Page 1 eſ OWNER`S MANUAL IH [OINT DA MANUEL DU

Page 1 eſ OWNER`S MANUAL IH [OINT DA MANUEL DU
« HONDA
OWNERS MANUAL
MANUEL DU CONDUCTEUR
FAHRER-HANDBUCH
CBR60OFS
CBR600F4:i
Honda CBR600OFS/CBR600F41
OWNER’S MANUAL
MANUEL DU CONDUCTEUR
FAHRER-HANDBUCH
© Honda Motor Co., Ltd. 2001
IMPORTANT INFORMATION
¢ OPERATOR AND PASSENGER
This motorcycle is designed to carry the operator and one passenger. Never exceed the
maximum weight capacity as shown on the accessories and loading label.
* ON-ROAD USE
This motorcycle is designed to be used only on the road.
® READ THIS OWNER’S MANUAL CAREFULLY
Pay special attention to the safety messages that appear throughout the manual. These
messages are fully explained in the “Safety Messages” section which appears opposite the
Contents page.
‘This manual should be considered a permanent part of the motorcycle and should remain
with the motorcycle when resold.
Honda CBR6OOFS/CBR600F4i
OWNER’S MANUAL
All information in this publication is based on the latest production information
available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the
right to make changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written permission.
WELCOME
The motorcycle presents you a challenge to master the machine, a challenge to adventure.
You ride through the wind, linked to the road by a vehicle that responds to your commands
as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a
pre ide inspection and regular maintenance are essential to your safety. Your reward is
freedom.
To meet the challenges safely, and to enjoy the adventure fully, you should become
thoroughly familiar with this owner’s manual BEFORE YOU RIDE THE MOTORCYCLE.
As you read this manual, you will find information that is preceded by a symbol. This
information is intended to help you avoid damage to your motorcycle, other property, or the
environment.
When service is required, remember that your Honda dealer knows your motorcycle best. If
you have the required mechanical “know-how” and tools, your dealer can supply you with an
official Honda Service Manual to help you perform many maintenance and repair tasks.
Pleasant riding, and thank you for choosing a Honda!
e Following codes in this manual indicate each country.
CBR600FS
Austria Italy E UK
Belgium Norway G | Germany Switzerland
Denmark Portugal F_| France
Finland Spain
Greece Sweden
Holland
CBR600OF4i _
[| U | Australia New Zealand |
e The specifications may vary with each locale.
A FEW WORDS ABOUT SAFETY
Your safety, and the safety of others, is very important. And operating this motorcycle safely
is an important responsibility.
To help you make informed decisions about safety, we have provided operating procedures
and other information on labels and in this manual. This information alerts you to potential
hazards that could hurt you or others.
Of course, it is not practical or possible to warn you about all hazards associated with
operating or maintaining a motorcycle. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
* Safety Labels — on the motorcycle.
* Safety Messages — preceded by a safety alert symbol £À and one of three signal words:
DANGER, WARNING, or CAUTION.
These signal words mean:
PNY You WILL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
A WARNING | You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
i CAUTION You CAN be HURT if you don’t follow instructions.
e Safety Headings — such as Important Safety Reminders or Important Safety Precautions.
e Safety Section — such as Motorcycle Safety.
* Instructions — how to use this motorcycle correctly and safely.
This entire manualis filled with important safety information — please read it carefully.
OPERATION
page page
1 MOTORCYCLE SAFETY 51 ESSENTIAL INDIVIDUAL
1 Important Safety Inforamation COMPONENTS
2 Protective Apparel 51 Ignition Switch
4 Load Limits and Guidelines 52 Keys
54 Immobilizer System (HISS)
8 PARTS LOCATION 56 Right Handlebar Controls
11 Instruments and Indicators 58 Left Handlebar Controls
28 MAJOR COMPONENTS
(Information you need to
opetate this motorcycle)
28 Suspension
34 Brakes
37 Clutch
39 Coolant
41 Fuel
44 Engine Oil
45 Tubeless Tyres
FEATURES
(Not required for operation)
Steering Lock
Seat
Helmet Holder
Document Bag
Storage Compartment for U-Shaped
Anti-theft Lock
Front Cowl
Inner Cowl
Inner Panel
Headlight Aim Vertical Adjustment
OPERATION
Pre-ride Inspection
Starting the Engine
Running-in
Riding
Braking
Parking
Anti-theft Tips
MAINTENANCE
8
80
81
82
83
86
87
88
89
93
98
99
100
101
107
108
109
110
117
119
122
125
126
page
0
MAINTENANCE
The Importance of Maintenance
Maintenance Safety
Safety Precautions
Maintenance Schedule
Tool Kit
Serial Numbers
Colour Label
Engine Oil
Spark Plugs
Throttle Operation
Idle Speed
Coolant
Drive Chain
Drive Chain Slider
Front and Rear Suspension
Inspection
Side Stand
Wheel Removal
Brake Pad Wear
Battery
Fuse Replacement
Stoplight Switch Adjustment
Bulb Replacement
page
132
136
136
138
139
143
144
CLEANING
STORAGE GUIDE
Storage
Removal from Storage
SPECIFICATIONS
CATALYTIC CONVERTER
NOISE CONTROL SYSTEM
(AUSTRALIA ONLY)
MOTORCYCLE SAFETY
IMPORTANT SAFETY INFORMATION
Your motorcycle can provide many years of
service and pleasure — if you take
responsibility for your own safety and
understand the challenges that you can
meet on the road.
There is much that you can do to protect
yourself when you ride. You'll find many
helpful recommendations throughout this
manual. Following are a few that we
consider most important.
Always Wear a Helmet
Its a proven fact: Helmets significantly
reduce the number and severity of head
injuries. So always wear a helmet and make
sure your passenger does the same. We
also recommend that you wear eye
protection, sturdy boots, gloves and other
protective gear (page 2 ).
Make Yourself Easy to See
Some drivers do not see motorcycles
because they are not looking for them. To
make yourself more visible, wear bright
reflective clothing, position yourself so
other drivers can see you, signal before
turning or changing lanes, and use your
horn when it will help others notice you.
Ride Within Your Limits
Pushing the limits is another major cause of
motorcycle accidents. Never ride beyond
your personal abilities or faster than
conditions warrant. Remember that alcohol,
drugs, fatigue and inattention can
significantly reduce your ability to make
good judgements and ride safely.
Keep Your Bike in Safe Condition
For safe riding, it's important to inspect
your motorcycle before every ride and
perform all recommended maintenance.
Never exceed load limits, and only use
accessories that have been approved by
Honda for this motorcycle. See page 4 for
more details.
PROTECTIVE APPAREL
For your safety, we strongly recommend
that you always wear an approved
motorcycle helmet, eye protection, boots,
gloves, long pants, and a long-sleeved shirt
or jacket whenever you ride. Although
complete protection is not possible, wearing
proper gear can reduce the chance of injury
when you ride.
Following are suggestions to help you
choose proper gear.
Not wearing a helmet increases the
chance of serious injury or death in a
crash.
Be sure you and your passenger
always wear a helmet, eye protection
and other protective apparel when you
ride.
Helmets and Eye Protection
Your helmet is your most important piece of
riding gear because it offers the best
protection against head injuries. A helmet
should fit your head comfortably and
securely. A bright-colored helmet can make
you more noticeable in traffic, as can
reflective strips.
An open-face helmet offers some protection,
but a full-face helmet offers more. Always
wear a face shield or goggles to protect
your eyes and help your vision.
Additional Riding Gear
In addition to a helmet and eye protection,
we also recommend:
¢ Sturdy boots with non-slip soles to help
protect your feet and ankles.
e Leather gloves to keep your hands warm
and help prevent blisters, cuts, burns and
bruises.
e A motorcycle riding suit or jacket for
comfort as well as protection. Pright-
colored and reflective clothing can help
make you more noticeable in traffic. Be
sure to avoid loose clothes that could get
caught on any part of your motorcycle.
LOAD LIMITS AND GUIDELINES
Your motorcycle has been designed to carry
you and one passenger. When you carry a
passenger, you may feel some difference
during acceleration and braking. But so long
as you keep your motorcycle well-
maintained, with good tyres and brakes, you
can safely carry loads within the given limits
and guidelines.
However, exceeding the weight limit or
carrying an unbalanced load can seriously
affect your motorcycle’s handling, braking
and stability. Non-Honda accessories,
improper modifications, and poor
maintenance can also reduce your safety
margin.
The following pages give more specific
information on loading, accessories and
modifications.
Loading
How much weight you put on your
motorcycle, and how you load it, are
important to your safety. Anytime you ride
with a passenger or cargo you should be
aware of the following information.
WARNING
Overloading or improper loading can
cause a crash and you can be
seriously hurt or killed.
Follow all load limits and other loading
guidelines in this manual.
Load Limits
Following are the load limits for your
motorcycle:
Maximum weight capacity:
189 kg (417 Ibs)
Includes the weight of the rider,
passenger, all cargo and all accessories
Maximum cargo weight:
27 kg (60 Ibs)
Loading Guidelines
Your motorcycle is primarily intended for
transporting you and a passenger. You may
wish to secure a jacket or other small items
to the seat when you are not riding with a
passenger.
If you wish to carry more cargo, check with
your Honda dealer for advice, and be sure
to read the information regarding
accessories on page 6 .
Improperly loading your motorcycle can
affect its stability and handling. Even if your
motorcycle is properly loaded, you should
ride at reduced speeds and never exceed
130 km/h (80 mph) when carrying cargo.
Follow these guidelines whenever you carry
a passenger or cargo:
e Check that both tyres are properly
inflated.
e If you change your normal load, you may
need to adjust the front suspension (page
28 ) and the rear suspension (page 31 ).
e To prevent loose items from creating a
hazard, make sure that all cargo is
securely tied down before you ride away.
e Place cargo weight as close to the center
of the motorcycle as possible.
e Balance cargo weight evenly on both
sides.
Accesories and Modifications
Modifying your motorcycle or using non-
Honda accessories can make your
motorcycle unsafe. Before you consider
making any modifications or adding an
accessory, be sure to read the following
information.
AWARNING
Improper accessories or modifications
can cause a crash in which you can
be seriously hurt or killed.
Follow all instructions in this owner's
manual regarding accessories and
modifications.
Accessories
We strongly recommend that you use only
genuine Honda accessories that have been
specifically designed and tested for your
motorcycle. Because Honda cannot test all
other accessories, you must be personally
responsible for proper selection, installation
and use of non-Honda accessories. Check
with your dealer for assistance and always
follow these guidelines:
e Make sure the accessory does not
obscure any lights, reduce ground
clearance and banking angle, limit
suspension travel or steering travel, alter
your riding position or interfere with
operating any controls.
e Be sure electrical equipment does not
exceed the motorcycle’s electrical system
capacity (page 142). A blown fuse can
cause a loss of lights or engine power.
e Do not pull a trailer or sidecar with your
motorcycle. This motorcycle was not
designed for these attachments, and their
use can seriously impair your motorcycle’s
handling.
Modifications
We strongly advise you not to remove any
original equipment or modify your
motorcycle in any way that would change its
design or operation. Such changes could
seriously impair your motorcycle’s handling,
stability and braking, making it unsafe to
ride.
Removing or modifying your lights,
mufflers, emission control system or other
equipment can also make your motorcycle
illegal.
