NSR 150 SP

NSR 150 SP
~ON"D.A.
For the new horizons
NSR 150 SP
33 KW6N E1 ASH
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NOISE CONTROL SYSTEl\1 (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 the 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.
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OWNER'S MANUAL
NSR 150 SP
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.
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IMPORTANT NOTICE
• OPERATOR AND PASSENGER
This motorcycle is designed to carry the operator and one passenger. Never exceed
the maximum weight capacity as shown on the tyre information labe/.
• ON-ROAD USE
This motorcycle is designed to be used only on the road.
• READ THIS OWNER'S MANUAL CAREFULLY
Pay special attention to statements preceded by the following words:
AWARNING
Indicates a strong possibility of severe personal injury or death if instructions
are not followed.
CAUTION:
Indicates a possibility of personal injury or equipment damage if instructions
are not followed.
NOTE: Gives helpful information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcycle when resold.
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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-ride 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.
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!
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OPERATION
Page
Page
Page
1.
1.
2.
2.
3.
6.
9.
15.
23. Fuel
27. Engine Oil
29. Tubeless tyres
38.
39.
40.
41.
42.
Document Bag
Side Cover
Middle Fairing
Lower Fairing
Inner Fairing
43.
43.
44.
47.
48.
49.
50.
51.
OPERATION
Pre-ride Inspection
Starting the Engine
Running-in
Riding
Braking
Parking
Anti-theft Tips
MOTORCYCLE SAFETY
Safe Riding Rules
Protective Apparel
Modifications
Loading and Accessories
PARTS LOCATION
Instruments and Indicators
MAJOR COMPONENTS
(Information you need to
operate this motorcycle)
15. Brakes
19. Clutch
21. Coolant
32. ESSENTIAL INDIVIDUAL
COMPONENTS
32. Ignition Switch
33. Right Handlebar Controls
34. Left Handlebar Controls
35. FEATURES
(Not required for operation)
35. Steering Lock
36. Seat
37. Helmet Holder
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MAINTENANCE
Page
52.
53.
56.
57.
58.
59.
61.
64.
66.
MAINTENANCE
Maintenance Schedule
Tool Kit
Serial Numbers
Maintenance Precautions
Maintenance Stand
Transmission Oil
Spark Plugs
Throttle Operation
68.
69.
73.
74.
Idle Speed
Drive Chain
Drive Chain Slider
Side Stand
Page
75. Brake Pad Wear
77. Wheel Removal
81. Battery
84. Fuse Replacement
86. Bulb Replacement
90. Stoplight Switch Adjustment
91. CLEANING
93. STORAGE GUIDE
93. Storage
95. Removal From Storage
96. SPECIFICATIONS
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MOTORCYCLE SAFETY
Make yourself conspicuous to help avoid the
accident that wasn't your fault:
• Wear bright or reflective clothing.
• Don't ride in another motorist's "blind spot."
4. Obey all national and local laws and
regulations.
• Excessive speed is a factor in many
accidents. Obey the speed limits, and
NEVER travel faster than conditions warrant.
• Signal before you make a turn or lane
change. Your size and maneuverability can
surprise other motorists.
5. Don't let other motorists surprise you. Use
extra caution at intersections, parking lot
entrances and exits, and driveways.
6. Keep both hands on the handlebars and
both feet on the footpegs while riding. A
passenger should hold on to the motorcycle or the operator with both hands and
keep both feet on the passenger footpegs.
A.WARNING
• Motorcycle riding requires special
efforts on your part to ensure your
safety. Know these requirements
before you ride:
SAFE RIDING RULES
1. Always make a pre-ride inspection (page
43) before you start the engine. You may
prevent an accident or equipment damage.
2. Many accidents involve inexperienced
riders. Most countries require a special
motorcycle riding test or license. Make
sure you are qualified before you ride.
NEVER lend your motorcycle to an
inexperienced rider.
