for smooth operation.

Details the procedure for removing and cleaning the air cleaner assembly.

Describes how to wash, dry, and apply filter oil to the air cleaner element.

Explains how to inspect the spark plug for damage, wear, and burning conditions.

Details spark plug inspection, gap adjustment, and torque specifications for installation.

Provides warnings about hot coolant, toxicity, and procedures for checking coolant level.

Details inspection of radiator, hoses, and clamps for damage or blockage.

Explains how to remove carbon deposits from the cylinder head combustion chamber.

Describes how to remove carbon deposits from flap valves and valve shaft.

Details the procedure for checking the transmission oil level.

Explains how to drain and refill the transmission oil, including capacity and recommended oil.

Provides guidelines for inspecting and maintaining the drive chain, emphasizing cleaning and lubrication.

Details how to remove, clean, lubricate, and adjust the drive chain slack.

Explains how to adjust chain slack and check for wear limits.

Covers inspection of drive chain sliders for wear and replacement.

Details inspection of drive chain rollers for wear or binding and their replacement.

Explains how to inspect sprocket teeth for wear or damage and when to replace them.

Guides on checking brake fluid levels in front and rear reservoirs and identifying potential causes for low levels.

Details rear brake fluid replacement, system checks, and torque values.

Explains how to check brake pads for wear and when to replace them.

Describes how to adjust the brake lever position using the adjuster and lock nut.

Explains how to measure and adjust clutch lever free play.

Details how to adjust the brake pedal height using the lock nut and adjusting bolt.

Covers removal, lubrication, and replacement of throttle and clutch cables.

Describes the procedure for replacing the glass wool packing in the silencer.

Details how to inspect the front suspension action, check for leaks, and clean fork seals.

Explains the effect of air pressure on fork action and how to release built-up pressure.

Guides on checking the shock absorber action, signs of leaks, and wheel bearing wear.

Covers inspection and maintenance of swingarm bearings, shock linkage, and pivot bearings.

Emphasizes checking that all fasteners are tightened to torque specifications and safety clips are secure.

Covers checking tire pressure, condition, wheel trueness, spokes, and rim locks.

Lists tire pressure, axle/rim runout, fork spring length, fluid level, and damping adjuster settings.

Lists torque values for front axle, steering stem, fork pinch bolts, and handlebar mounting.

Lists tools required for front wheel, suspension, and steering maintenance.

Addresses issues like hard steering, tracking problems, wheel wobble, and suspension performance.

Details removing brake disc cover, axle nut, axle holder bolts, and the front wheel assembly.

Explains how to measure axle runout using V-blocks and a dial indicator.

Guides on checking wheel bearings for smooth rotation and proper fit.

Details checking rim runout using a turning stand and dial indicator.

Explains removing wheel bearings, distance collar, and preparing the rim for spoke lacing.

Guides on placing the rim, hub, and beginning spoke lacing.

Details torquing spokes, installing rim lock, band, tube, and tire.

Covers installing brake disc, dust seals, wheel collars, and checking for wear.

Guides on cleaning axle shaft, installing front wheel, caliper, axle nut, and holder bolts.

Details seating axle, tightening fork holder bolts, installing disc cover, and removing fork protector.

Steps for removing the front wheel and brake caliper before fork disassembly.

Guides on loosening pinch bolts, removing fork cap, and disassembling the fork leg.

Details removing fork cap, lock nut, spring seat, spring, distance collar, and O-ring.

Explains removing partition plate, fork oil, and the damper rod assembly using special tools.

Guides on removing dust seal, stop ring, slider bushing, and other slider components.

Details checking the fork center bolt for damage and replacing O-rings and washers.

Covers checking slider and outer tube for scoring, scratches, wear, or deformation.

Explains inspecting the wear ring and replacing it if necessary.

Details measuring fork spring free length and checking spring guide for wear.

Explains checking the distance collar for bend, wear, or damage.

Guides on cleaning parts, installing slider bushings, oil seals, stop rings, and the fork damper.

Details installing dust seal, stop ring, oil seal, back-up ring, guide bushing, and slider into the outer tube.

Guides on installing stop ring, checking bladder length, and applying oil to bladder lips.

Details installing fork damper, O-ring, center bolt, and attaching fork rod holder assembly.

Guides on installing lock nut, spring guide, and adjusting fork oil level.

Explains how to bleed air from the fork after assembly by extending and compressing.

Details removing lock nut and spring guide, and installing spring seat onto fork spring.

Guides on installing fork cap, tightening pinch bolts, and tightening fork cap.

Explains how to position fork outer tubes for air pressure release and align top bridge.

Details tightening brake hose guide bolts, installing fork protector, and mounting the front brake caliper.

Steps for removing the front wheel and brake caliper before fork disassembly.

Steps for removing engine stop button connectors, number plate, wire bands, clutch lever, and master cylinder.

Explains removing throttle housing as an assembly or disassembling it by removing covers and cables.

Guides on replacing handlebar grips, aligning throttle grip flange, and installing handlebar holders.

Details tightening handlebar holder nuts, aligning punch marks, and installing throttle housing.

