- 1Contents
- 2Symbols
- 3General Information
- 3General Safety
- 3Carbon Monoxide
- 3Gasoline
- 4Coolant
- 4Nitrogen Pressure
- 5Model Identification
- 6Specifications
- 8Lubrication System
- 8Fuel System
- 8Cooling System
- 8Clutch System
- 15Torque Values
- 18Tools
- 20Lubrication & Seal Points
- 22Cable & Harness Routing
- 25Optional Parts
- 29Frame/Body Panels/Exhaust System Service Information
- 29Frame/Body Panels/Exhaust System Troubleshooting
- 30Seat Removal
- 30Seat Installation
- 30Side Covers Removal/Installation
- 30Fuel Tank Removal/Installation
- 31Fuel Tank Disassembly/Assembly
- 31Silencer Removal/Installation
- 31Expansion Chamber Removal/Installation
- 32Sub-frame Removal
- 32Sub-frame Installation
- 33Maintenance Service Information
- 33Maintenance Specifications
- 33Maintenance Special Tools
- 34Service Access Guide
- 36Competition Maintenance Schedule
- 37Additional Items Requiring Frequent Replacement
- 38Throttle Operation
- 38Air Cleaner
- 40Spark Plug
- 40Radiator Coolant
- 40Cooling System
- 40Inspecting & Adding Transmission Oil
- 41Replacing Transmission Oil
- 42Drive Chain
- 42Drive Chain Adjustment
- 43Drive Chain Sliders
- 43Drive Chain Rollers
- 43Drive/Driven Sprocket
- 44Brake Pads Wear
- 44Front Brake Fluid
- 44Rear Brake Fluid
- 45Brake System Maintenance
- 45Clutch System Maintenance
- 45Brake Lever Adjustment
- 45Brake Pedal Adjustment
- 46Control Cables
- 47Expansion Chamber/Silencer
- 47Control Cables Lubrication
- 47Throttle Assembly
- 48Silencer Glass Wool Replacement
- 48Front Suspension
- 49Swingarm/Shock Linkage
- 49Rear Suspension
- 50Nuts, Bolts, Fasteners
- 50Wheels/Tires
- 50Steering Head Bearings
- 53Fuel System Service Information
- 53Fuel System Specifications
- 54Fuel System Troubleshooting
- 55Minor Carburetor Adjustment
- 55Major Carburetor Adjustment
- 56Turning Information Chart
- 57Turning for Special Conditions
- 58Carburetor Removal
- 58Carburetor Disassembly
- 59Carburetor Assembly
- 61Carburetor Installation
- 61Reed Valve Removal
- 62Air Cleaner Housing
- 62Reed Valve Disassembly
- 62Reed Valve Assembly
- 62Reed Valve Installation
- 63Air Cleaner Installation
- 65Cooling System Service Information
- 65Cooling System Specifications
- 65Cooling System Tools
- 66Cooling System Troubleshooting
- 67Coolant Replacement
- 68Radiator Removal
- 68Radiator Installation
- 69Water Pump Water Seal Inspection
- 69Water Pump Disassembly
- 69Water Pump Bearing Replacement
- 70Water Seal/Oil Seal Replacement
- 71Water Pump Assembly
- 75Engine Removal/Installation Service Information
- 75Engine Removal/Installation Specifications
- 76Engine Removal
- 77Engine Installation
- 78Cylinder Head/Cylinder/Piston Exploded View
- 79Cylinder Head/Cylinder/Piston Service Information
- 79Cylinder Head/Cylinder/Piston Specifications
- 80Cylinder Head/Cylinder/Piston Troubleshooting
- 81Cylinder Head Removal
- 81Cylinder Head Combustion Chamber Decarbonizing
- 81Cylinder Head Inspection
- 82Cylinder Head Installation
- 83Cylinder Removal
- 83Cylinder Inspection
- 84Piston Removal
- 85Piston/Piston Pin Inspection
- 85Piston Ring Inspection
- 85Connecting Rod Inspection
- 86Piston Installation
- 86Cylinder Installation
- 88Clutch/Kickstarter/Gearshift Linkage Exploded View
- 89Clutch/Kickstarter/Gearshift Linkage Service Information
- 89Clutch/Kickstarter/Gearshift Linkage Specifications
- 89Clutch/Kickstarter/Gearshift Linkage Tool
- 90Clutch/Kickstarter/Gearshift Linkage Troubleshooting
- 91Right Crankcase Cover Removal
- 91Right Crankcase Cover Installation
- 92Clutch Removal
- 93Clutch Lifter Lever Removal
- 94Clutch Lifter Lever Installation
- 94Clutch Installation
- 96Kickstarter Disassembly
- 96Kickstarter Assembly
- 97Gearshift Linkage Removal
- 98Gearshift Linkage Installation
- 102Crankcase/Crankshaft/Transmission Exploded View