PARTS LOCATION
Ignition switch Coolant temperature meter
Rearview mirror Indicators Tachometer Rearview mirror
Multi-function display Front brake fluid
reservoir
Passing switch : -¥ Engine stop switch
(Except U type) <<
Clutch lever : SN Front brake lever
Headlight dimmer © 7
switch Throttle grip
Turn signal switch Headlight switch
(Except U type)
Horn button Starter button
Front spring preload adjuster/ Fuel fill cap
Front rebound damping adjuster
Storage compartment Rear brake fluid reservoir
Helmet holder Coolant reserve tank
, / e Y Front compression
^. Tool box и Вацегу и + damping adjuster
E
Passenger footpeg Footpeg Oil filler cap
Rear rebound damping adjuster Rear brake pedal Engine oil inspection window
9
Rear compression Helmet holder
damping adjuster \
Storage compartment for
“U-shaped anti-theft lock
Fuse box , "
Front compression Side stand Footpeg Passenger footpeg
damping adjuster Gearshift pedal Rear spring preload adjuster
10
INSTRUMENTS AND
INDICATORS
The indicators are contained in the
instrument panel. Their functions are
described in the tables on the following
pages.
(1) Tachometer
(2) Tachometer red zone
(3) Tachometer red zone indicator
(4) Immobilizer system (HISS) indicator
(5) Coolant temperature meter
(6) Multi-function display
(7) Reset button
(8) Select button
(9) Left turn signal indicator
(10) Malfunction indicator
(11) Neutral indicator
(12) PGM-FI indicator
(13) High beam indicator
(14) Right turn signnal indicator
a ay —Q)
(12) | (14) ©
(9) (10)
11
(Ref No.) Description
Function
(1) Tachometer
Shows engine revolutions per minute.
The tachometer needle will swing to the maximum
scale on the dial once when the ignition switch is
turned ON.
(2) Tachometer red zone
Never allow the tachometer needle to enter the red
zone, even after the engine has been broken in.
Running the engine beyond recommended maximum
engine speed (the beginning of the tachometer red
zone) can damage the engine.
(3) Tachometer red zone
indicator (yellow)
Flashes when the tachometer needle enter the red
zone. Should lights for a few seconds and then go off
when the ignition switch is turned ON.
12
(Ref.No.) Description
Function
(4) Immobilizer system
(HISS) indicator
(green)
This indicator lights for a few seconds when the
ignition switch is turned ON and the engine stop
switch is at () (RUN). It will then go off if the
properly-coded key has been inserted. If an
improperly-coded key has been inserted, the
indicator will remain on and the engine will not start
(page 54 ).
(5) Coolant temperature
meter
Shows coolant temperature (page 27).
This meter shows the initial display (page 18 ).
13
(Ref.No.) Description
Function
(6) Multi-function display
The display includes the following functions;
This display shows the initial display (page 18 ).
Low oil pressure
indicator/Coolant
temperature indicator
Flashes the low oil pressure indicator and/or coolant
temperature indicator to notify that there is
abnormality in engine oil pressure and/or coolant
temperature when the malfunction indicator lights.
See page 20, 21.
Fuel indicator
Lights when there is only few fuel left in the fuel tank.
Amount of fuel left in the tank with the vehicle set
upright is approximately;
3.5 2 (0.92 US gal , 0.77 Imp gal)
See page 22 .
Speedometer Shows riding speed (page 23 ).
Odometer Shows accumulated mileage (page 23 ).
Tripmeter Shows mileage per trip (page 23 ).
Digital clock Shows hour and minute (page 25 ).
14
(Ref .No.) Description
Function
(7) Reset button
This button is used to reset the tripmeter or to adjust
the time.
(8) Select button
Except E type:
This button is used to select the tripmeter or to
adjust the time.
For E type:
This button is used to select the tripmeter or to
adjust the time or to change the speed and mileage
units for the speedometer/odometer/tripmeter.
(9) Left turn signal indicator
(green)
Flashes when the left turn signal operates. Should
lights for a few seconds and then go off when the
ignition switch is turned ON.
15
(Ref.No.) Description
Function
(10) Malfunction indicator
(red)
Lights when coolant is over the specified
temperature, and/or engine oil pressure is below
normal operating range. Should also light when
ignition switch is ON and engine is not running.
Should go out when engine starts, except for
occational flickering at or near idling speed when
engine is warm.
See page 20 , 21.
(11) Neutral indicator (green)
Lights when the transmission is in neutral. Should
also lights for a few seconds and then go off when
the ignition switch is turned ON.
(12) PGM-FI indicator (red)
Flashes when there is any abnormality in the PGM-FI
(Programmed Fuel Injection) system. Should also
light for a few seconds and then go off when the
ignition switch is turned ON and engine stop switch
isat () (RUN).
If it comes on at any other time , reduce speed and
take the motorcycle to your Honda dealer as soon as
possible.
16
(Ref.No.) Description
Function
(13) High beam indicator
(blue)
Lights when the headlight is on high beam. Should
also lights for a few seconds and then go off when
the ignition switch is turned ON.
(14) Right turn signal indicator
(green)
Flashes when the right turn signal operates. Should
lights for a few seconds and then go off when the
ignition switch is turned ON.
17
Initial Display
When the ignition switch is turned ON, the
multi-function display (1) and coolant
temperature meter (2) will temporarily
show all the modes and digital segments.
Thereafter, the speedometer (3) will show
from 290 km/h to 0 km/h (E type only:
From 180 mph to 0 mph in mph) so that you
can make sure the liquid crystal display is
functioning properly.
The unit “mph” (4) will be displayed only
for E type.
Digital clock (5), tripmeter (6) and fuel
indicator (7) will reset if the battery 1s
disconnected.
18
(7)
(1) Multi-function display
(2) Coolant temperature meter
(3) Speedometer
(4) “mph”
(5) Digital clock
(6) Tripmeter
(7) Fuel indicator
Multi-function Display
Multi-function display (1) includes the
following functions:
Low oil pressure indicator
Coolant temperature indicator
Speedometer
Odometer
Tripmeter
Fuel indicator
Digital clock
@ an ©
N. | ON
ao | SC IvamE) |e
e SC)
ras (E) AAA N
O = 00
© 5 sagaz O
AF \ x р
/ \ \
(7) (5) (6)
(1) Multi-function display
(2) Low oil pressure indicator
(3) Coolant temperature indicator
(4) Speedometer
(5) Odometer
(6) Tripmeter
(7) Fuel indicator
(8) Digital clock
(9) Reset button
(10) Select button
(11) Malfunction indicator
19
Low Oil Pressure Indicator and
Malfunction Indicator
The low oil pressure indicator (1) flashes
and the red malfunction indicator (2) lights
when engine oil pressure is below the
normal operating range.
The low oil pressure indicator should flash
and the red malfunction indicator light
when the engine is not running with the
ignition switch turned ON. Both should go
off when the engine starts, except for
occational flickering at or near idling speed
when the engine is warm.
Running the engine with insufficient oil
pressure may cause serious engine damage.
20
(1) Low oil pressure indicator
(2) Malfunction indicator
Coolant Temperature Indicator and
Malfunction Indicator
The coolant temperature indicator (1)
flashes and the red malfunction indicator
(2) lights when the coolant is over the
specified temperature.
Exceeding maximum running temperature
may cause serious engine damage.
(2)
À
[El EN
—
<” (1)
[EE
(1) Coolant temperature indicator
(2) Malfunction indicator
21
Fuel indicator
Lights when there is only few fuel left in the
tank. Thereafter, the fuel segment will flash
in sequence according to the distance
traveled. When the fuel indicator lights, fuel
will be low and you should refill the tank as
soon as possible.
When fuel indicator lights, the amount of
fuel left in the tank with the vehicle set
upright is approximately:
3.5 2 (0.92 US gal , 0.77 Imp gal)
After refueling, the fuel indicator will go
OFF only when all of the following
conditions are met:
e More than 90 seconds have elapsed after
the ignition switch was turned ON.
e The engine is running.
e The side stand is raised.
o The amount of fuel in the tank is more
than
3.52 (0.92 US gal , 0.77 Imp gal).
Fuel indicator will reset if the battery is
disconnected.
22
|= НОНО
(1) Fuel indicator
(2) Fuel segment
Speedometer/Odometer/Tripmeter/
Speed and Mileage Unit Change
Speedometer
Shows riding speed.
Odometer
Shows accumulated mileage.
Tripmeter
Shows mileage per trip.
There are two tripmeters, tripmeter À (4)
and tripmeter B (5). Switch between the À
and B displays by pressing the select button
(6) repeatedly.
To reset the tripmeter, push and hold the
reset button (7) with the display in the
tripmeter A or tripmeter B mode.
O— 0 0
ln
2) —— 300 a (cu (3)
(6) a (chu (4)
Sue (5)
—
O ——5 29
@ \
DT
(4) Tripmeter A
(5) Tripmeter B
(6) Select button
(7) Reset button
(1) Speedometer
(2) Odometer
(3) Tripmeter
23
Speed and Mileage Unit Change
(Etypeonly) —
The speedometer displays both “km/h” and
“mph”.
The odometer/tripmeter displays both
“km” and “mile”.
Push and hold the select button (6) to (6)
select “km/h”/“km” or “mph” /“mile”.
(6) Select button
24
Digital clock
Shows hour and minute. To adjust the time,
proceed as follows:
1. Turn the ignition switch ON.
2. Press and hold both the select button (2)
and reset button (3) for more than 2
seconds. The clock will be set in the
adjust mode with the hour display
flashing.
(1) — — = Ам: TOT
ET
(2)
(3) —
(1) Digital clock
(2) Select button
(3) Reset button
3. To set the hour, press the reset button
until the desired hour and AM/PM are
displayed.
25
4. Press the select button. The minute
display will start flashing.
5. To set the minute, press the reset button 6. To end the adjustment, press the select
until the desired minute. The minute button or tum the ignition switch OFF.
display will return to “00” when “60” is The display will stop flashing
reached without affecting the hour automatically and the adjustment will be
display. cancelled if the button is not pressed for
about 30 seconds.
26
Coolant Temperature Meter
The coolant temperature meter (1) shows
coolant temperature digitally.
Temperature Display
Below 34°C “— —” is displayed.
Between 35°C Actual coolant tempera-
and 132°C ture is indicated.
Above 132°C The display will remain
“132° С”
(1)
E 5 Æ E
(1) Coolant temperature meter
Overheating Message
When the coolant temperature reaches
122°C, the display begin to flash. At the
same time, the red malfunction indicator
(2) lights and the coolant temperature
indicator (3) flashes.
If this occurs, stop the engine and check the
reserve tank coolant level. Read pages
39 — 40 and do not ride the motorcycle
until the problem has been corrected.
Exceeding maximum running temperature
may cause serious engine damage.
(2)
3)
(2) Malfunction indicator
(3) Coolant temperature indicator
27
MAJOR COMPONENTS
(Information you need to operate this motorcycle)
SUSPENSION
Front Suspension
Spring Preload:
Adjust the spring preload by turning the
preload adjuster (1) with the 10 X 14 mm
wrench provided in the tool kit.
Make sure that both fork legs are adjusted
to the same position.
To reduce (SOFT) :
Turn the adjuster counterclockwise toward
SOFT for a light load and smooth road
condition.
To increase (HARD) :
Turn the adjuster clockwise toward HARD
for a firmer ride and rough road condition.
28
Standard Position:
lo return to the standard position, turn the
adjusters until the fourth groove from the
top aligns with the top surface of the fork
caps.
(1)
Standard position
(1) Preload adjuster
Rebound Damping:
To reduce SOFT ) :
Turn the adjuster counterclockwise toward
SOFT for a light load and smooth road
condition.
To increase (HARD) :
Turn the adjuster clockwise toward HARD
for a firmer ride and rough road condition.
To adjust the adjuster to the standard
position, proceed as follows :
1. Turn the damping adjuster (1) clockwise
until it will no longer turn (lightly seats).
This is the full hard setting.
2. The adjuster is set in the standard
position when the adjuster is turned
counterclockwise approximately
13/4 turn so that its punch mark (2)
aligns with the reference mark (3).
3. Make sure that both fork legs are
adjusted to the same position.