Covers mounting master cylinder, aligning punch marks, installing holder, brake hose eyelet, and filling reservoir.

Guides on installing clutch lever bracket, engine stop button, and routing wires.

Details removing number plate, handlebar, front wheel, fender, and brake hose guide.

Explains removing steering stem nut, washer, fork legs, top bridge, and adjusting nut.

Guides on removing and replacing upper and lower bearing outer races from the head pipe.

Details installing new outer races, bearing race installers, and shafts using special tools.

Guides on installing dust seal, lower bearing, upper bearing, steering stem, and adjusting nut.

Covers seating bearings, installing top bridge, fork legs, stem nut, and brake hose guide.

Safety warnings for shock absorber pressure and contaminated brake discs, general servicing notes.

Lists tire pressure, axle/rim runout, hub distance, chain slack, and drive chain size.

Details shock absorber specs like gas pressure, compressed force, spring length, and damping adjuster settings.

Lists torque values for rear axle nut, spoke nipple, rim lock, brake disc bolts, and suspension mounting points.

Lists specialized tools required for rear wheel and suspension maintenance.

Addresses issues like soft/hard suspension, rear wheel wobbling, and steering alignment.

Details removing axle nut, washer, adjusting block, drive chain, axle, and rear wheel.

Explains how to measure axle runout using V-blocks and a dial indicator.

Guides on checking wheel bearings for smooth rotation and proper fit.

Details checking rim runout using a turning stand and dial indicator.

Covers removing brake disc, dust seals, sprocket bolts, nuts, and the driven sprocket.

Explains removing bearing retainer, wheel bearings, and distance collar using special tools.

Guides on packing bearings with grease and pressing new bearings into the hub using special tools.

Details placing the rim, hub, adjusting hub position, and lacing spokes.

Covers torquing spokes, installing rim lock, band, tube, and tire.

Explains peening the retainer edge, installing driven sprocket, bolts, nuts, and dust seals.

Guides on installing the brake disc, cleaning bolts, and tightening them with locking agent.

Covers installing caliper bracket, rear wheel, drive chain, adjusting block, and tightening axle nut.

Details snugging adjusting bolts and tightening lock nuts.

Steps for removing rear wheel, sub-frame, upper and lower mounting bolts/nuts.

Guides on loosening spring nut/adjusting nut, measuring spring length, and removing spring components.

Details replacing the bladder, including warnings about pressure and protective gear.

Covers releasing nitrogen, removing end plate, rubber stopper, and damper rod assembly.

Guides on cleaning reservoir, applying shock oil, seating stop ring, and charging with air.

Details unstaking end nut, removing burrs, filing threads, cleaning rod, and removing valve components.

Covers removing compression valves, valve stopper, and inspecting/replacing piston ring and O-ring.

Explains inspecting and replacing the piston ring and O-ring using special tools.

Guides on inspecting the damper rod sliding surface for damage or distortion.

Details washing parts, assembling valves, piston, washers, and rod components.

Shows the arrangement of damper assembly components, including valves, piston, and springs.

Illustrates assembly of rubber seal, stopper, end plate, rod guide case, and rebound rubber.

Guides on installing valve stopper, compression valves, piston, rebound valves, washers, and end nut.

Covers coating damper rod, inserting assembly, installing stop ring, and filling damper case with oil.

Details bleeding air from reservoir, charging with air, filling damper, and installing damping adjuster.

Guides on installing lock nut, spring guide, and adjusting fork oil level.

Explains how to press out and install spherical bearings using special tools and grease.

Explains pressing needle bearings into shock arm pivots using special tools and grease.

Explains pressing needle bearings into shock link pivots using special tools and grease.

Guides on setting shock absorber, installing lower and upper mounting bolts/nuts.

Details removing sub-frame, bolt, drive chain roller, shock absorber bolts, shock arm, and shock link.

Covers inspecting dust seals, collars, needle bearings, shock arm, and shock link for wear or damage.

Steps for raising rear wheel, removing rear wheel, brake pedal, shock arm bolts, and caliper.

Covers removing swingarm pivot nut, bolt, swingarm, chain slider, and chain guide.

Details removing side collars, dust seals, washers, needle bearings, and collars from the swingarm.

Explains pressing needle bearings into swingarm pivots using special tools and grease.

Guides on installing washers, bearings, dust seals, collars, side collars, and chain slider.

Details cleaning pivot bolt surface, installing chain guide, swingarm, pivot bolt, and tightening pivot nut.

Covers installing rear brake caliper, brake hose guides, shock arm nut, and installing the rear wheel.

General notes, warnings about contaminated discs/pads, and handling brake fluid.

Lists common issues like soft/spongy brakes, hard lever/pedal, and brake drags.

Explains procedures for draining, filling, and bleeding air from the hydraulic brake system.

Covers inspecting brake pads and discs for wear, thickness, and damage.

Details removing the front master cylinder assembly, including brake hose and reservoir.

Safety notes on fluid handling and specifications for front and rear brake components.

Lists specs for specified brake fluid, pad wear, disc thickness/runout, and master cylinder/caliper dimensions.