3. Many automobile/motorcycle accidents
happen because the automobile driver does
not "see" the motorcyclist.
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PROTECTIVE APPAREL
MODIFICATIONS
1. Most motorcycle accident fatalities are
due to head injuries: ALWAYS wear a
helmet. You should also wear a face
shield or goggles as well as boots, gloves
and protective clothing. A passenger
needs the same protection.
2. The exhaust system becomes hot during
operation, and it remains hot for a while
after stopping the engine. Be careful not
to touch the exhaust system while it is
hot. Wear clothing that fully covers your
legs.
3. Do not wear loose clothing which could
catch on the control levers, footpegs or
wheels.
AWARNING
• Modification of the motorcycle, or
removal of original equipment, may
render the vehicle unsafe or illegal.
Obey all national and local equipment
regulations.
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Loading
LOADING AND ACCESSORIES
1. Keep cargo and accessory weight low
and close to the center of the
motorcycle. Load weight equally on
both sides to minimize imbalance. As
weight is located further from the
motorcycle's center of gravity, handling
is proportionally affected.
2. Adjust tyre pressure (page 29) to suit
load weight and riding conditions.
AWARNING
• To prevent an accident, use extreme
care when adding and riding with
accessories and cargo. Addition of
accessories and cargo can reduce a
motorcycle's stability, performance and
safe operating speed. Never ride an
accessory-equipped motorcycle at
speeds above 130 kmlh (80 mph). And
remember that this 130 kmlh (80 mph)
limit may be reduced by installation of
non-Honda accessories, improper
loading, worn tyres and overall
motorcycle condition, poor road or
weather conditions. These general
guidelines may help you decide whether
or how to equip your motorcycle and
how to load it safely.
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Accessories
Genuine Honda accessories have been
specifically designed for and tested on this
motorcycle. Because the factory cannot
test all other accessories, you are personally responsible for proper selection,
installation, and use of non-Honda accessories. Always follow the guidelines under
Loading, and these:
1. Carefully inspect the accessory to make
sure it does not obscure any lights, reduce
ground clearance and banking angle, or
limit suspension travel, steering travel or
control operation.
2. Large fork-mounted fairings or windshields, or poorly designed or improperly mounted fairings can produce
aerodynamic forces that cause unstable
handling. Do not install fairings that
decrease cooling air flow to the engine.
3. Vehicle handling and stability can be
adversely affected by loose cargo.
Recheck cargo security and accessory
mounts frequently.
4. Do not attach large or heavy items
(such as a sleeping bag or tent) to the
handlebars, fork, or fender. Unstable
handling or slow steering response may
result.
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3. Accessories which alter your riding
position by moving hands or feet away
from controls may increase reaction
time in an emergency.
4. Do not add electrical equipment that
will exceed the motorcycle's electrical
system capacity. A blown fuse could
cause a dangerous loss of lights or
engine power.
5. This motorcycle was not designed to
pull a sidecar or trailer. Handling may
be seriously impaired if so equipped.
6. Any modification of the COOling system
may cause overheating and serious
engine damage. Do not modify the
radiator shrouds or install accessories
which block or deflect air away from the
radiator.
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PARTS LOCATION
Indicators
Coolant temperature gauge
Rearview mirror
Fuel gauge
Clutch lever
Front brake lever
~---
Throttle grip
Engine stop switch
Turn signal switch
Horn button
Fuel fill cap
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Ignition switch
Battery
Passenger footpeg
Coolant reserve tank
Fuse box
Footpeg
Rear brake pedal
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Kickstarter pedal
Fuel cock
Toolbox
Choke knob
Engine oil tank
Gearshift pedal
Side stand
Footpeg
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Passenger footpeg
INSTRUMENT AND INDICATORS
The indicators are located within and near
the instrument panel.
Their functions are described in the table
on the following page.