(2)
(3) Reference mark
(1) Damping adjuster
(2) Punch mark
29
Compression Damping:
To reduce (SOFT):
Turn the adjuster counterclockwise toward
SOFT for a light load and smooth road
condition.
To increase (HARD) :
Turn the adjuster clockwise toward HARD
for a firmer ride and rough road condition.
To adjust the adjuster to the standard
position, proceed as follows :
1. Turn the damping adjuster (1) clockwise
until it will no longer turn (lightly seats).
This is the full hard setting.
2. The adjuster is set in the standard
position when the adjuster is turned
counterclockwise approximately
11/4 turn so that its punch mark (2)
aligns with the reference punch mark (3).
3. Make sure that both fork legs are
adjusted to the same position.
30
(1) Damping adjuster
(2) Punch mark
(3) Reference punch
mark
Rear Suspension
Rebound Damping:
To reduce SOFT ) :
Turn the adjuster counterclockwise toward
SOFT for a light load and smooth road
condition.
To increase (HARD) :
Turn the adjuster clockwise toward HARD
for a firmer ride and rough road condition.
To adjust the adjuster to the standard
position, proceed as follows :
1. Turn the damping adjuster (1) clockwise
until it will no longer turn (lightly seats).
This is the full hard setting.
2. The adjuster is set in the standard
position when the adjuster is turned
counterclockwise approximately
11/2 turn so that its punch mark (2)
aligns with the reference punch mark (3).
(1)
(1) Damping adjuster (3) Reference punch
(2) Punch mark mark
31
Compression Damping:
To reduce (SOFT):
Turn the adjuster counterclockwise toward
SOFT for a light load and smooth road
condition.
To increase (HARD) :
Turn the adjuster clockwise toward HARD
for a firmer ride and rough road condition.
To adjust the adjuster to the standard
position, proceed as follows :
1. Turn the damping adjuster (1) clockwise
until it will no longer turn (lightly seats).
This is the full hard setting.
2. The adjuster is set in the standard
position when the adjuster is turned
counterclockwise approximately
11/2 turn so that its punch mark (2)
aligns with the reference punch mark (3).
32
Z
(2)
(1) Damping adjuster (3) Reference punch
(2) Punch mark mark
Spring Preload:
The spring preload adjuster (1) has
7 spring preload positions for different
load or riding conditions.
Use the pin spanner (2) and extension bar
(3) to adjust the rear shock.
Positions 1 to 2 are for a light load and
smooth road conditions. Position 3 is the
standard position. Positions 4 to 7 increase
spring preload for a stiffer rear suspension
and can be used when the motorcycle is
more heavily loaded.
The rear shock absorber assembly includes
a damper unit that contains high pressure
nitrogen gas. Do not attempt to disassemble
or service the damper; it cannot be rebuilt
and must be replaced when worn out.
Disposal should only be done by your
Honda dealer. The instructions found in this
owner's manual are limited to adjustment of
the shock assembly only.
(3) (2)
— D EUCH Y
(D
(1) Spring adjuster (3) Extension bar
(2) Pin spanner
33
BRAKES
Both the front and rear brakes are the
hydraulic disc types.
As the brake pads wear, the brake fluid
level drops.
There are no adjustments to perform, but
fluid level and pad wear must be inspected
periodically. The system must be inspected
frequently to ensure there are no fluid leaks.
If the control lever or pedal free travel
becomes excessive and the brake pads are
not worn beyond the recommended limit
(page 117 ), there is probably air in the
brake system and it must be bled. See your
Honda dealer for this service.
Front Brake Fluid Level:
With the motorcycle in an upright position,
check the fluid level. It should be above the
LOWER level mark (1). If the level is at or
below the LOWER level mark (1), check
the brake pads for wear (page 117 ).
34
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.
The recommended brake fluid is Honda
DOT 4 brake fluid from a sealed container,
or an equivalent.
(1) LOWER level mark
Front Brake Lever:
The distance between the tip of the brake
lever (1) and the grip can be adjusted by
turning the adjuster (2).
Align the arrow (3) on the brake lever with
the index mark (4) on the adjuster.
Apply the brake several times and check for
free wheel rotation after the brake lever is
released. (4)
7
(2)
(
S|
a
7
(3) Arrow
(4) Index mark
(1)
(1) Brake lever
(2) Adjuster
Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses and
fittings.
35
Rear Brake Fluid Level: Rear
With the motorcycle in an upright position,
check the fluid level. It should be between
the UPPER (1) and LOWER (2) level
marks. If the level is at or below the
LOWER level mark (2), check the brake
pads for wear (page 117 ).
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.
The recommended brake fluid is Honda
DOT 4 brake fluid from a sealed container,
or an equivalent.
(1) UPPER level mark
(2) LOWER level mark
36
CLUTCH 1. Loosen the lock nut (2) and turn the
Clutch adjustment may be required if the adjuster (3). Tighten the lock nut (2)
motorcycle stalls when shifting into gear or and check the adjustment.
tends to creep; or if the clutch slips, causing 2. If the adjuster is threaded out near its
acceleration to lag behind engine speed. limit or if the correct free play cannot be
Minor adjustments can be made with the obtained, loosen the lock nut (2) and turn
clutch cable adjuster (3) at the lever (1). in the cable adjuster (3) completely.
Normal clutch lever free play is: Tighten the lock nut (2).
10 — 20 тт (0.4—0.8 тп)
(1) Clutch lever (2) Lock nut (A) Increase free play
(3) Clutch cable adjuster (B) Decrease free play
37
3. Remove the right front cowl (page 65 ).
4. Loosen the lock nut (5) at the lower end
of the cable. Turn the adjusting nut (4) to
obtain the specified free play. Tighten the
lock nut (5) and check the adjustment.
5. Install the right front cowl.
6. Start the engine, pull in the clutch lever
and shift into gear. Make sure the engine
does not stall and the motorcycle does
not creep. Gradually release the clutch
lever and open the throttle. The
motorcycle should begin to move
smoothly and accelerate gradually.
(4)
(4) Adjusting nut
(5) Lock nut
38
(A) Increase free play
(B) Decrease free play
If proper adjustment cannot be obtained or
the clutch does not work correctly, see your
Honda dealer.
Other Checks:
Check the clutch cable for kinks or signs of
wear that could cause sticking or failure.
Lubricate the clutch cable with a
commercially available cable lubricant to
prevent premature wear and corrosion.
COOLANT
Coolant Recommendation
The owner must properly maintain the
coolant to prevent freezing, overheating,
and corrosion. Use only high quality
ethylene glycol antifreeze containing
corrosion protection inhibitors specifically
recommended for use in aluminum engines.
(SEE ANTIFREEZE CONTAINER LABEL).
Use only low-mineral drinking water or
distilled water as a part of the antifreeze
solution. Water that is high in mineral
content or salt may be harmful to the
aluminum engine.
Using coolant with silicate inhibitors may
cause premature wear of water pump seals
or blockage of radiator passages.
Using tap water may cause engine damage.
The factory provides a 50/50 solution of
antifreeze and distilled water in this
motorcycle. This coolant solution is
recommended for most operating
temperatures and provides good corrosion
protection. A higher concentration of
antifreeze decreases the cooling system
performance and is recommended only
when additional protection against freezing
is needed. A concentration of less than 40/
60 (40% antifreeze) will not provide proper
corrosion protection. During freezing
temperatures, check the cooling system
frequently and add higher concentrations of
antifreeze (up to a maximum of 60%
antifreeze) if required.
39
Inspection
The reserve tank is behind the frame.
Check the coolant level in the reserve tank
(1) while the engine is at the normal
operating temperature with the motorcycle
in an upright position. If the coolant level is
below the LOWER level mark (3), remove
the reserve tank cap (4) and add coolant
mixture until it reaches the UPPER level
mark (2). Always add coolant to the reserve
tank.
Do not attempt to add coolant by removing
the radiator cap.
If the reserve tank is empty, or if coolant
loss is excessive, check for leaks and see
your Honda dealer for repair.
40
(1) Reserve tank
(2) UPPER level mark
(3) LOWER level mark
(4) Reserve tank cap
FUEL
Fuel Tank
The fuel tank capacity including the reserve
supply is:
18.0 2 (4.76 US gal , 3.96 Imp gal)
To open the fuel fill cap (1), insert the
ignition key (2) and turn it clockwise. The
fuel fill cap is hinged and will lift up.
Do not overfill the tank. There should be no
fuel in the filler neck (3).
After refueling, to close the fuel fill cap,
push the fuel fill cap into the filler neck until
it snaps closed and locks. Remove the key.
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
e Stop the engine and keep heat,
sparks, and flame away.
e Refuel only outdoors.
e Wipe up spills immediately.
(1) Fuel fill cap
(2) Ignition key
(3) Filler neck
41
For E, F, ED:
Use unleaded or low-lead petrol with a
research octane number of 91 or higher.
We recommend that you use unleaded
petrol because it produces fewer engine and
spark plug deposits and extends the life of
exhaust system components.
For G:
Use unleaded petrol with a research octane
number of 91 or higher.
The use of leaded petrol will cause
premature damage to the catalytic
converter.
For U:
Use unleaded petrol with a research octane
number of 91 or higher.
42
If “spark knock” or “pinking” occurs at a
steady engine speed under normal load,
change brands of petrol. If spark knock or
pinking persists, consult your Honda dealer.
Failure to do so is considered misuse, and
damage caused by misuse is not covered by
Honda's Limited Warranty.
Petrol Containing Alcohol
If you decide to use a petrol containing
alcohol (gasohol), be sure it’s octane rating
is at least as high as that recommended by
Honda. There are two types of “gasohol”:
one containing ethanol, and the other
containing methanol. Do not use petrol that
contains more than 10 % ethanol. Do not use
petrol containing methanol (methyl or wood
alcohol) that does not also contain
cosolvents and corrosion inhibitors for
methanol. Never use petrol containing more
than 5 % methanol, even if it has cosolvents
and corrosion inhibitors.
Fuel system damage or engine performance
problems resulting from the use of fuels
that contain alcohol is not covered under
the warranty. Honda cannot endorse the
use of fuels containing methanol since
evidence of their suitability is as yet
incomplete.
Before buying fuel from an unfamiliar
station, try to find out if the fuel contains
alcohol. If it does, confirm the type and
percentage of alcohol used. If you notice
any undesirable operating symptoms while
using a petrol that contains alcohol, or one
that you think contains alcohol, switch to a
petrol that you know does not contain
alcohol.
ENGINE OIL
Engine Oil Level Check
Check the engine oil level each day before
riding the motorcycle.
The level must be maintained between the
upper (1) and lower (2) level marks in the
inspection window (3).
1. Start the engine and let it idle for a few
minutes. Make sure the low oil pressure
indicator goes off. If the indicator
remains flashing, stop the engine
immediately.
2. Stop the engine and hold the motorcycle
in an upright position on firm, level
ground.
3. After a few minutes, check that the oil
level is between the upper (1) and lower
(2) level marks in the inspection window
(3).
4. If required, remove the oil filler cap (4)
and add the specified oil (page 89) up to
the upper level mark. Do not overfill.
44
5. Reinstall the oil filler cap. Check for oil
leaks.
Running the engine with insufficient oil
pressure may cause serious engine damage.
1
eri
(3) Inspection window
(1) UPPER level mark
(2) LOWER level mark (4) Filler cap
TUBELESS TYRES
To safely operate your motorcycle, your
tyres must be the proper type and size, in
good condition with adequate tread, and
correctly inflated for the load you are
carrying. The following pages give more
detailed information on how and when to
check your air pressure, how to inspect
your tyres for damage, and what to do when
your tyres need to be repaired or replaced.
Using tyres that are excessively worn
or improperly inflated can cause a
crash in which you can be seriously
hurt or killed.
Follow all instructions in this owners
manual regarding tyre inflation and
maintenance.