Lists torque values for brake hose bolts, lever pivot bolts, master cylinder components, and caliper bolts.

Identifies the snap ring pliers tool for brake system service.

Addresses issues like soft/spongy brakes, hard lever/pedal, and brake drags.

Guides on draining brake fluid from front and rear master cylinders and reservoirs.

Details connecting bleed hose, pumping lever, loosening valve, and checking for air bubbles.

Continues air bleeding procedures, tightening bleed valves, and filling reservoirs.

Explains removing brake disc cover, caliper pistons, pad pin plug, pad pin, and brake pads.

Guides on installing new brake pads, O-ring, pad spring, and tightening pad pin.

Covers visually inspecting brake disc for damage, measuring thickness, and checking warpage.

Details removing the front master cylinder assembly, including brake hose and reservoir.

Explains removing dust cover, pivot bolt, boot, snap ring, piston, and spring.

Covers checking piston boot, cups, cylinder, and piston for wear or damage.

Details measuring the master cylinder's inside diameter and checking for wear.

Measures the master cylinder piston outer diameter for wear or damage.

Guides on coating parts with brake fluid, installing piston, spring, snap ring, boot, and push rod.

Covers mounting master cylinder, aligning punch marks, installing holder, brake hose eyelet, and filling reservoir.

Details draining brake system, removing brake hose, oil bolt, and rear master cylinder mounting bolts.

Explains removing cotter pin, joint pin, snap ring, boot, push rod, and piston.

Details draining brake system, removing pads, wheel, caliper mounting bolts, and caliper assembly.

Explains removing caliper bracket, pad spring, retainer, pins, boots, and pistons.

Covers measuring caliper cylinder I.D. for wear or damage.

Details replacing seals, boots, coating parts, installing piston, dust seals, pad retainer, and pad spring.

Guides on installing caliper guard plate, brake hose eyelets, filling reservoir, and bleeding system.

Details draining brake system, removing pads, wheel, caliper, oil bolts, and caliper guard plate.

Explains removing caliper bracket, pad spring, retainer, pins, boots, and pistons.

Covers measuring caliper cylinder I.D. for wear or damage.

Details replacing seals, boots, coating parts, installing piston, dust seals, pad retainer, and pad spring.

Guides on cleaning screw threads, installing disc cover, caliper guard plate, brake hose eyelets, and filling/bleeding system.

Details removing pivot bolt and return spring.

Guides on installing brake pedal joint, cotter pin, applying grease, and tightening pivot bolt.

General notes, warnings about electrical components, ignition timing, and spark plug usage.

Guides on diagnosing issues with the ignition system, such as no spark or poor performance.

Lists spark plug types, gap, ignition coil resistance, pulse generator specs, and alternator specs.

Specifies torque values for flywheel nut and alternator cover screws.

Addresses problems related to faulty spark plugs or connections.

Diagnoses issues related to ignition coil, exciter coil, and ignition pulse generator performance.

Details checking connections, measuring peak voltage using a multimeter and adapter.

Explains how to measure ignition coil primary peak voltage and check connections.

Guides on checking exciter coil peak voltage and troubleshooting wire harness issues.

Details measuring ignition pulse generator peak voltage and troubleshooting wire harness faults.

Explains how to remove the ICM from its rubber case.

Covers measuring primary and secondary coil resistance and replacing the coil if out of range.

Details measuring exciter coil resistance and replacing the stator if out of range.

Covers measuring resistance between terminals and replacing the stator if out of range.

Steps for removing alternator cover, disconnecting electrical connectors.

Details removing alternator cover, rubber gasket, and bolts/screws.

Guides on installing woodruff key, stator, grommet, flywheel, washer, and nut.

Covers checking rubber gasket, installing alternator cover, and connecting ignition coil/ground cable.

Details connecting engine stop switch connectors and ignition control module connector.

Explains how to check ignition timing using a timing light and tachometer.

Guides on aligning stator index marks, elongating bolt holes, and reinstalling stator for correct timing.

Covers checking engine stop switch continuity when pressed and unpressed.

Shows the wiring schematic for the ignition system, engine stop switch, and alternator for 2000-2001 models.

Displays the wiring schematic for the ignition system, engine stop switch, and alternator for models after 2001.

Explains the function and operation of the RC valve system in improving engine output.

Details the components of the RC valve system (governor, pinion rod, etc.) and how they work at different engine speeds.

Provides a flowchart to diagnose and identify causes for the engine not starting or being hard to start.

Lists possible causes for the engine lacking power, covering wheels, tire pressure, clutch, and carburetor issues.

Addresses issues like incorrect ignition timing, carburetor adjustments, intake leaks, and spark issues affecting low-speed performance.

Covers diagnosing poor performance at high speed, including ignition, fuel flow, air cleaner, RC valve, and jetting.

Addresses handling issues like heavy steering, wheel wobble, and the motorcycle pulling to one side.

Addresses front end handling problems like oversteer, understeer, hunting, shaking, and hopping.

Provides notes on setting forks, shock, and making single adjustments for troubleshooting.