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Honda CR125R 1992 User Manual

Honda CR125R 1992
226 pages
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Honda CR125R 1992 Specifications

General IconGeneral
Bore x Stroke54.0mm x 54.5mm
Compression Ratio8.5:1
Transmission5-speed
Front BrakeSingle disc
Rear BrakeSingle disc
Front Tire80/100-21
Rear Tire100/90-19
IgnitionCDI
Engine TypeLiquid-cooled, single-cylinder, two-stroke
Rear SuspensionShowa, Pro-Link, adjustable compression and rebound damping

Summary

Important Safety Notice

General Information

Engine Torque Values

Lists torque values for engine mounting and component fasteners.

Frame Torque Values

Lists torque values for frame, body panels, and suspension fasteners.

Frame, Body Panels, and Exhaust System

Maintenance

Fuel System

Carburetor Removal and Disassembly

Provides step-by-step instructions for safely removing and disassembling the carburetor.

Cooling System

Engine Removal and Installation

Engine Removal

Details the step-by-step procedure for safely removing the engine from the motorcycle frame.

Engine Installation

Covers the process of reinstalling the engine into the motorcycle frame, including torque specifications.

Cylinder Head, Cylinder, and Piston

Cylinder Head Removal and Installation

Details the procedures for removing and installing the cylinder head, including gasket replacement.

Cylinder and Piston Removal

Details the procedure for removing the cylinder and piston assembly from the engine.

Piston Removal

Covers the steps for removing the piston, pin, clips, and rings.

Cylinder Installation

Details the process of installing the cylinder over the piston and onto the crankcase, including alignment.

Cylinder and Piston Final Installation

Covers final installation steps for hoses, covers, and fluid checks after cylinder/piston assembly.

H.P.P. (Honda Power Port) System

Clutch, Kickstarter, and Gearshift Linkage

Clutch Removal

Details the steps for removing the clutch cover and clutch components, including springs and pressure plate.

Clutch Installation

Details the process of installing clutch outer guide, needle bearing, outer clutch, and thrust washer onto the mainshaft.

Gearshift Linkage Removal

Details the removal of the gearshift linkage components, including the drum, forks, and shifter collar.

Gearshift Linkage Installation

Covers the assembly and installation of the gearshift linkage components, including drum, forks, and pins.

Crankcase, Crankshaft, and Transmission

Crankcase Separation

Details the procedure for separating the crankcase halves for access to internal components.

Transmission Disassembly

Covers disassembly of the transmission, including shift forks, drum, and mainshaft/countershaft assemblies.

Crankshaft Removal

Details the procedure for removing the crankshaft from the crankcase, including bearing removal.

Crankshaft Installation

Details the procedure for installing the crankshaft into the crankcase, including cleaning and lubrication.

Transmission Assembly

Covers the assembly of the mainshaft and countershaft gears and their placement into the crankcase.

Crankcase Assembly

Details the process of assembling the crankcase halves, including dowel pins, gaskets, oil seals, and breather.

Front Wheel, Suspension, and Steering

Front Wheel Removal and Disassembly

Details procedures for removing and disassembling the front wheel assembly, including axle, bearings, and brake disc.

Front Wheel Installation

Details the steps for installing the front wheel assembly onto the fork, including axle tightening and brake caliper fitment.

Fork Removal and Disassembly

Covers removal and disassembly procedures for the front fork legs, including fork caps and pinch bolts.

Fork Assembly and Installation

Covers installation of the fork leg into the triple tree and tightening of bridge bolts.

Steering Stem Removal

Details removal of the steering stem, fork legs, triple trees, and related components from the head pipe.

Rear Wheel and Suspension

Rear Wheel Removal and Disassembly

Details procedures for removing and disassembling the rear wheel, including axle, sprockets, and brake disc.

Torque Values

Lists specified torque values for rear wheel, suspension, and swingarm components.

Rear Wheel Installation

Covers installation of the rear wheel, brake disc, driven sprocket, caliper, and drive chain.

Shock Absorber Removal

Details the procedure for safely removing the rear shock absorber from the motorcycle, including safety warnings.

Shock Absorber Disassembly

Covers disassembly of the shock absorber, including spring, nuts, and reservoir components.

Bladder Replacement

Details the procedure for replacing the internal bladder of the shock absorber, including safety precautions.

Damper Disassembly

Covers disassembly of the shock absorber damper, including removing the end nut, oil, and stop ring.

Damper Assembly

Covers washing, cleaning, inspecting, and preparing damper assembly parts before reassembly.

Shock Linkage Removal

Details removal of shock linkage components, including roller, caps, bolts, pivot collars, and dust seals.

Shock Linkage Installation

Covers connecting the shock link to the shock arm and swingarm, and tightening bolts to specified torque.

Swingarm Removal

Details the procedure for removing the rear wheel, shock linkage, brake components, and the swingarm from the frame.

Brake System

Brake Fluid Replacement and Air Bleeding

Details the procedure for replacing brake fluid and bleeding air from the hydraulic system.

Brake Pad Replacement

Details the procedure for replacing worn brake pads on both front and rear brakes, emphasizing pair replacement.

Front Brake Caliper Removal

Covers removal of the front brake caliper and its associated components.

Front Brake Caliper Service

Details disassembly and assembly of the front brake caliper pistons, seals, and boots.

Front Brake Caliper Installation

Details installation of the front brake caliper, bracket, brake hose, and fluid bleeding.

Rear Brake Caliper Removal

Covers removal of the rear brake caliper, its guard plate, brake pads, and hose.

Rear Brake Caliper Service

Details disassembly and assembly of the rear brake caliper pistons, seals, and boots.

Ignition System and Alternator

Troubleshooting

Guides users through diagnosing and resolving ignition system and alternator issues, like no spark or poor performance.

Alternator Removal

Details removal of the alternator cover, flywheel, and stator assembly.

Alternator Installation

Covers installation of the stator, flywheel, and alternator cover, including alignment and torque.

Ignition Timing Check and Adjustment

Explains how to check and adjust ignition timing using a timing light and marks on the stator and crankcase.

Wiring Diagram

Technical Feature: H.P.P. (Honda Power Port) System

Troubleshooting

Engine Starting Issues

Guides users through diagnosing and resolving common engine starting problems, from fuel to ignition.

Engine Power Loss Issues

Helps diagnose causes for reduced engine power, such as clutch slipping, lean mixtures, or ignition problems.

Poor Handling Diagnosis

Addresses causes for poor motorcycle handling, such as heavy steering, wheel wobble, or pulling to one side.

Front End Handling Adjustments

Provides solutions for front end steering and suspension issues based on riding conditions.

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