(1) Speedometer
(2) Odometer
(3) Tachometer
(4) Tachometer red zone
(5) Low oil level indicator
(6) Coolant temperature gauge
(7) Fuel gauge
(8) Neutral indicator
(9) Turn signal indicator
(10) High beam indicator
(11) Tripmeter
(12) Tripmeter reset knob
(4)
(3)
(5)
(12)
(11) (10)
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(9)
(8)
(7)
Ref. No.
Description
Function
(1 )
Speedometer
Shows riding speed.
(2)
Odometer
Shows accumulated mileage.
(3)
Tachometer
Shows engine rpm.
(4)
Tachometer red zone
Never allow the tachometer needle to
enter the red zone, even after the
engine has been broken in.
CAUTION:
•
(5)
Running the engine beyond
recommended maximum engine
speed (tachometer red zone) can
damage the engine.
Lights when oil level is low (see page
12).
Low oil level indicator
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Ref. No.
Description
Function
(6)
Coolant temperature gauge
Shows coolant temperature. (see
page 13).
(7)
Fuel gauge
Shows approximate fuel supply
available (see page 14).
(8)
Neutral indicator
Lights when the transmission is in
neutral.
(9)
Turn signal indicator
Flashes when either turn signal is
operated.
(10)
High beam indicator
Lights when the head light is on high
beam.
(11 )
Tripmeter
Shows mileage per trip.
(12)
Tripmeter reset knob
Resets tripmeter to zero (0) by turning
the knob in direction shown.
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Low Oil Level Indicator
The low oil level indicator (1) lights when
the 2-stroke engine oil is below
approximately:
AWARNING
• If the low oil level indicator comes
on while riding, stop riding and shut
the engine off. Fill the oil tank to the
UPPER level ridge with the
recommended oil (page 28).
Continuing to ride with a low oil
level may lead to engine failure that
could result in an accident.
(1) Low oil level indicator
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Coolant Temperature Gauge
CAUTION:
When the needle begins to move above the
C (Cold) mark, the engine is warm enough
for the motorcycle to be ridden. The normal
operating temperature range is within the
section between the Hand C marks. If the
needle reaches the H (Hot) mark, stop the
engine and check the reserve tank coolant
level. Read page 21-22 and do not ride the
motorcycle until the problem has been
corrected.
(1 )
• Exceeding maximum running
temperature may cause serious
engine damage.
(1) Coolant temperature gauge
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Fuel Gauge
The fuel gauge (1) shows the approximate
fuel supply available. At F (Full), the fuel
tank capacity including reserve is :
(1 )
10.5 I (2.8 US gal, 2.3 Imp gal)
When the gauge needle first points to
RES, refill the tank as soon as possible. At
RES there is :
2.7 I (0.7 US gal, 0.6 Imp gal)
(1) Fuel gauge
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Front Brake
Front Brake Fluid Level:
MAJOR COMPONENTS
(Information you need to operate this
motorcycle)
AWARNING
AWARNING
•
•
Brake fluid may cause irritation. Avoid
contact with skin or eyes. In case of
contact, flush thoroughly with water and
call a doctor if your eyes were exposed.
• KEEP OUT OF REACH OF CHILDREN.
If the Pre-ride Inspection (page 43) is
not performed, severe personal injury
or vehicle damage may result.
BRAKES
CAUTION:
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
75), there is probably air in the brake system and it
must be bled. See your authorized Honda dealer
for this service.
•
Handle brake fluid with care because it
can damage plastic and painted surfaces.
When adding brake fluid, be sure the
reservoir is horizontal before the cap is
removed or brake fluid may spill out.
• Use only DOT 3 or 4 brake fluid from a
sealed container.
• Never allow contaminants such as dirt or
water to enter the brake fluid reservoir.
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Check that the fluid level is above the
LOWER level mark (1) with the motorcycle in an upright position.
Brake fluid must be added to the reservoir
whenever the fluid level begins to reach
the LOWER level mark (1). Remove the
screws (2), reservoir cover (3), diaphragm
plate (4), diaphragm (5), and float (6). Fill
the reservoir with DOT 3 or 4 BRAKE
FLUID from a sealed container up to the
upper level mark (7). Reinstall the float,
diaphragm, diaphragm plate, and cover.
