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*CR125R (E) COVER,HYO2
Honda CR125R
OWNER’S MANUAL
2004
All information in this publication is based on the latest product information available at the time of
approval for printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without
notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
Honda Motor Co., Ltd. 2003
MAINTENANCE PREPARATIONS
SEAT
Seat Removal
1. Remove the seat bolts and collars.
2. Slide the seat back.
FUEL TANK
Fuel Tank Removal
1. Turn the fuel valve OFF.
2. Remove the seat (this page).
3. Remove the shroud A bolts/collars, B bolts/collars
and shrouds.
7. Disconnect the fuel line from the fuel valve.
The fuel line leading to the carburetor must be dis-
connected, not the fuel line leading to the fuel tank.
8. Remove the fuel tank.
•
Gasoline is extremely flammable and is explosive
under certain conditions. Perform this operation in
a well-ventilated area with the engine stopped. Do
not smoke or allow flames or sparks in the area
where gasoline is drained or stored and where the
fuel tank is refueled.
2
1
(1) SEAT BOLTS/COLLARS
(2) SEAT
(1) SHROUD A BOLTS/COLLARS
(2) SHROUD B BOLTS/COLLARS
(3) SHROUD
Seat Installation
1. Slide the seat front prong onto the seat bracket and
the seat rear prong onto the tabs by pushing down
and forward on the seat in each of these areas.
2. Install the collars and seat bolts.
4. Pull the breather tube out of the steering stem nut.
5. Unhook and remove the fuel tank band.
6. Remove the fuel tank bolt.
(1) FUEL LINE
(2) FUEL VALVE
TORQUE: 2.0 lbf·ft (26 N·m, 2.7 kgf·m)
1
2
3
4
(1) BREATHER TUBE
(2) FUEL TANK BAND
(3) FUEL TANK BOLT
(1) SEAT FRONT PRONG (2) SEAT BRACKET
(3) SEAT REAR PRONG (4) TABS
17
4. SERVICE AND MAINTENANCE
Fuel Tank Installation
1. Install the fuel tank on the frame.
2. Connect the fuel line.
6. Install the shrouds, collars and tighten the shroud A
/B bolts.
SUBFRAME
Subframe Removal
1. Remove the seat (page 17).
2. Remove the bolt, collar and right side cover.
(1) FUEL VALVE
(2) FUEL LINE
(1) SHROUD
(2) SHROUD A BOLTS/COLLARS
(3) SHROUD B BOLTS/COLLARS
(1) BOLT/COLLAR
(2) SIDE COVER
3. Install and tighten the fuel tank bolt.
4. Hook the fuel tank band.
5. Put the breather tube in the steering stem nut.
7. Install the seat (page 17).
3. Remove the bolt, washer and silencer.
(1) BOLT/WASHER
(2) SILENCER
(1) FUEL TANK BOLT
(2) FUEL TANK BAND
(3) BREATHER TUBE
18
4. SERVICE AND MAINTENANCE
MAINTENANCE PROCEDURES
TRANSMISSION OIL
Inspecting and Adding Transmission Oil
1. Run the engine for three minutes, then shut it off.
2. Wait three minutes after shutting off the engine to
allow the oil to properly distribute itself in the clutch
and transmission.
3. Support the CR in an upright position on a level
surface.
4. Remove the oil filler cap and oil check bolt from the
right crankcase cover. A small amount of oil should
flow out of the oil check bolt hole. Allow any excess
oil to flow out of the oil check bolt hole.
5. If no oil flows out of the oil check bolt hole, add oil
slowly through the oil filler hole until oil starts to
flow out of the oil check bolt hole. Install the oil
check bolt and oil filler cap.
6. Repeat steps 1-5.
7. After inspecting the oil level or adding oil, tighten
the oil check bolt and oil filler cap securely.
Oil Check Bolt Torque:
7 lbf
•
ft (9.8 N
•
m, 1.0 kgf
•
m)
5. After the oil has drained completely, install the oil
drain bolt with a new sealing washer.
Drain Bolt Torque: 22 lbf
•
ft (29 N
•
m, 3.0 kgf
•
m)
6. Add the recommended oil.
Capacity: 0.60 US qt (0.57 liter, 0.50 lmp qt) at
oil change
7. Check the oil level by following the steps in Inspec-
ting and Adding Transmission Oil.