Air Pressure
Keeping your tyres properly inflated
provides the best combination of handling,
tread life and riding comfort. Generally,
underinflated tyres wear unevenly,
adversely affect handling, and are more
likely to fail from being overheated.
Overinflated tyres make your motorcycle
ride more harshly, are more prone to
damage from road hazards, and wear
unevenly.
We recommend that you visually check
your tyres before every ride and use a
gauge to measure air pressure at least once
a month or any time you think the tyres
might be low.
Tubeless tyres have some self-sealing
ability if they are punctured. However,
because leakage is often very slow, you
should look closely for punctures whenever
a tyre is not fully inflated.
Always check air pressure when your tyres
are “cold” — when the motorcycle has been
parked for at least three hours. If you check
air pressure when your tyres are “warm” —
when the motorcycle has been ridden for
even a few miles — the readings will be
higher than if the tyres were “cold”. This is
normal, so do not let air out of the tyres to
match the recommended cold air pressures
given below. If you do, the tyres will be
underinflated.
The recommended “cold” tyre pressures
are:
Front 250 kPa
(2.50 kgf/cm? , 36 psi)
Rear 290 kPa
(2.90 kgf/cm? , 42 psi)
Inspection
Whenever you check the tyre pressures,
you should also examine the tyre treads and
sidewalls for wear, damage, and foreign
objects:
Look for:
e Bumps or bulges in the side of the tyre or
the tread. Replace the tyre if you find any
bumps or bulges.
¢ Cuts, splits or cracks in the tyre. Replace
the tyre if you can see fabric or cord.
e Excessive tread wear.
Also, if you hit a pothole or hard object, pull
to the side of the road as soon as you safely
can and carefully inspect the tyres for
damage.
Tread Wear
Replace tyres before tread depth at the
center of the tyre reaches the following
limit:
Minimum tread depth
Front: 1.5 mm (0.06 in)
Rear: 2.0 mm (0.08 in)
<For Germany >
German law prohibits use of tyres whose
tread depth is less than 1.6 mm.
(2)
(1) Wear indicator
(2) Wear indicator location mark
47
Tyre Repair
If a tyre is punctured or damaged, you
should replace it, not repair it. As discussed
below, a tyre that is repaired, either
temporarily or permanently, will have lower
speed and performance limits than a new
tyre.
A temporary repair, such as an external
tubeless tyre plug, may not be safe for
normal speeds and riding conditions. If a
temporary or emergency repair is made to a
tyre, you should ride slowly and cautiously
to a dealer and have the tyre replaced. If
possible, you should not carry a passenger
or cargo until a new tyre is installed.
Even if a tyre is professionally repaired with
a permanent internal patch plug, it will not
be as good as a new tyre. You should not
exceed 80 km/h (50 mph) for the first 24
hours, or 130 km/h (80 mph) at any time
thereafter. In addition, you may not be able
to safely carry as much weight as with a
new tyre. Therefore, we strongly
recommend that you replace a damaged
tyre. If you choose to have a tyre repaired,
be sure the wheel is balanced before you
ride.
Tyre Replacement
The tyres that came on your motorcycle
were designed to match the performance
capabilities of your motorcycle and provide
the best combination of handling, braking,
durability and comfort.
ENCE
Instailing improper tyres on your
motorcycle can affect handling and
stability. This can cause a crash in
which you can be seriously hurt or
killed.
Always use the size and type of tyres
recommended in this owners manual.
The recommended tyres for your
motorcycle are:
Front: 120/70ZR17 (58W)
BRIDGESTONE
BTO10F RADIAL F
DUNLOP
D207FV
MICHELIN
Pilot SPORT E
Rear: 180/55ZR17 (73W)
BRIDGESTONE
BTO10R RADIAL F
DUNLOP
D207P
MICHELIN
Pilot SPORT E
Whenever you replace a tyre, use one that
is equivalent to the original and be sure the
wheel is balanced after the new tyre is
installed.
Important Safety Reminders
¢ Do not install a tube inside a tubeless tyre
on this motorcycle. Excessive heat build-
up can cause the tube to burst.
® Use only tubeless tyres on this
motorcycle. The rims are designed for
tubeless tyres, and during hard
acceleration or braking, a tube-type tyre
could slip on the rim and cause the tyre to
rapidly deflate.
50
ESSENTIAL INDIVIDUAL COMPONENTS
IGNITION SWITCH
The ignition switch (1) is below the
indicator panel.
(1) Ignition switch
Key Position Function Key Removal
LOCK Steering is locked. Engine and lights cannot be | Key can be
steering lock) | operated. removed
OFF Engine and lights cannot be operated. Key can be
removed
ON Engine and lights can be operated. Key cannot be
removed
51
KEYS
This motorcycle has two keys and a key
number plate.
(2)
1)
(1) Keys (2) Key number plate
52
You will need the key number if you ever
have to replace a key. Store the plate in a
safe place.
To reproduce keys, bring all keys, key
number plate and motorcycle to your Honda
dealer.
Up to four keys can be registered with the
immobilizer system (HISS), including the
ones in hand.
If all keys are lost, the PGM-FI unit/ignition
control module must be replaced. To avoid
this possibility we recommend that if only
one key is left, you immediately have it
reproduced to ensure that a back-up is
available.
These keys contain electronic circuits that
are activated by the immobilizer system
(HISS). They will not work to start the
engine if the circuits are damaged.
* Do not drop the keys or set heavy objects
on them.
* Do not grind, drill or in any way alter the
original shape of the keys.
e Keep the keys away from magnetic
objects.
53
IMMOBILIZER SYSTEM (HISS)
HISS is the abbreviation of Honda Ignition
Security System.
The immobilizer system (HISS) protects
your motorcycle from theft. A properly-
coded key must be used in the ignition
switch for the engine to start. If an
improperly-coded key (or other device) is
used the engine’s starting circuit is disabled.
When the ignition switch is turned ON and
the engine stop switch is at “ С) ” (RUN),
the immobilizer system (HISS) indicator
lights for a few seconds, then go off. If the
indicator remains on, it means the system
does not recognize the coding of the key.
Turn the ignition switch to OFF, remove
the key, reinsert and turn the switch ON
again.
54
If the system repeatedly does not recognize
the coding of your key, contact your Honda
dealer.
e The system may not recognize the key’s
coding if any other immobilizer key is
near the ignition switch. To make sure
the system recognize the key code, keep
each immobilizer key on a separate ring.
e Do not attempt to alter the immobilizer
system (HISS) or add other devices to it.
Electrical problems could result, making
it impossible to start your motorcycle.
e If all keys are lost, the PGM-FI unit/
ignition control module must be replaced.
EC Directives
This immobilizer system complies with the
R & TTE (Radio equipment and telecommu-
nications terminal equipment and the
mutual recognition of their conformity)
Directive.
CE0891 D
The declaration of conformity to R & TTE
Directive is provided to the owner at the
time of purchase. The declaration of
conformity should be kept at a safe place.
When the declaration of conformity is lost
or is not provided, contact your Honda
dealer.
55
RIGHT HANDLEBAR CONTROLS
(Except U type>
Engine Stop Switch
The engine stop switch (1) is next to the
throttle grip. When the switch is in the
С) (RUN) position, the engine will operate.
When the switch is in the 9% (OFF)
position, the engine will not operate. This
switch is intended primarily as a safety or
emergency switch and should normally
remain in the () (RUN) position.
Headlight Switch
The headlight switch (2) has three
positions; 0: , 002 and OFF marked by a
dot to the right of ZDGE.
Headlight, taillight, position
light and meter lights on.
"005; Position light, taillight and
meter lights on.
Headlight, taillight, position
light and meter lights off.
OFF (dot):
56
Starter Button
The starter button (3) is below the
headlight switch (2).
When the starter button is pressed, the
starter motor cranks the engine. If the
engine stop switch is in the & (OFF)
position, the starter motor will not operate.
See page 71 for the starting procedure.
> (1)
И DA
CONS = mn
©] lo
— | — ©
a
e (3)
(1) Engine stop switch
(2) Headlight switch
(3) Starter button
RIGHT HANDLEBAR CONTROLS
<U type only >
Engine Stop Switch
The engine stop switch (1) is next to the
throttle grip. When the switch is in the
() (RUN) position, the engine will operate.
When the switch is in the $9 (OFF)
position, the engine will not operate. This
switch is intended primarily as a safety or
emergency switch and should normally
remain in the () (RUN) position.
Starter Button
The starter button (2) is below the engine
stop switch (1).
When the starter button is pressed, the
starter motor cranks the engine. If the
engine stop switch is in the 5% (OFF)
position, the starter motor will not operate.
See page 71 for the starting procedure.
(1) Engine stop switch
(2) Starter button
(2)
57
LEFT HANDLEBAR CONTROLS
Headlight Dimmer Switch (1)
Push the dimmer switch to zD (HD to
select high beam or to ¿D (LO) to select
low beam.
Passing Light Control Switch (2)
When this switch is pressed, the headlight
flashes on to signal approaching cars or
when passing.
Turn Signal Switch (3)
Move to <a (L) to signal a left turn,
> (R) to signal a right turn. Press to turn
signal off.
Horn Button (4)
Press the button to sound the horn.
58
(1) Headlight dimmer switch
(2) Passing light control switch
(3) Turn signal switch
(4) Horn button
FEATURES
(Not required for operation)
STEERING LOCK
To lock the steering, turn the handlebars all
the way to the left or right, turn the key (1)
to LOCK while pushing in. Remove the key.
To unlock the steering, turn the key to OFF
while pushing in.
Do not turn the key to LOCK while riding
the motorcycle; loss of vehicle control will
result.
To unlock
(A) Push in
(B) Turn to LOCK
(C) Turn to OFF
(1) Ignition key
59
SEAT
Front seat
To remove the front seat (1), pull up the
seat end and remove the two mounting
bolts (2), and then pull the seat back and up.
To install the front seat, insert the tab (3)
into the recess under the frame and tighten
the mount bolts securely.
60
(2)
(1) Front seat (3) Tab
(2) Mouting bolts
Rear seat
To remove the rear seat (4), insert the
ignition key (5) into the seat lock (6). Turn
it clockwise, then pull the rear seat up and
back.
To install the rear seat, insert the prongs
(7) into the rear stay (8) on the frame, and
then push down on the rear of the rear seat.
Be sure the seat is locked securely in
position after installation.
(5)
(8) (6)
(4) Rear seat (7) Prongs
(5) Ignition key (8) Rear stay
(6) Seat lock
61
HELMET HOLDER
The helmet holders are located below the
rear seat.
Remove the rear seat (page 61).
Hang the helmets on the holder hooks (1).
Install the rear seat and lock it securely.
A WARNING
Riding with a helmet attached to the
holder can interfere with the rear wheel
or suspension and could cause a
crash in which you can be seriously
hurt or killed.
Use the helmet holder only while
parked. Do not ride with a helmet
secured by the holder.
(1) Holder hooks
DOCUMENT BAG
The document bag (1) is in the document
compartment (2) on the reverse side of the
rear seat (3).
This owner's manual and other documents
should be stored in the document bag.
When washing your motorcycle, be careful
not to flood this area with water.
(1) Document bag
(2) Document compartment
(3) Rear seat
STORAGE COMPARTMENT FOR U-
SHAPED ANTI-THEFT LOCK
The rear fender has a storage compartment
to store a U-shaped anti-theft lock under the
rear seat. After storing, be sure to fasten
the lock with the rubber band (1) securely.
Some U-shaped locks may not be stored in
the compartment due to their size or design.
64
(1)
(1) Rubber band
FRONT COWL
The right and left front cowls can be
removed in the same manner.
Removal:
1. Remove the clips (1).
2. Remove the screws (2).
3. Remove the bolts A (3).
(5) Y
(1) Clips
(2) Screws
(3) Bolts A
4. Pull out the hooks (4) from the
grommets (5).
