Honda CR60R, CR80R, CR125R Pro-Link Repair Manual 1981-1988

• Honda CR60R 1983-1984
• Honda CR80R 1981-1988
• Honda CR125R 1981-1988

This chapter contains information for removal, inspection, service and reassembly of the liquid-cooled engines on the following models.

1. CR80R (1983-on)



2. CR125R (all)

Although the clutch and transmission are located within the engine they are covered in Chapter Six to simplify this material.

Alternator service is described in Chapter Eight. For cooling system service procedures, refer to Chapter Nine.

Before beginning any engine work, re-read the service hints in Chapter One. You will do a better job with the information fresh in your mind.

Tables 1-3 at the end of the chapter provide engine and torque specifications.


ENGINE OPERATING PRINCIPLES

Figure 1 explains how the engine works. This will be helpful when troubleshooting or repairing the engine.


ENGINE LUBRICATION

Lubrication for the engine is provided by the fuel/oil mixture used to power the engine. There is no oil supply in the crankcase as it would be drawn into the cylinder and foul the spark plug.

There is sufficient oil in the mixture to lubricate both the crankshaft bearings and the cylinder. The clutch and transmission have their own oil supply.


SERVICING ENGINE IN THE FRAME

The following components can be serviced while the engine is in the frame. The bike's frame is a great holding fixture for breaking loose stubborn bolts and nuts.

1. Cylinder Head.
   
   
2. Cylinder.



3. Piston.



4. Alternator.



5. Carburetor.



6. Clutch.



7. External shift mechanism.



8. Water pump.

The front fork suspension uses a spring controlled, hydraulically damped, telescopic fork. Removal and installation are basically the same on all models.

Overhaul procedures vary from model to model. To simplify this material, the forks are divided into groups. Be sure to use the correct procedure for your specific model.

Air assist forks are used on all models except the CR60R.

Before suspecting major trouble, drain the front fork oil and refill with the proper type and quantity; refer to Chapter Three. If you still have trouble, such as poor damping, a tendency to bottom or top out or leakage around the rubber seals, follow the service procedures in this chapter.

To simplify fork service and prevent the mixing of parts, the legs should be removed, serviced and installed individually.


REMOVAL/INSTALLATION

1. Remove the front wheel as described in this chapter. Refer to A, Figure 57, or A, Figure 58.


Warning: Always bleed off all air pressure. Failure to do so may cause fork oil to spurt out with the air. Protect your eyes and clothing accordingly.


2. On models with air assist, remove the air valve cap and gradually bleed off the air pressure by depressing the valve stem (Figure 59). Repeat for both fork assemblies.

• Quick Reference Data
• General Information
• Troubleshooting
• Lubrication, Maintenance and Tune-up
• Engine
• Clutch and External Gearshift Linkage
• Transmission and Internal Shift Mechanism
• Fuel and Emission Systems
• Exhaust System
• Electrical System
• Wheels, Tires and Drive Chain
• Front Suspension and Steering
• Rear Suspension
• Brakes
• Body and Frame
• Wiring Diagrams