1987 CR250 Service Manual

The 1987 Honda CR250 is a high-performance motocross motorcycle featuring a 249cc liquid-cooled two-stroke engine, Pro-Link rear suspension, and advanced chassis design. This service manual covers complete maintenance procedures, specifications, troubleshooting, and repair instructions for proper servicing and optimal performance of your 1987 CR250.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine Service 5. Carburetor Service 6. Chassis Service 7. Electrical System 8. Troubleshooting 9. Lubrication Points 10. Torque Specifications

General Information

This manual provides detailed service information for the 1987 Honda CR250 motocross motorcycle. Includes safety precautions, tool requirements, and general maintenance procedures.

Component	Description
Model	CR250R
Year	1987
Type	Motocross Competition
Frame	Single cradle steel
Recommended Fuel	Premium unleaded with 2-stroke oil
Oil Capacity	750ml transmission oil

Specifications

Engine Type: 249cc liquid-cooled single-cylinder two-stroke
Bore x Stroke: 67.0mm x 70.8mm
Compression Ratio: 8.4:1
Carburetor: 38mm Keihin PWK
Ignition: CDI electronic ignition
Transmission: 5-speed constant mesh
Front Suspension: 43mm conventional fork
Rear Suspension: Pro-Link single shock
Front Brake: Single disc 240mm
Rear Brake: Single disc 220mm
Dry Weight: 99 kg (218 lbs)

Periodic Maintenance

Regular maintenance schedule for optimal performance and safety.

After each ride: Clean air filter, check tire pressure, inspect chain tension
Every 10 hours: Change transmission oil, check spark plug
Every 20 hours: Clean carburetor, check brake pads
Every 30 hours: Check wheel bearings, suspension linkage
Every 50 hours: Top end inspection, check clutch plates

WARNING! Always use proper safety equipment and follow torque specifications.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Cylinder Head: Remove, clean carbon deposits, check for warpage
Cylinder: Measure bore wear, check for scoring
Piston: Inspect rings, measure clearance, replace if worn
Crankcase: Split cases, inspect crankshaft and bearings
Clutch: Inspect plates, springs, and basket for wear
Water Pump: Check impeller and seals for leaks

CAUTION! Use new gaskets during reassembly and proper sealant where specified.

Carburetor Service

Keihin PWK carburetor adjustment and maintenance.

Setting	Specification
Main Jet	175
Pilot Jet	55
Needle Clip Position	3rd from top
Air Screw	1.5 turns out
Float Height	16mm

Adjustment procedure: Clean all jets, check float operation, set mixture screws to specification.

Chassis Service

Frame, suspension, and brake system maintenance.

Front Fork: Change fork oil, inspect seals and bushings
Rear Shock: Check nitrogen pressure, inspect linkage bearings
Steering Head: Adjust bearing preload, check for play
Wheels: True rims, check spoke tension
Brakes: Replace pads, bleed hydraulic system
Chain & Sprockets: Check wear, adjust tension (35-45mm play)

Electrical System

CDI ignition, lighting, and charging system service.

Spark Plug: NGK BR8ES, gap 0.6-0.7mm
Ignition Timing: Fixed at 1.5mm BTDC
Stator Resistance: 0.1-1.0 ohms (lighting coil)
CDI Unit: Non-serviceable, replace if faulty
Kill Switch: Check continuity, clean contacts

Tip: Always disconnect battery before electrical service.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled plug, low compression	Replace spark plug, check compression (140+ psi)
Poor performance	Clogged carburetor, worn piston	Clean carburetor jets, inspect top end
Transmission noise	Worn gears, low oil	Change transmission oil, inspect gears
Overheating	Low coolant, water pump failure	Check coolant level, inspect pump
Brake fade	Contaminated pads, air in system	Replace pads, bleed brakes

Lubrication Points

Critical lubrication points and recommended lubricants.

Chain: Use quality chain lube after cleaning
Cables: Lubricate throttle and clutch cables regularly
Swingarm Pivot: Grease with high-temperature bearing grease
Steering Head: Pack with waterproof grease
Wheel Bearings: Repack annually or when servicing
Brake Lever: Light machine oil at pivot points

Torque Specifications

Component	Torque Value
Cylinder Head Nuts	20 Nm (14.5 ft-lbs)
Spark Plug	12 Nm (8.7 ft-lbs)
Clutch Spring Bolts	8 Nm (5.8 ft-lbs)
Axle Nuts	90 Nm (65 ft-lbs)
Sprocket Bolts	35 Nm (25 ft-lbs)
Engine Mount Bolts	40 Nm (29 ft-lbs)
Fork Clamp Bolts	25 Nm (18 ft-lbs)

WARNING! Always use a calibrated torque wrench and follow specified sequences.