5. Remove the bolts B (6).
6. Remove the bolts C (7).
Installation:
e Installation can be done in the reverse
order of removal.
e Run the tubes through the clip of the left
front cowl. , (5)
== Fa Html
(1) ce (3)
ZANE
(2) FA = (4)
| es + == X ! ~
A
(7) 7 eo OÙ
À a (6)
DIT (1)
(4) Hooks (6) Bolts B
(5) Grommets (7) Bolts C
65
INNER COWL
Removal:
1. Remove the front cowl (page 65 ).
2. Remove the clips (1).
Installation:
e Installation can be done in the reverse
order of removal.
(1) Clips
66
INNER PANEL
The right and left inner panels can be
removed in the same manner.
Removal:
1. Remove the bolt A (1) and bolt B (2).
2. Remove the grommet A (3) from the
hook A (4).
3. Remove the hook B (5) from the
grommet B (6).
4. Remove the hook C (7) from the fuel
tank (8).
5. Remove the hook D (9) from the slot
(10).
Installation:
e Installation can be done in the reverse
order of removal.
(1) Bolt A
(2) Bolt B
(3) Grommet A
(4) Hook A
(5) Hook B
(6) Grommet B
(7) Hook C
(8) Fuel tank
(9) Hook D
(10) Slot
67
HEADLIGHT AIM VERTICAL
ADJUSTMENT
Vertical adjustment can be made by turning
the screws (1) and (2) in or out as
necessary.
Obey local laws and regulations.
68
For G, F, ED:
,
8)
(1) — 7
WI X
(1) Screw (low beam)
(2) Screw (high beam)
(A) Up
(B) Down
OPERATION
PRE-RIDE INSPECTION
For your safety, it is very important to take
a few moments before each ride to walk
around your motorcycle and check its
condition. If you detect any problem, be
sure you take care of it, or have it corrected
by your Honda dealer.
Improperly maintaining this motorcycle
or failing to correct a problem before
riding can cause a crash in which you
can be seriously hurt or killed.
Always perform a pre-ride inspection
before every ride and correct any
problems.
1. Engine oil level —add engine oil if
required (page 44 ). Check for leaks.
2. Fuel level — fill fuel tank when necessary
(page 41). Check for leaks.
3. Coolant level—add coolant if required.
Check for leaks (pages 39 — 40).
4. Front and rear brakes — check operation;
make sure there is no brake fluid leakage
(pages 34 — 36).
69
5. Tyres—check condition and pressure
(pages 45 — 50).
6. Drive chain — check condition and slack
(page 101). Adjust and lubricate if
necessary.
7. Throttle — check for smooth opening and
full closing in all steering positions.
8. Lights and horn—check that headlight,
tail/brake light, turn signals, indicators
and horn function properly.
9. Engine stop switch—check for proper
function (pages 56 — 57).
10. Side stand ignition cut-off system — check
for proper function (page 109 ).
70
STARTING THE ENGINE
Always follow the proper starting procedure
described below.
This motorcycle is equipped with a side
stand ignition cut-off system. The engine
cannot be started if the side stand is down,
unless the transmission is in neutral. If the
side stand is up, the engine can be started in
neutral or in gear with the clutch lever
pulled in. After starting with the side stand
down, the engine will shut off if the
transmission is put in gear before raising
the side stand.
For G type:
To protect the catalytic converter in your
motorcycle’s exhaust system, avoid
extending idling and the use of leaded
petrol.
Your motorcycle’s exhaust contains
poisonous carbon monoxide gas. High
levels of carbon monoxide can collect
rapidly in enclosed areas such as a garage.
Do not run the engine with the garage door
closed. Even with the door open, run the
engine only long enough to move your
motorcycle out of the garage.
Do not use the electric starter for more than
5 seconds at a time. Release the starter
button for approximately 10 seconds before
pressing it again.
71
Preparation
Before starting, insert the key, turn the
ignition switch ON and confirm the
following:
e The transmission is in NEUTRAL
(neutral indicator light ON).
e The engine stop switchisat () (RUN).
e The red malfunction indicator is ON.
e The low oil pressure indicator is flashing.
e The PGM-FI indicator is OFF.
e The immobilizer system (HISS) indicator
is OFF.
The low oil pressure indicator should go off
a few seconds after the engine starts. If the
light stays flashing, stop the engine
immediately and check the engine oil level.
Operating the engine with insufficient oil
pressure can cause serious engine damage.
72
Starting Procedure
This motorcycle has a fuelinjected engine
with an automatic fast idle. Follow the
procedure indicated below.
Any Air Temperature
e Press the starter button with the throttle
completely closed.
The engine will not start if the throttle is
fully open (because the electronic control
module cuts off the fuel supply).
Flooded Engine
If the engine fails to start after repeated
attempts, it may be flooded engine.
1. Leave the engine stop switch set to
() (RUN).
2. Open throttle fully.
3. Press the starter button for 5 seconds.
4. Then follow the normal starting
procedure.
5. If the engine start, then open the throttle
slightly if idling is unstable.
If the engine does not start, wait for 10
seconds, then follow steps 1—4 again.
Ignition Cut Off
Your motorcycle is designed to
automatically stop the engine and fuel pump
if the motorcycle is overturned (a banking
sensor cuts off the ignition system). Before
restarting the engine, you must turn the
ignition switch to the OFF position and then
back to ON.
73
RUNNING-IN
Help assure your motorcycle’s future
reliability and performance by paying extra
attention to how you ride during the first
500 km (300 miles).
During this period, avoid full-throttle starts
and rapid acceleration.
74
RIDING
Review Motorcycle Safety (pages 1 — 7)
before you ride.
Make sure you understand the function of
the side stand mechanism. (See MAIN-
TENANCE SCHEDULE on page 85 and
explanation for SIDE STAND on page 109).
{For G type >
Make sure flammable materials such as dry
grass or leaves do not come in contact with
the exhaust system when riding, idling, or
parking your motorcycle.
1. After the engine has been warmed up,
the motorcycle is ready for riding.
2. While the engine is idling, pull in the
clutch lever and depress the gearshift
pedal to shift into 1st (low) gear.
3. Slowly release the clutch lever and at the
same time gradually increase engine
speed by opening the throttle.
Coordination of the throttle and clutch
lever will assure a smooth positive start.
4. When the motorcycle attains a moderate
speed, close the throttle, pull in the clutch
lever and shift to 2nd gear by raising the
gearshift pedal.
This sequence is repeated to progres
sively shift to 3rd, 4th, 5th and 6th(top)
gear.
75
5. Coordinate the throttle and brakes for
smooth deceleration.
6. Both front and rear brakes should be
used at the same time and should not be
applied strongly enough to lock the wheel,
or braking effectiveness will be reduced
and control of the motorcycle be difficult.
©
«<?
5
76
BRAKING
For normal braking, apply both the brake
pedal and lever while down-shifting to
match your road speed. For maximum
braking, close the throttle and firmly apply
the pedal and lever; pull in the clutch lever
before coming to a complete stop to prevent
stalling the engine.
Important Safety Reminders:
e Independent operation of only the brake
lever or brake pedal reduces stopping
performance.
e Extreme application of the brake controls
may cause wheel lock, reducing control of
the motorcycle.
e When possible, reduce speed or brake
before entering a turn; closing the
throttle or braking in mid-turn may cause
wheel slip. Wheel slip will reduce control
of the motorcycle.
e When riding in wet or rainy conditions, or
on loose surfaces, the ability to maneuver
and stop will be reduced. All of your
actions should be smooth under these
conditions. Rapid acceleration, braking or
turning may cause loss of control. For
your safety, exercise extreme caution
when braking, accelerating or turning.
e When descending a long, steep grade,
use engine compression braking by down-
shifting, with intermittent use of both
brakes.
Continuous brake application can
overheat the brakes and reduce their
effectiveness.
Riding with your foot resting on the
brake pedal or your hand on the brake
lever may actuate the brakelight, giving a
false indication to other drivers. It may
also overheat the brakes, reducing
effectiveness.
77
PARKING
1. After stopping the motorcycle, shift the
transmission into neutral, turn the
handlebar fully to the left, turn the
ignition switch OFF and remove the key.
2. Use the side stand to support the
motorcycle while parked.
Park the motorcycle on firm, level ground to
prevent it from falling over.
If you must park on a slight incline, aim the
front of the motorcycle uphill to reduce the
possibility of rolling off the side stand or
overturning.
3. Lock the steering to help prevent theft
(page 59 ).
78
(For G type>
Make sure flammable materials such as dry
grass or leaves do not come in contact with
the exhaust system when parking your
motorcycle.
ANTI-THEFT TIPS
1. Always lock the steering and never leave
the key in the ignition switch. This
sounds simple but people do forget.
2. Be sure the registration information for
your motorcycle is accurate and current.
3. Park your motorcycle in a locked garage
whenever possible.
4, Use an additional anti-theft device of
good quality.
5. Put your name, address, and phone
number in this Owner's Manual and keep
it on your motorcycles at all times.
Many times stolen motorcycles are
identified by information in the Owner's
Manuals that are still with them.
NAME:
ADDRESS:
PHONE NO:
79
MAINTENANCE
THE IMPORTANCE OF
MAINTENANCE
A well-maintained motorcycle is essential
for safe, economical and trouble-free riding.
It will also help reduce air pollution.
To help you properly care for your
motorcycle, the following pages include a
Maintenance Schedule and a Maintenance
Record for regularly scheduled
maintenance.
These instructions are based on the
assumption that the motorcycle will be used
exclusively for its designed purpose.
Sustained high speed operation or operation
in unusually wet or dusty conditions will
require more frequent service than
specified in the Maintenance Schedule.
Consult your Honda dealer for
recommendations applicable to your
individual needs and use.
80
If your motorcycle overturns or becomes
involved in a crash, be sure your Honda
dealer inspects all major parts, even if you
are able to make some repairs.
AWARNING
Improperly maintaining this motorcycle
or failing to correct a problem before
you ride can cause a crash in which
you can be seriously hurt or killed.
Always follow the inspection and
maintenance recommendations and
schedules in this owner's manual.
MAINTENANCE SAFETY
This section includes instructions on some
important maintenance tasks. You can
perform some of these tasks with the tools
provided — if you have basic mechanical
skills.
Other tasks that are more difficult and
require special tools are best performed by
professionals. Wheel removal should
normally be handled only by a Honda
technician or other qualified mechanic;
instructions are included in this manual only
to assist in emergency service.
Some of the most important safety
precautions follow. However, we cannot
warn you of every conceivable hazard that
can arise in performing maintenance. Only
you can decide whether or not you should
perform a given task.
EY CTC
Failure to properly follow maintenance
instructions and precautions can
cause you to be seriously hurt or killed.
Always follow the procedures and
precautions in this owners manual.
81
SAFETY PRECAUTIONS
e Make sure the engine is off before you
begin any maintenance or repairs. This
will help eliminate several potential
hazards:
+ Carbon monoxide poisoning from
engine exhaust.
Be sure there is adequate ventilation
whenever you operate the engine.
+ Burns from hot parts.
Let the engine and exhaust system cool
before touching.
+ Injury from moving parts.
Do not run the engine unless instructed
to do so.
e Read the instructions before you begin,
and make sure you have the tools and
skills required.
e To help prevent the motorcycle from
falling over, park it on a firm, level
surface, using the side stand or a
maintenance stand to provide support.
82
e To reduce the possibility of a fire or
explosion, be careful when working
around petrol or batteries. Use only
nonflammable solvent, not petrol, to clean
parts. Keep cigarettes, sparks and flames
away from the battery and all fuel-related
parts.
Remember that your Honda dealer knows
your motorcycle best and is fully equipped
to maintain and repair it.
