Manuals and Parts

Maintained by mods and admins. but contains all the answers to all those questions that get asked over and over and over . .
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knackeredMk1
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Manuals and Parts

Post by knackeredMk1 » 30 Oct 2009, 10:44

There are several manuals around but some are easier to get hold of than others.

Owners manual - Little booklet giving basic information about setup and riding of machine. Tyre pressures etc.

Honda produced a Japanese only workshop manual but it has many many photos. This is very rare. They also did an English version for the AR when released in Australia.

Leisure Trail produce an edited workshop manual for the Mk1, 2 & 3 and an AR addition. This gives good basic information and many diagrams about dissembling and rebuilding engine and servicing generally together with a black and white wiring diagram. These are very common and very useful. LT phone no. 0115 973 2466 and have a web site.

Honda produce parts manuals for different Mks that give detailed exploded diagrams and exact part nos. There are some around and they occassionally come up on eBay etc. Almost all honda dealers will supply parts if you have the exact part no.

eBay is quite a good source of second hand parts. Usual caveats apply to buying things unseen but generally good resource.

Occasionally new parts come up and these can be very useful but be aware that very often these parts are still available from Honda and regularly available at less cost than the final bid on eBay. Sometimes parts go for two or three times the current Honda cost :!: .

Useful parts suppliers -

Leisure Trail - http://www.leisuretrail.co.uk/

David Silver - http://www.davidsilverspares.co.uk/

Lings - http://www.lingshondaparts.com/

CMS - http://www.cmsnl.com/

If you are desperate and/or not in the UK; Rinkya (Japanese eBay) are useful but beware of transport and 'service' costs/commision. Really only good for high value (in UK) and lightweight parts.

https://www.rinkya.com/en/front/search/ ... 250&page=1

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Honda Manuals

Post by knackeredMk1 » 28 Nov 2009, 20:52

With some help from Alan H:

Current parts manuals (10/09). All available through your Honda dealership :shock: :

Mk1 - 11KAEKJ4
Mk2 - 11KAEMJ4
Mk3 - 11KAERJ4
AR - 11KAEVJ4

For some reason the AR manual costs less than the others. The first time an AR part costs less than all other models :o

LT CRM general manual - http://www.offwidth.co.uk/bike/crm_rebuild/crm250.pdf

Deciphering part codes - viewtopic.php?f=6&t=3907

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Re: Manuals and Parts

Post by knackeredMk1 » 13 Jun 2010, 14:22


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Re: Manuals and Parts

Post by knackeredMk1 » 13 Jun 2010, 14:24


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Colour Wiring Diagram Mk2/3

Post by knackeredMk1 » 13 Feb 2011, 16:26

Colour Wiring Diagram Mk2/3 -

http://www.holidayinholland.org.uk/imag ... wiring.jpg

A black and white version of the AR wiring diagram is on page 18-1 of the AR manual. The manual gives in depth description of the various electrical components and testing. It is useful for other Mks - particularly the Mk3.

Colour wiring diagram for AR -

Image

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Re: Manuals and Parts

Post by knackeredMk1 » 04 Sep 2013, 12:06

Below is a mishmash of recommendations that have been made over the years by forum members -


Plastics:
Dutz fittings (airbox) 17225KN5670

Speedos - Google - Trailtech Vapor. Cost about £100 with the computer and backing plate. A few owners on this forum have one viewtopic.php?f=14&t=3484&start=40.

Apparently XR400 speedos work :?: . If your nifty with the connections/wiring any CRM/XR400 speedo will do.

90s CR fork guards can be used on USD forked CRMs but You will have to modify the new guards to fit the original speedo bracket. Easily done.


Frame:
Chain guide (white block) 52146MN1671
Chain guide slider (black insert) 52147MN1670

Stay to fix expansion chamber to frame in front of engine 18355KAE000

All footrests fit all Mks. Alternatives - XR650, CR85, XR 400.........

Chain adjusters from an Africa Twin fit CRMs.

Apparently the xr400 side stand was a straight swap but made the bike sit up more. So might be a good swap anyway as the crm leans the bike over a hell of a lot.

Fuel caps will fit from - MTX125, MTX200, NX650 S/T DOMINATOR 95-96, NX650 J/K/L/M DOMINATOR 88-91, NX650 N/P/R DOMINATOR 92-94, SLR650 V/W 97-99, XL250 RL 1990, XL250 RE/RF 84-85, XL250 RG/RH 87-89.