CAUTION:
•
Oil is a major factor affecting the performance and
service life of the transmission and clutch. Non-
detergent, vegetable, or castor based racing oils are
not recommended.
Other viscosities shown in the chart below may be used
when the average temperature in your riding area is
within the indicated range.
(1) OIL DRAIN BOLT
JASO T 903 standard
The JASO T 903 standard is an index to choose engine
oils for 4-stroke motorcycle engines.
There are two classes: MA and MB.
Oil conforming to the standard has the following clas-
sification on the oil container.
Recommended Transmission Oil
Use Pro Honda HP Trans Oil, Pro Honda GN4 or HP4 (without
molybdenum additives) 4–stroke oil, or an equivalent.
*
4–stroke oil performance
API classification
SG or higher except oils labeled as energy
conserving on the circular API service label
SAE 10W–40
MA
without friction modifiers as molybde-
num additives
(1)
viscosity (weight)
JASO T 903
others
*
Suggested oils are equal in performance to SJ oils that are not
labeled as energy conserving on the circular API service label.
(2)
(1) OIL FILLER CAP (2) OIL CHECK BOLT
Replacing Transmission Oil
1. Run the engine for three minutes, then shut it off.
2. Support the CR in an upright position on a level
surface.
3. Remove the oil filler cap from the right crankcase
cover.
4. Place an oil drain pan under the engine to catch the
oil. Then remove the oil drain bolt and sealing
washer.
• Your CR does not need oil additives. Use recommended oil.
• Do not use oils with graphite or molybdenum additives.
They may adversely affect clutch operation.
• Do not use API SH or higher oils displaying a circular API
“energy conserving” label on the container. They may
affect lubrication and clutch performance.
(1) code number of the sales company of the oil
(2) oil classification
NOT RECOMMENDED OK
20
COOLANT
Coolant Recommendation
Use Pro Honda HP coolant or an equivalent high quality
ethylene glycol based anti-freeze containing corrosion
protection inhibitors specifically recommended for use
in aluminum engines (See anti-freeze container label).
CAUTION:
•
2. Add coolant up to the filler neck if the level is low.
NOTE:
•
Inspect the coolant level before each outing. A
coolant loss of 0.7—2.0 US oz (20—60 cm
3
, 0.7—2.1
lmp, oz) through the over flow tube is normal. If
coolant loss is more than this, inspect the cooling
system.
Capacity: 1.03 US qt (0.97 liter, 0.85 lmp qt)
at disassembly
0.93 US qt (0.88 liter, 0.77 lmp qt)
at coolant change
3. Install the radiator cap securely.
CAUTION:
•
If the radiator cap is not installed properly, it will
cause excessive coolant loss and may result in
overheating and engine damage.
Cooling System Inspection
1. Check the cooling system for leaks (see the Honda
Service Manual for troubleshooting of leaks).
2. Check water hoses for cracks, deterioration, and
clamp bands for looseness.
3. Check the radiator mount for looseness.
4. Make sure the overflow tube is connected and not
clogged.
5. Check the radiator fins for clogging.
6. Check the water leakage check hole below the
water pump for leakage. Make sure the hole remains
open. If water leaks through the check hole, the
water pump seal is damaged. If oil leaks through the
check hole, the transmission oil seal is damaged.
See the Honda Service Manual or consult your
authorized Honda dealer for replacing the water
pump seal or the transmission oil seal. Both seals
should be replaced at the same time.
2
Hard water or salt water is harmful to aluminum.
The factory provides a 50/50 mix of anti-freeze and
water in your CR. This mixture is recommended for
most operating temperatures and provides good
corrosion protection. A higher concentration of anti-
freeze decreases the cooling system performance
and is recommended only when additional protec-
tion against freezing is needed. Using less than 40%
anti-freeze will not provide proper cooling or corro-
sion protection.
1
•
Using coolant with silicate inhibitors may cause
premature wear of water pump seals or blockage
of radiator passages. Using tap water may cause
engine damage.
Coolant Level
Never remove the radiator cap when the engine is
hot. The coolant is under pressure and severe
scalding could result.
1. With the engine cold, remove the radiator cap and
check coolant level. The coolant level is correct
when it is at the bottom of the radiator filler neck.
2
(1) OVERFLOW TUBE
(2) WATER HOSE
(3) WATER PUMP COVER
(4) WATER LEAKAGE CHECK HOLE
(1) RADIATOR CAP
21
•
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