To ensure the best quality and reliability,
use only new genuine Honda parts or their
equivalents for repair and replacement.
MAINTENANCE SCHEDULE
Perform the Pre-ride Inspection (page 69) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A:ADJUST L: LUBRICATE
The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating
condition. Maintenance work should be performed in accordance with standards and specifications of Honda by
properly trained and equipped technicians. Your Honda dealer meets all of these requirements.
* Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is
mechanically qualified. Refer to the Official Honda Shop Manual.
** In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Honda recommends that your Honda dealer should road test your motorcycle after each periodic maintenance is
carried out.
NOTES: (1) At higher odometer readings, repeat at the frequency interval established here.
(2) Service more frequently if the motorcycle is ridden in unusually wet or dusty areas.
(3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires
mechanical skill.
84
ODOMETER READING [NOTE (1)]
TO
EVERY 12,000 km (8,000 mi) I,
ODOMETER READING | NOTE (1) ]
Refer
to
85
TOOL KIT
The tool kit (1) is in the tool box under the
rear seat (page 61 ).
Some roadside repairs, minor adjustments
and parts replacement can be performed
with the tools contained in the Kit.
e Spark plug wrench
e 10 X 12 mm Box end wrench
¢ 22 mm Box end wrench
¢ 27 mm Box end wrench
e 8 X 12 mm Open end wrench
¢ 10 X 14 mm Open end wrench
e 5 mm Hex wrench
e No. 2 phillips screwdriver
e No. 2 screwdriver
e Screwdriver handle
e Pliers
e Extension bar
¢ Pin spanner
e 0.7 mm Feeler gauge
e Tool bag
86
(1) Tool kit
SERIAL NUMBERS
The frame and engine serial numbers are
required when registering your motorcycle.
They may also be required by your dealer
when ordering replacement parts.
Record the numbers here for your
reference.
FRAME NO.
= (1)
TON
< AM 1
(1) Frame number
The frame number (1) is stamped on the
right side of the steering head.
The engine number (2) is stamped on top
of the crankcase.
ENGINE NO.
(2) Engine number
87
COLOUR LABEL
The colour label (1) is attached to the rear
fender below the rear seat (see page 61 ).
It is helpful when ordering replacement
parts. Record the colour and code here for
your reference.
COLOUR
CODE
(1) Colour label
88
ENGINE OIL
Refer to the Safety Precautions on page 82 .
Engine Oil
Good engine oil has many desirable
qualities. Use only high detergent, quality
motor oil certified on the container to meet
or exceed requirements for API Service
Classification SE, SF or SG.
Viscosity:
Viscosity grade of engine oil should be
based on average atmospheric temperature
in your riding area. The following provides a
guide to the selection of the proper grade or
viscosity of oil to be used at various
atmospheric temperatures.
—10 0 10 20 30 40°C
20 40 60 80 100
(1) Single grade (2) Multi grade
89
Engine Oil and Filter
Engine oil quality is the chief factor
affecting engine service life. Change the
engine oil as specified in the maintenance
schedule (page 84 ).
When running in very dusty conditions, oil
changes should be performed more
frequently than specified in the
maintenance schedule.
Please dispose of used engine oil in a
manner that is compatible with the
environment. We suggest you take it in a
sealed container to your local recycling
center or service station for reclamation. Do
not throw it in the trash or pour it on the
ground or down a drain.
Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis,
it is still advisable to thoroughly wash your
hands with soap and water as soon as possi-
ble after handling used oil.
90
Changing the oil filter requires a special oil
filter tool and a torque wrench. If you do not
have these tools and the necessary skill, we
recommend that you have your Honda
dealer perform this service.
If a torque wrench is not used for this
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Change the engine oil with the engine at
normal operating temperature and the
motorcycle on its side stand to assure
complete and rapid draining.
1. To drain the oil, remove the oil filler cap 2. Remove the oil filter (3) with a filter
and crankcase drain plug (1) and sealing wrench and let the remaining oil drain out.
washer (2). Discard the oil filter.
(1) Crankcase drain plug (2) Sealing washer (3) Oil filter
91
3. Apply a thin coat of engine oil to the new
oil filter rubber seal (4).
4. Using a special tool and a torque wrench,
install the new oil filter and tighten to a
torque of:
26 N-m (2.7 kgf-m , 20 Ibf-ft)
Use only the Honda genuine oil filter or a
filter of equivalent quality specified for your
model. Using the wrong Honda filter or a
non-Honda filter which is not of equivalent
quality may cause engine damage.
(4) Oil filter rubber seal
92
5. Check that the sealing washer on the
drain plug is in good condition and install
the plug. Replace the sealing washer
every other time the oil is changed, or
each time if necessary.
Oil Drain Plug Torque:
29 N-m (3.0 kgf-m , 22 Ibf-ft)
6. Fill the crankcase with the recommended
grade oil; approximately:
3.32 (3.5 US gt , 2.9 Imp at)
7. Install the oil filler cap.
8. Start the engine and let it idle for 2—3
minutes.
9. Several minutes after stopping the engine,
check that the oil level is at the upper
level mark in the inspection window with
the motorcycle upright on firm, level
ground. Make sure there are no oil leaks.
SPARK PLUGS
Refer to the Safety Precautions on page 82 .
Recommended plugs:
Standard:
IMR9C-9H (NGK) or
VUH27D (DENSO)
Never use a spark plug with an improper
heat range. Severe engine damage could
result.
This motorcycle uses the spark plugs that
have a iridium coated center electrode. Be
sure to observe the following when
servicing the spark plugs.
e Do not clean the spark plug. If the
electrode is contaminated with
acumulated objects or dirt, replace the
spark plug with a new one.
e Use only “wire-type feeler gauge” to
check the spark plug gap to prevent
damaging the iridium coating of the
center electrodes. Never use “leaf-type
feeler gauge”.
e Do not adjust the spark plug gap. If the
gap is out of specification, replace the
spark plug with a new one.
93
1. Remove the front cowl (page 65) and
the inner cowl (page 66 ).
2. Disconnect the radiator fan connector
3. Remove the lower mount nut (2) and
lower mount bolt (3).
4. Remove the upper mount bolt (4).
94
(2) (3)
(1) Radiator fan connector
(2) Lower mount nut
(3) Lower mount bolt
(4) Upper mount bolt
5. Move the radiator (5) out of the way and 7. Disconnect the ignition coil connectors
remove the grommet (6) from the hook (8).
(7). 8. Disconnect the ignition coils (9) from the
6. Pull the radiator toward the front. spark plugs.
(5) Radiator (7) Hook (8) Ignition coil connectors
(6) Grommet (9) Ignition coils
95
9. Clean any dirt from around the spark plug 10. Inspect the electrodes and center
bases. porcelain for deposits, erosion or carbon
Remove the spark plugs using the spark fouling. If the erosion or deposit is heavy,
plug wrench (10) furnished in the tool kit. replace the plug.
11. Make sure that the 1.0 mm wire-type
feeler gauge does not insert between the
(10) spark plug gap (11). If the gauge is
inserted into the gap, replace the plug
with a new one.
(10) Spark plug wrench (11) Spark plug gap
96
12. Make sure the plug washer is in good
condition,
13. With the plug washer attached, thread
the spark plug in by hand to prevent
cross-threading.
14. Tighten a new spark plug 1/2 turn with a
spark plug wrench to compress the
washer. If you are reusing a plug, it
should only take 1/8 —1/4 turn after the
plug seats.
The spark plug must be securely tightened.
An improperly tightened plug can become
very hot and possibly damage the engine.
15. Reinstall the ignition coils.
16. Connect the ignition coil connectors to
the ignition coils as before removal.
17. Install the remaining parts in the reverse
order of removal.
97
THROTTLE OPERATION
Refer to the Safety Precautions on page 82 .
1. Check for smooth rotation of the throttle
grip from the fully open to the fully
closed position at both full steering
positions.
2. Measure the throttle grip free play at the
throttle grip flange.
The standard free play should be
approximately:
2-4 mm (0.1—0.2 in)
To adjust the free play, loosen the lock nut
(1) and turn the adjuster (2).
98
(1) Lock nut
(2) Adjuster
IDLE SPEED
Refer to the Safety Precautions on page 82 .
The engine must be at normal operating
temperature for accurate idle speed
adjustment. Ten minutes of stop-and-go
riding is sufficient.
1. Warm up the engine, and shift to neutral,
and place the motorcycle on its side stand.
2. Adjust idle speed with the throttle stop
screw (1).
Idle speed (In neutral):
1,300 + 100 min” (rpm)
1)
(A) Increase
(B) Decrease
(1) Throttle stop screw
99
COOLANT q
Refer to the Safety Precautions on page 82. A WARNI № С
Coolant Replacement Removing the radiator cap while the
Coolant should be replaced by a Honda engine is hot can cause the coolant to
dealer, unless the owner has proper tools spray out, seriously scalding you.
and service data and is mechanically
qualified. Refer to an official Honda Service Always let the engine and radiator
Manual. cool down before removing the
radiator cap.
Always add coolant to the reserve tank. Do
not attempt to add coolant by removing the
radiator cap.
100
DRIVE CHAIN
Refer to the Safety Precautions on page 82 .
The service life of the drive chain is
dependent upon proper lubrication and
adjustment. Poor maintenance can cause
premature wear or damage to the drive
chain and sprockets.
The drive chain should be checked and
lubricated as part of the Pre-ride Inspection
(page 69 ). Under severe usage, or when
the motorcycle is ridden in unusually dusty
or muddy areas, more frequent
maintenance will be necessary.
Inspection:
1. Turn the engine off, place the motorcycle
on its side stand and shift the
transmission into neutral.
2. Check slack in the lower drive chain run
midway between the sprockets.
Drive chain slack should be adjusted to
allow the following vertical movement by
hand:
25— 35 mm (1.0—1.4 in)
3. Roll the motorcycle forward. Stop. Check
the drive chain slack. Repeat this
procedure several times. Drive chain
slack should remain constant. If the chain
is slack only in certain sections, some
links are kinked and binding. Binding and
kinking can frequently be eliminated by
lubrication.
(1) Drive chain
101
4. Roll the motorcycle forward. Stop and Damaged sprocket Worn sprocket
place it on its side stand. Inspect the drive Teeth Teeth
chain and sprockets for any of the
following conditions: Replace Replace
DRIVE CHAIN
*Damaged Rollers
*Loose Pins
*Dry or Rusted Links
*Kinked or Binding Links
*Excessive Wear
*Improper Adjustment
*Damaged or Missing O-rings
SPROCKETS
*Excessively Worn Teeth
*Broken or Damaged Teeth Normal sprocket Teeth
A drive chain with damaged rollers, loose
pins, or missing O-rings must be replaced. A GOOD
chain which appears dry, or shows signs of
rust, requires supplementary lubrication.
Kinked or binding links should be thor-
oughly lubricated and worked free. If links
cannot be freed, the chain must be replaced.
102
Adjustment;
Drive chain slack should be checked and
adjusted, if necessary, every 1,000 km (600
miles). When operated at sustained high
speeds or under conditions of frequent
rapid acceleration, the chain may require
more frequent adjustment.
4) 1)
/
оо а
( «о №
A 0 CA.
(2)
(1) Axle nut
(2) Adjusting bolt
(3) Scale
(4) Index mark
If the drive chain requires adjustment, the
procedure is as follows:
1. Place the motorcycle on its side stand
with the transmission in neutral and the
ignition switch off.
2. Loosen the axle nut (1).
3. Turn both adjusting bolts (2) an equal
number of turns until the correct drive
chain slack is obtained. Turn the
adjusting bolts counterclockwise to
tighten the chain, or clockwise to provide
more slack. Adjust the chain slack at a
point midway between the drive sprocket
and the rear wheel sprocket. Rotate the
rear wheel and recheck slack at other
sections of the chain.