- 103Crankcase/Crankshaft/Transmission Service Information
- 103Crankcase/Crankshaft/Transmission Specifications
- 104Crankcase/Crankshaft/Transmission Troubleshooting
- 104Crankcase/Crankshaft/Transmission Tools
- 105Crankcase Separation
- 106Transmission Disassembly
- 107Transmission Assembly
- 108Crankshaft Removal
- 109Crankcase Bearing/Oil Seal Locations
- 109Crankshaft Bearings
- 110Transmission Bearings
- 111Crankshaft Installation
- 111Right Crankcase Bearings
- 112Crankcase Assembly
- 117Front Wheel/Suspension/Steering Exploded View
- 119Front Wheel/Suspension/Steering Service Information
- 119Front Wheel/Suspension/Steering Specifications
- 120Front Wheel/Suspension/Steering Tools
- 121Front Wheel/Suspension/Steering Troubleshooting
- 122Front Wheel Removal
- 122Front Wheel Disassembly
- 123Front Wheel Inspection
- 123Front Wheel Bearings
- 123Front Wheel Rim
- 124Front Wheel Assembly
- 128Front Wheel Installation
- 129Fork Removal
- 129Fork Disassembly
- 132Fork Inspection
- 133Fork Assembly
- 136Fork Installation
- 147Handlebar Removal
- 147Handlebar Installation
- 149Steering Stem Removal
- 150Steering Stem Bearing Replacement
- 151Steering Stem Installation
- 154Rear Wheel/Suspension Exploded View
- 156Rear Wheel/Suspension Service Information
- 156Rear Wheel/Suspension Specifications
- 157Rear Wheel/Suspension Tools
- 158Rear Wheel/Suspension Troubleshooting
- 159Rear Wheel Removal
- 159Rear Wheel Disassembly
- 159Rear Wheel Inspection
- 159Rear Wheel Bearings
- 160Rear Wheel Rim
- 161Rear Wheel Assembly
- 163Rear Wheel Installation
- 165Shock Absorber Removal
- 165Shock Absorber Spring Removal
- 165Shock Absorber Bladder Replacement
- 169Shock Absorber Damper Disassembly
- 170Piston Ring Replacement
- 171Damper Rod Disassembly
- 173Rod Guide Inspection
- 174Rod Guide Assembly
- 181Spherical Bearing Replacement
- 183Shock Absorber Installation
- 183Shock Linkage Removal
- 183Shock Linkage Inspection
- 184Needle Bearing Replacement
- 186Swingarm Removal
- 187Swingarm Replacement
- 188Swingarm Assembly
- 189Swingarm Installation
- 190Brake System Exploded View
- 191Brake System Service Information
- 191Brake System Specifications
- 192Brake System Troubleshooting
- 192Brake System Tools
- 193Brake Fluid Draining
- 193Brake Fluid Filling/Air Bleeding
- 195Brake Pad Replacement
- 195Front Master Cylinder Disassembly
- 196Front Master Cylinder Assembly
- 197Rear Master Cylinder Removal
- 197Rear Master Cylinder Disassembly
- 198Rear Master Cylinder Assembly
- 198Rear Master Cylinder Installation
- 199Front Brake Caliper Removal
- 199Front Brake Caliper Disassembly
- 200Front Brake Caliper Assembly
- 201Front Brake Caliper Installation
- 201Rear Brake Caliper Removal
- 201Rear Brake Caliper Disassembly
- 202Rear Brake Caliper Assembly
- 203Rear Brake Caliper Installation
- 205Electrical System Service Information
- 205Electrical System Specifications
- 205Electrical System Tools
- 206Electrical System Location
- 207Electrical System Troubleshooting
- 208Ignition Control Module (ICM) System Inspection
- 208Ignition Control Module Removal/Installation
- 209Alternator
- 209Exciter Coil Inspection
- 209Ignition Pulse Generator Inspection
- 209Alternator Removal
- 210Alternator Installation
- 211Ignition Coil Inspection
- 211Ignition Timing
- 212Engine Stop Button
- 213Wiring Diagram
- 215Troubleshooting
- 215Engine Does Not Start or Is Hard to Start
- 216Engine Lacks Power
- 217Poor Performance at Low and Idle Speed
- 218Poor Performance at High Speed
- 218Poor Handling
- 221Index
Honda Cr500r Service Repair Manual 1985-1991 Cr500 DOWNLOAD HERE Instant download of the a repair manual for the 1985-1991 Honda CR500R two-stroke bike. Covers complete tear down and rebuild, torque specs, maintenance, troubleshooting, etc. You name it and it's in here. Has clickable chapters so you can easily find what you're.