I believe all CRM USD fork seals (oil & dust) are the same and CR USD forks with the same diameter stantions use the same seals. I don't know about the bushes and don't have the specific part no.s :cry: .

Swing arm bearing and seal kit - All Balls Racing Part number 28-1012, Pivot Works PWSAK-H21-004. Designed for XR400 but apparently fit CRMs (all CRMs are the same) comes with 18mm bearings instead of 12mm originals. (There are 8 bearings in the kit 4 12mm bearings and 4 18mm bearings, so the original bearings are in the kit as well, but you are better off with the 18mm bearings). http://www.pivotworks.com/index.cfm?

The off-white chain guide that fits under the swingarm and before the rear sprocket is definately not the most aesthetically pleasing part of a CRM. However it is a common part with a few other Honda bikes these include the XR650L. This is mainly a US bike but there are some nice aftermarket replacements available that will fit the CRM. http://www.xrsonly.com/parts-categories ... 650l-black


Engine:
All engine gaskets are the same.

Water pump gasket is 19229KAE740 and fits all CRMs.

Honda have no more Mk1 water pump shafts. Mk2 shafts fit but you have to change the bearing at the bottom off the shaft as the end is 1mm larger. Old bearing 19 ext dia, 7mm int dia, 6mm deep - New 19,8,6.
Mk2 water pump cshaft - 19240-KAE-870

Mk3 Intake rubber - 16220-KAE-405 this is a Honda upgrade for Mk1 & Mk2. AR is different.

A CR250 2003 kickstart fits the splines on a CRM250. I believe all CR250 kickstarts from at least 2002-2007 are the same

All the internal parts of the powervalve servo in all CRM250s are the same as those found in NSR and CRM 125s. In fact the only differences it seems are the plug and the pulley that the control cables connect to (the wiring is the same). The usual thing that goes wrong is the teeth breaking on the gears inside and these can easily be replaced.

The Boyesen Rad Valve to fit CRM250 as direct replacement of the original intake is Part No. RAD-02SJ.

FERODO, EBC and NEWFREN do clutch plates for CRMs.

Gear shaft seal - Part no.91203-KA4-772. All Mks. Any seal size 14x22x5 will do.

All gear clusters and shafts are interchangeable Mk2/3/AR. MK1 has different clutch shaft and bearing for this.

Apparently the RegRec of CRM250AR (SH572B-11) can be replaced with RegRec of Honda CG125 (SH572LB) - all you need to do is replace generator side connector (3 yellow wires).

XR400 air filter fits all CRMs.

CR 500 gear lever fits all CRMs.

Balance shaft - the mk3 (and AR?) balance shaft nut is different to the Mk1/2 one because it has provision for staking it.
Part number is 90021-KAE-740


Lights:
Mk1/2/3: Headlight unit 33123KAE003
Adjuster bolt for above 33103187671
Spring for above 33107333000

The headlight lens from my yz250wr fits into the AR cowling provided you use the crm mounting bracket.

The rear lamp in CRM 250 MK3 is same s Honda xlr125 from 98'


Brakes:
Front caliper seals from a DR350 fit all CRMs.

Brake light switches - One option is to junk the originals and replace them with pressure switches made by HEL and others. You need M10 1.25mm thread bolts in the kit. This is also a way to replace knackered master cylinders with those used by MXers.

A DT125RE or X rear master cylinder and caliper fit straight on the Mk2/3/AR.


Wheels:
Rear sprockets for xr250/400 fit but only the front sprockets from xr400 do.

I believe (though not entirely sure) that all Honda big bike (125 up) off road sprockets (CR, XR, CRM, CRF) have the same basic holes. The CRM and XR sprockets that I have bought have multi capacity CR and CRF applications on the label when they have arrived. The length of the retaining bolts may vary and the shape of the bolt heads :?:

It seems that some CRMs have rear hubs that have 8mm bolt holes and some have 10mm bolt holes. There seems to be no rhyme or reason to the fitting so I can only think that some owners have replaced the original wheels/hubs with ones that have 10mm retaining bolts from a source as yet unknown. If you have a hub with 10mm retaining bolts you can drill out the holes on an 8mm holed sprocket to get it to fit.


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