Chain slack should be:
25— 35 mm (1.0— 1.4 in)
103
4. Check the rear axle alignment by
confirming the scale (3) on the drive
chain adjusters against the index marks
(4) on the swingarm.
Both left and right scales should
correspond. If the axle is misaligned, turn
the left or right adjusting bolt until the
scales correspond on both side of
swingarm and recheck chain slack.
5. Tighten the axle nut to specified torque.
Axle nut torque:
93 N-m (9.5 kgf-m , 69 Ibf-ft)
If a torque wrench is not used for this
installation, see your Honda dealer as soon
as possible to verify proper assembly.
6. Tighten the adjusting bolts lightly.
104
Wear Inspection:
Check the chain wear label when adjusting
the chain. If the red zone (6) on the label
aligns with the index mark (5) on the
swingarm after the chain has been adjusted
to the proper slack, the chain is excessively
worn and must be replaced. The proper
slack is:
25—35 mm (1.0—1.4in)
Damage to the bottom part of the frame
may be caused by excessive drive chain
slack of more than:
50 mm (2.0 in)
Replacement chain:
DID 525HV
or
RK 525ROZ1
This motorcycle has a staked master link
drive chain which requires a special tool for
cutting and staking. Do not use an ordinary
master link with this chain. See your Honda
ealer.
(5) Index mark
(6) Red zone
105
Lubrication and Cleaning:
Lubricate every 1,000 (600 miles) or
sooner if chain appears dry.
The drive chain on this motorcycle is
equipped with small O-rings between the
link plates. These O-rings retain grease
inside the chain to improve its service life.
The O-rings in this chain can be damaged
by steam cleaning, high pressure washers,
and certain solvents. Clean the side surfaces
of the chain with a dry cloth. Do not brush
the rubber O-rings. Brushing will damage
them. Wipe dry and lubricate only with SAE
80 or 90 gear oil. Commercial chain lubri-
cants may contain solvents which could
damage the rubber O-rings.
106
DRIVE CHAIN SLIDER
Refer to the Safety Precautions on page 82.
Check the chain slider (1) for wear.
The chain slider must be replaced if it is
worn to the wear limit line (2). For
replacement, see your Honda dealer.
(1) Chain slider (2) Wear limit line
107
FRONT AND REAR SUSPENSION
INSPECTION
Refer to the Safety Precautions on page 82.
1. Check the fork assembly by locking the
front brake and pumping the fork up and
down vigorously. Suspension action
should be smooth and there must be no
oil leakage. |
2. Swingarm bearings should be checked by
pushing hard against the side of the rear
wheel while the motorcycle is on a
support block. Free play indicates worn
bearings.
3. Carefully inspect all front and rear
suspension fasteners for tightness.
108
SIDE STAND
Refer to the Safety Precautions on page 82.
Perform the following maintenance in
accordance with the maintenance schedule.
Functional Check:
e Check the spring (1) for damage or loss
of tension and the side stand assembly
for freedom of movement.
e Check the side stand ignition cut-off
system:
1. Sit astride the motorcycle; put the side
stand up and the transmission in
neutral.
2. Start the engine and with the clutch
lever pulled in, shift the transmission
into gear.
3. Lower the side stand. The engine
should stop as you put the side stand
down.
If the side stand system does not operate as
described, see your Honda dealer for
service.
(1) Side stand spring
109
WHEEL REMOVAL
Refer to the Safety Precautions on page 82 .
Front Wheel Removal
1. Raise the front wheel off the ground by
placing a support block under the engine.
2. Remove the right and left caliper
assembly (1) from the fork leg by
removing the fixing bolts (2).
To avoid damage to the brake hose, support
the caliper assembly so that it doesn’t hang
from the hose. Do not twist the brake hose.
110
(1) Brake caliper assembly
(2) Fixing bolts
Do not depress the brake lever when the 3. Loosen the right and left axle pinch bolts
caliper assembly is removed. The caliper (3), and remove the axle bolt (4).
piston will be forced out of the cylinder with 4. Withdraw the front axle (5) and remove
subsequent loss of brake fluid. If this occurs, the front wheel.
servicing of the brake system will be
necessary. See your Honda dealer for this
service.
(4)
(3) (5) (3)
(3) Axle pinch bolts (4) Axle bolt
(5) Front axle
111
Installation:
1. Position the front wheel between the fork
legs and insert the front axle from the left
pide: through the left fork leg and wheel
ub.
2. Tighten the axle bolt to the specified
torque:
59 N-m (6.0 kgf-m , 43 Ibf-ft)
3. Tighten the axle pinch bolts on the right
fork leg to specified torque:
22 N-m (2.2 kgf-m , 16 Ibf-ft)
112
4. Install the right and left caliper assembly
to the fork legs and tighten the fixing
bolts to the specified torque:
30 N-m (3.1 kgf-m , 22 Ibf-ft)
To avoid damaging the brake pads while
installing the caliper assembly, carefully
fit both brake disks between the pads.
5. Temporarily tighten the axle pinch bolts
on the left fork leg until lightly seat.
6. Operate the front brake and pump the
fork several times.
7. Measure the clearance (6) between each
surface of the left brake disc ( 7 ) and the
left brake caliper body (8 ) (not brake
pads) with a 0.7 mm (0.028 in) feeler 9
gauge (9 ) (see illustration).
= (6
Го
+)
T=
fey
(8)
(7)
(6) Clearance (8) Caliper body (9) Feeler gauge
(7) Brake disc
113
8. If the feeler gauge inserts easily, tighten
the left axle pinch bolts (3) to the
specified torque:
22 N-m (2.2 kgf-m , 16 Ibf-ft)
If the feeler gauge cannot be inserted
easily, pull the left fork outward or push
inward to adjust the clearance. Then
tighten the left axle pinch bolts to the
specified torque.
9. After installing the wheel, apply the
brakes several times, then recheck the
both discs for caliper body (not brake
pads) to disc clearance. Do not operate
the motorcycle without adequate
clearance.
e Check for free wheel rotation after the
brake lever is released. Recheck the
wheel if the brake drags or if the wheel
does not rotate freely.
e Verify proper brake operation before
riding.
Failure to provide adequate disc to caliper
body (not brake pads) clearance may dam-
age the brake discs and impair braking
efficiency.
114
If the torque wrench was not used for
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.
Rear Wheel Removal
1. Raise the rear wheel off the ground by
placing a support block under the engine.
2. Loosen the rear axle nut (1).
3. кровей the drive chain adjusting bolts
2).
4. Remove the rear axle nut.
5. Remove the drive chain (3) from the
driven sprocket by pushing the rear
wheel forward.
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(1) Rear axle nut
(2) Drive chain adjusting bolts
(1)
6. Remove the axle shaft (4), side collar and
rear wheel from the swingarm.
Do not depress the brake pedal while the
wheel is off the motorcycle. The caliper
pistons will be forced out of the cylinders
with subsequent loss of brake fluid. If this
occurs, servicing of the brake system will be
necessary. See your Honda dealer for this
service.
(3) Drive chain
(4) Axle shaft
115
Installation Notes:
e To install the rear wheel, reverse the
removal procedure.
* Make sure that the slot (5) on the brake
caliper is located in the lug (6) in the
swingarm (7).
o Tighten the axle nut to the specified
torque:
93 N-m (9.5 kgf-m , 69 Ibf-ft)
e Adjust the drive chain.
When installing the wheel, carefully fit the
brake disc between the brake pads to avoid
damaging the pads.
After installing the wheel, apply the brake
several times and then check if the wheel
rotates freely. Recheck the wheel if the
brake drags or if the wheel does not rotate
freely.
116
If a torque wrench was not used for
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.
(5)
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(7) у Ne
(5) Slot (7) Swingarm
(6) Lug
BRAKE PAD WEAR
Refer to the Safety Precautions on page 82.
Brake pad wear depends upon the severity
of usage, the type of riding, and road
conditions. (Generally, the pads will wear
faster on wet and dirty roads.)
Inspect the pads at each regular
maintenance interval (page 85).
Front Brake
Check the grooves (1) in each pad.
If either pad is worn to the bottom of the
grooves, replace both pads as a set. See
your Honda dealer for this service.
(FRONT BRAKE»
lllustration shows left side,
right side similar.
(1) Cutouts
117
Rear Brake (REAR BRAKE»
Check the cutout (2) in each pad.
If either pad is worn to the cutout, replace
both pads as a set. See your Honda dealer
for this service.
(2) Cutouts
118
BATTERY
Refer to the Safety Precautions on page 82. L ÆAWARNING ИИ
It is not necessary to check the battery
electrolyte level or add distilled water as the
battery is a maintenance-free (sealed) type.
If your battery seems weak and/or is
leaking electrolyte (causing hard starting or
other electrical troubles), contact your
Honda dealer.
Your battery is a maintenance-free type and
can be permanently damaged if the cap strip
is removed.
The battery gives off explosive
hydrogen gas during normal operation.
À spark or flame can cause the
battery to explode with enough force
to kill or seriously hurt you.
Wear protective clothing and a face
shield, or have a skilled mechanic do
the battery maintenance.
119
Battery Removal
The battery (7) is in the battery box below
the front seat.
1. Remove the front seat (page 60).
2. Pull out the engine control module (1)
from the rubber band (2).
3. Unhook the rubber band.
4. Pull the clips (3) and open the battery
cover (4).
120
(1) Engine control module
(2) Rubber band
(3) Clips
(4) Battery cover
5. Disconnect the negative (—) terminal
lead (5) from the battery first, then
disconnect the positive (+) terminal lead (7) (5)
(6).
6. Pull out the battery (7) from the battery
box.
(5) Negative (—) terminal lead
(6) Positive (+) terminal lead
(7) Battery
121
FUSE REPLACEMENT
Refer to the Safety Precautions on page 82 .
When frequent fuse failure occurs, it
usually indicates a short circuit or an
overload in the electrical system. See your
Honda dealer for repair.
Never use a fuse with a different rating
from that specified. Serious damage to the
electrical system or a fire may result,
causing a dangerous loss of lights or engine
power.
122
Blown fuse
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Fuse Box:
The fuse box is located under the front seat.
The specified fuses are:
10 À, 20A
1. Remove the front seat (page 60 ).
2. Open the fuse box cover (1).
3. Pull out the old fuse and install a new fuse.
The spare fuses (2) are located in the
fuse box.
4. Close the fuse box cover and install the
front seat.
(1) Fuse box cover
(2) Spare fuses
123
Main Fuse:
[he main fuse (1) is located under the
front seat.
The specified fuse is:
30 À
1. Remove the front seat (page 60 ).
2. Disconnect the wire connector (2 ) of
the starter magnetic switch.
3. Pull out the old fuse and install a new fuse.
The spare fuse (3) is located behind the
starter magnetic switch.
4. Reconnect the connector and install the
front seat.
FI Fuse:
The FI fuse (4) is located under the front
seat.
The specified fuse is:
20 À
1. Remove the front seat (page 60 ).
2. Open the FI fuse box cover (5).
3. Pull out the old fuse and install a new fuse.
The spare fuse is located in the fuse box.
4. Close the FI fuse box cover and install
the front seat.
124
(1) (2)
(5) (4)
(1) Main fuse
(2) Wire connector
(3) Spare main fuse
(3)
(4) FI fuse
(5) FI fuse box cover
STOPLIGHT SWITCH
ADJUSTMENT
Refer to the Safety Precautions on page 82 . A (1)
NO
Check the operation of the stoplight switch LN
(1) at the right side behind the engine from № a )
time to time. done b he ad LAS
justment is done by turning the adjusting 9
nut (2). Turn the nut in the direction (A) if 9 (B) Zn )
the switch operates too late and in direction €; (A) |
(B) if the switch operates too soon. x)
(2)
(1) Stoplight switch
(2) Adjusting nut
125
BULB REPLACEMENT
Refer to the Safety Precautions on page 82 . e Be sure to turn the ignition switch OFF
when replacing the bulb.
