1992-1997 Honda CR125R Workshop Manual
Complete service documentation for CR125R addressing engine rebuilds, cylinder head/piston diagnostics, H.P.P. valve system tuning. PJ15E carburetor specifications, transmission gear selection.
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Sample pages from the 1992-1997 Honda CR125R Workshop Manual manual
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Models Covered & Key Technical Specifications
Honda CR125R (1992–1997) Analytical Handbook Segment | CR125R Series Container.
- Calibrated Displacement Data: 124.82 cc (7.6 cu-in) is configured at the engine cylinder architecture Sequences.
- Primary Bore and Stroke Measurement: For optimal performance, 54 × 54.5 mm (2.1 × 2.1 in) limits the piston travel geometry Baseline.
- Authorized Compression Ratio: 9.1:1 — is set to the combustion chamber pressure Requirements.
- Maximum Fuel Containment Volume: The fuel tank requires 7.5 liters (2.0 US gal) for operational range Threshold.
- System Front Suspension Travel: 309 mm (12.2 in) represents the fork stroke extension Mapping.
- Principal Rear Suspension Articulation: 320 mm (12.6 in) is measured at the swingarm linkage Configuration.
Professional Workshop Service Manual & Technical Specifications
In-Depth Quality Field Manual: 1992-1997 Honda CR125R Service Documentation Maintenance-Registry
Repair-Classification: CR125R (1992-1997) // Machine-Range: Motorcycle engine service and transmission maintenance / Single-cylinder 2-stroke power system Logic // System-Identifier: Complete technical specifications and diagnostic framework.
| Performance-Element | Parameters | Validation-Data |
|---|---|---|
| Engine Systems | Bore and stroke 54 x 54.5 mm, displacement 124.82 cm³, liquid-cooled | Complete specifications provided |
| Transmission | Six-speed constant mesh, primary reduction 3.150:1, final reduction 3.923:1 | Documented gear ratios for all six speeds |
| Frame Structure | Semi-double cradle, telescopic front suspension, swingarm rear suspension | Technical measurements and clearance data included |
| Brake Systems | Hydraulic single-disc front and rear, swept areas documented | Brake fluid specifications and caliper dimensions referenced |
| Electrical Architecture | COI ignition system, alternator with pulse generator, lighting circuits | Resistance values and connector information provided |
Repair procedures are structured around cylinder head and cylinder service, which addresses engine sealing and combustion chamber maintenance. The repository is divided into comprehensive sections covering general information with model identification data, service access guides, and competition maintenance schedules that outline inspection intervals for all critical components. Transmission service information covers oil change procedures, clutch operation, and gearshift linkage adjustment protocols that affect gear engagement and vehicle driveability.
Advanced Nexus
Tool requirements are listed for removal of suspension components, bearing replacement using specialized drivers, and crankcase separation procedures. The manual provides detailed references for spring free length specifications, fork oil capacity ranges, and damping adjuster calibration. Documentation encompasses both front and rear suspension service, including shock absorber nitrogen pressurization protocols and linkage bearing maintenance with molybdenum disulfide grease application guidelines.
Precise Threshold
Installation guidelines are provided for crankshaft and transmission assembly following separation and bearing replacement. Bearing locations include crankshaft positions on both right and left crankcase sides, mainshaft and countershaft bearings in transmission housings, and shift drum bearing set plates with specified torque sequences. The document references special tool applications for pressing bearings and includes inspection procedures for wear limits on transmission gears, bushings, and shift fork clearances.
Core Logic-Path
Maintenance guidelines are included for drive chain service with slack adjustment procedures between sprockets, chain slider and roller wear inspection, and driven sprocket tooth examination. The manual covers cooling system maintenance including radiator hose routing, water pump bearing replacement, and water seal replacement procedures using specialized installation tools. Brake system maintenance is documented for hydraulic fluid level checks, pad wear thickness limits, and master cylinder seal inspection protocols.
Comprehensive Interface
OEM guidelines are included for fuel system carburetors with jet needle position specifications, air screw initial opening measurements, and float level gauge calibration. The H.P.P. (Honda Power Port) exhaust valve system is documented with governor spring preload specifications and exhaust valve timing adjustment procedures. Ignition timing verification is referenced at 5,000 rpm with stator index mark alignment documentation, and alternator output specifications are included with exciter coil resistance ranges.
Technical Nexus
Transmission service information covers mainshaft and countershaft disassembly with gear identification, transmission gear bushing clearance measurements, and shift fork claw thickness inspection. The manual documents torque specifications for crankshaft primary drive gear bolts, countershaft bearing set plates, and gearshift drum center pins. Complete specifications are provided for piston ring end gap clearance, cylinder bore taper and runout measurements, and connecting rod small end bearing inspection procedures with service limit values.
The document provides a framework for systematic maintenance through detailed electrical system testing, including pulse generator resistance measurement, alternator exciter coil resistance verification, and COI unit connector terminal identification for ignition primary coil and engine stop switch continuity checks. Service access guides identify part locations for air filter contamination assessment, radiator coolant leakage detection, and wheel bearing play evaluation. The manual documents torque specifications for the engine mounting bolts to ensure proper structural misalignment prevention and supports accurate assembly of all critical fasteners throughout the powertrain.
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