The light bulb becomes very hot while the e Do not use bulbs other than that specified.
light is ON, and remain hot for a while after e After installing a new bulb, check that the
it is turned OFF. Be sure to let it cool down light operates properly.
before servicing.
Do not put finger prints on the headlight
bulb, as they may create hot spots on the
bulb and cause it to break.
Wear clean gloves while replacing the bulb.
If you touch the bulb with your bare hands,
clean it with a cloth moistened with alcohol
to prevent its early failure.
126
Headlight Bulb
1. Remove the inner panel (page 67 ).
2. Remove the hook (1) from the stay (2).
3. Pull off the socket (3) without turning.
4. Remove the dust cover (4).
5. Remove the bulb (6) while pressing
down on the pin (5).
6. Pull out the bulb (6) without turning.
7. Install a new bulb in the reverse order of
removal.
e Install the dust cover with its “TOP”
mark facing up.
(2) (6)
(3)
(1) (5) (4)
(1) Hook (4) Dust cover
(2) Stay (5) Pin
(3) Socket (6) Bulb
127
Position Light Bulb
(Except U type)
1. Turn the position light socket (1)
approximately 45° counterclockwise,
then pull it out toward you.
2. Pull out the bulb (2) without turning.
3. Install a new bulb in the reverse order of
removal.
(1) Position light socket
(2) Bulb
128
Stop/Taillight Bulb
1. Remove the rear seat (page 61).
2. Turn the socket (1) approximately 45°
counterclockwise, then pull it out toward
you.
3. Pull out the bulb (2) without turning.
4. Install a new bulb in the reverse order of
removal.
(2)
(1) Socket
(2) Bulb
129
Front/Rear Turn Signal Bulb
1. Remove the rear turn signal lens (1) and
the lens packing (4) by removing the
screw (2).
2. Slightly press the bulb (3) and turn it
counterclockwise.
3. Install a new bulb in the reverse order of
removal.
(1)
(3)
(1) Lens (3) Bulb
(2) Screw (4) Lens packing
130
License Light Bulb
1. Remove the A nuts (1), washer and
license plate bracket (2).
2. Remove the B nuts (3), license light
cover (4), license light lens (5) and
socket (6) from the license plate bracket.
3. Slightly press the bulb (7) and turn it
counterclockwise.
4. Install a new bulb in the reverse order of
removal.
(3) (2)
(1) A nuts
(2) License plate bracket
(3) B nuts
(4) License light cover
(5) License light lens
(6) Socket
(7) Bulb
131
CLEANING
Clean your motorcycle regularly to protect
the surface finishes and inspect for damage,
wear, and oil, coolant or brake fluid leakage.
Avoid cleaning products that are not
specifically designed for motorcycle or
automobile surfaces.
They may contain harsh detergents or
chemical solvents that could damage the
metal, paint, and plastic on your motorcycle.
If your motorcycle is still warm from recent
operation, give the engine and exhaust
system time to cool off.
We recommend avoiding the use of high
pressure water spray (typical in coin-
operated car washes).
132
High pressure water (or air) can damage
certain parts of the motorcycle.
Do not apply the pressured water directly to
the air intake. The water can be drawn into
the throttle body and/or enter the air
cleaner.
(1) Air intake
Washing the motorcycle
1. Rinse the motorcycle thoroughly with
cool water to remove loose dirt.
2. Clean the motorcycle with a sponge or
soft cloth using cool water.
Avoid directing water to muffler outlets
and electrical parts.
3. Clean the plastic parts using a cloth or
sponge dampened with a solution of mild
detergent and water. Rub the soiled area
gently rinsing it frequently with fresh
water.
Take care to keep brake fluid or chemical
solvents off the motorcycle.
They will damage the plastic and painted
surfaces.
The inside of the headlight lens may be
clouded immediately after washing the
motorcycle. Moisture condensation inside
the headlight lens will disappear gradually
by lighting the headlight in high beam. Run
the engine while keeping the headlight on.
4. After cleaning, rinse the motorcycle
thoroughly with plenty of clean water.
Strong detergent residue can corrode
alloy parts.
5. Dry the motorcycle, start the engine, and
let it run for several minutes.
6. Test the brakes before riding the
motorcycle. Several applications may be
necessary to restore normal braking
performance.
7. Lubricate the drive chain immediately
after washing and drying the motorcycle.
Braking efficiency may be temporarily
impaired immediately after washing the
motorcycle.
Anticipate longer stopping distance to avoid
a possible accident.
133
Finishing Touches
After washing your motorcycle, consider
using a commercially-available spray
cleaner/polish or quality liquid or paste wax
to finish the job. Use only a non-abrasive
polish or wax made specifically for
motorcycles or automobiles. Apply the
polish or wax according to the instructions
on the container.
If a surface on your motorcycle is chipped
or scratched, your Honda dealer has touch-
up paint to match your motorcycle’s colour.
Be sure to use your motorcycle’s colour
code (page 88) when you buy touch-up
paint.
134
Removing Road Salt
The salt contained in the road surface
freezing prevention medicine which a road
was sprayed with in winter, and the
seawater becomes the cause which rust
occurs in.
Wash your motorcycle by the following
point after it runs through such a place.
1. Clean the motorcycle using cool water
(page 132 ).
Do not use warm water.
This worsens the effect of the salt.
2. Dry the motorcycle and the surface of the
metal is protected with the wax.
Painted Aluminum Wheel Maintenance
Aluminum may corrode from contact with
dirt, mud, or road salt. Clean the wheels
after riding through any of these
substances. Use a wet sponge and mild
detergent. Avoid stiff brushes, steel wool, or
cleaners containing abrasives or chemical
compounds.
After washing, rinse with plenty of water
and dry with a clean cloth.
Apply touch-up paint to the wheels where
damage has resulted.
135
STORAGE GUIDE
Extended storage, such as for winter,
requires that you take certain steps to
reduce the effects of deterioration from
non-use of the motorcycle. In addition,
necessary repairs should be made BEFORE
storing the motorcycle; otherwise, these
repairs may be forgotten by the time the
motorcycle is removed from storage.
STORAGE
1. Change the engine oil and filter.
2. Make sure the cooling system is filled
with a 50/50 % antifreeze solution.
3. Empty the fuel tank into an approved
petrol container using a commercially
available hand siphon or an equivalent
method. Spray the inside of the tank with
an aerosol rust-inhibiting oil.
Reinstall the fuel fill cap on the tank.
136
TCR
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
e Stop the engine and keep heat,
sparks, and flame away.
e Refuel only outdoors.
e Wipe up spills immediately.
4. To prevent rusting in the cylinders,
perform the following:
e Remove the ignition coil connectors
and ignition coils from the spark plugs.
Using tape or string, secure the
connectors to any convenient plastic
body part so that they are positioned
away from the spark plugs.
e Remove the spark plugs from the
engine and store them in a safe place.
Do not connect the ignition coils to the
ignition coil connectors.
e Pour a tablespoon (15—20 cm’) of
clean engine oil into each cylinder and
cover the spark plug holes with a piece
of cloth.
e Crank the engine several times to
distribute the oil.
¢ Reinstall the spark plugs, ignition coils
and ignition coil connectors.
5. Remove the battery. Store in an area
protected from freezing temperatures
and direct sunlight.
Slow charge the battery once a month.
6. Wash and dry the motorcycle. Wax all
painted surfaces. Coat chrome with
rustinhibiting oil.
7. Lubricate the drive chain (page 106 ).
8. Inflate the tyres to their recommended
pressures. Place the motorcycle on blocks
to raise both tyres off the ground.
9. Cover the motorcycle (don’t use plastic or
other coated materials) and store in an
unheated area, free of dampness with a
minimum of daily temperature variation.
Do not store the motorcycle in direct
sunlight.
137
REMOVAL FROM STORAGE
1. Uncover and clean the motorcycle.
Change the engine oil if more than 4
months have passed since the start of
storage.
2. Charge the battery as required. Install the
battery.
3. Drain any excess aerosol rust-inhibiting
oil from the fuel tank. Fill the fuel tank
with fresh petrol.
4. Perform all Pre-ride Inspection checks
(page 69).
Test ride the motorcycle at low speeds in
a safe riding area away from traffic.
138
SPECIFICATIONS
DIMENSIONS
Overall length
Overall width
Overall height
Wheelbase
WEIGHT
Dry weight
CAPACITIES
Engine oil After draining
After draining and
oil filter change
After disassembly
Fuel tank
Cooling system capacity
Passenger capacity
Maximum weight capacity
2,100 mm (82.7 in)
685 mm (27.0 in)
1,135 mm (44.7 in)
1,385 mm (54.5 in)
169 kg (373 Ibs) ... Except G
170 kg (375 Ibs) ... G
(3.2 US qt, 2.6 Imp qt)
Q
2 (3.5 US gt , 2.9 Imp gt)
2 (3.9 US gt , 3.3 Imp gt)
8.0 2 (4.76 US gal , 3.96 Imp gal)
7 2 (2.9 US gt, 2.4 Imp gt)
Operator and one passenger
189 kg (417 Ibs)
3.0
3.3
3.7
18.
2.
139
ENGINE
Bore and stroke
Compression ratio
Displacement
Spark plug
Standard
Idle speed
Valve clearance (Cold)
140
67.0 x 42.5 mm (2.64 x 1.67 in)
12.0:1
599 cm? (36.5 cu-in)
IMR9C-9H (NGK) or
VUH27D (DENSO)
1,300 + 100 min” (rpm)
Intake 0.20 mm (0.008 in)
Exhaust 0.28 mm (0.011 in)
CHASSIS AND SUSPENSION
Caster
Trail
Tyre size, front
Tyre size, rear
POWER TRANSMISSION
Primary reduction
Gear ratio, 1st
2nd
3rd
4th
5th
6th
Final reduction
24°
96 mm (3.8 in)
120/70ZR17 (58W)
180/55ZR17 (73W)
1.822
2.833
2.062
1.647
1.421
1.272
1.173
2.875
141
ELECTRICAL
Battery
Generator
LIGHTS
Headlight
Tail/brake light
Turn signal light Front
Rear
Position light
License light
FUSE
Main fuse
FI fuse
Other fuses
142
12V—8.6 Ah
0.433 kW
12V—-55W
12 V— 21/5 W
12V—21W
12V—21 W
12V—-5W... Except U
12V—-5W
30A
20A
10A, 20A
CATALYTIC CONVERTER
(For G>
This motorcycle is equipped with a catalytic
converter.
The catalytic converter contains precious
metals that serve as catalysts, promoting
chemical reactions to convert the exhaust
gasses without affecting the metals.
The catalytic converter acts on HC, CO, and
NOx. A replacement unit must be an
original Honda part or its equivalent.
The catalytic converter must operate at a
high temperature for the chemical reactions
to take place. It can set on fire any
combustible materials that come near it.
Park your motorcycle away from high
grasses, dry leaves, or other flammables.
A defective catalytic converter contributes
to air pollution, and can impair your engine’s
performance. Follow these guidelines to
protect your motorcycle’s catalytic
converter.
¢ Always use unleaded petrol. Even a small
amount of leaded petrol can contaminate
the catalyst metals, making the catalytic
converter ineffective.
e Keep the engine tuned-up.
e Have your motorcycle diagnosed and
replaced if it is misfiring, backfiring,
stalling or otherwise not running properly.
143
NOISE CONTROL SYSTEM (AUSTRALIA ONLY)
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners are
warned that the law may prohibit : (a) The removal or rendering inoperative by any person
other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after
such device or element of design has been removed or rendered inoperative by any person.
144
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