Tighten the screws securely.
Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses
and fittings.
(1) LOWER level mark (4) Diaphragm plate
(2) Screws
(5) Diaphragm
(3) Reservoir cover
(6) Float
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Rear Brake
Rear Brake Fluid Level:
CAUTION:
• Handle brake fluid with care because
it can damage plastic and painted
surfaces. When adding brake fluid,
be sure the reservoir is horizontal
before the cap is removed or brake
fluid may spill out.
• Use only DOT 3 or 4 brake fluid from
a sealed container.
• Never allow contaminants such as
dirt or water to enter the brake fluid
reservoir.
AWARNING
• Brake fluid may cause irritation.
Avoid contact with skin or eyes. In
case of contact, flush thoroughly
with water and call a doctor if your
eyes were exposed.
• KEEP OUT OF REACH OF CHILDREN.
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Check the brake fluid level from the inspection
window (1) of the right side cover with the
motorcycle in an upright position.
Brake fluid must be added to the reservoir
whenever the fluid level begins to reach the
LOWER level mark (2). Remove the right side
cover (page 39). Remove the screws (3),
reservoir cover(4), diaphragm plate (5) and
diaphragm (6). Fill the reservoir with DOT 3 or
4 BRAKE FLUID from a sealed container up to
the UPPER level mark (7). Reinstall the
diaphragm, diaphragm plate and cap securely.
(3)
(4)
(7)
(2)
-----f~
(2) LOWER level mark (5) Diaphragm plate
(3) Screws
(6) Diaphragm
(4) Reservoir cover
(7) UPPER level mark
Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses
and fittings.
(1) Inspection window
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CLUTCH
1. Loosen the lock nut (2) and turn the
adjuster (3). Tighten the lock nut (2)
and check the adjustment.
2. If the adjuster is threaded out near its
limit or if the correct free play cannot be
obtained, loosen the lock nut (2) and
turn in the cable adjuster (3) completely.
Tighten the lock nut (2).
Clutch adjustment may be required if the
motorcycle stalls when shifting into gear
or tends to creep; or if the clutch slips,
causing acceleration to lag behind engine
speed. Minor adjustments can be made
with the clutch cable adjuster (3) at the
lever (1).
Normal clutch lever free play is :
10-20 mm (0.4-0.8 in)
(2)~J'~(3)
®
(2) Lock nut
(3) Clutch cable adjuster
(A) Decrease free play
(8) Increase free play
(1) Clutch lever
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(8)
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.
(4)
3. Loosen the lock nut (4) at the lower end
of the cable. Turn the adjusting nut (5)
to obtain the specified free play. Tighten
the lock nut (4) and check the
adjustment.
4. 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.
(5)
NOTE:
• If proper adjustment cannot be obtained
or the clutch does not work correctly,
see your authorized Honda dealer.
(4) Lock nut
(A) Increase free play
(5) Adjusting nut (8) Decrease free play
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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.
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.)
CAUTION:
• 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.
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If the reserve tank is empty, or if coolant
loss is excessive, check for leaks and see
your authorized Honda dealer for repair.
Inspection
The reserve tank is under the front seat.
Check the coolant level in the reserve tank
(1) while the engine is at the normal
operating temperature with the motorcycle in an uplight position. If the coolant
level is below the LOW level mark (2),
remove the reserve tank cap (3). Add
coolant mixture until it reaches the
UPPER level mark (4). Do not remove the
radiator cap.
(3)
(2)
(4)
-~-r="-~
AWARNING
• Do not remove the radiator cap when
the engine is hot. The coolant is
under pressure and could scald you.
(1 )
(1) Reserve tank
(2) LOWER level mark
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(3) UPPER level mark
(4) Reserve tank cap
FUEL
AWARNING
FuelCock
The fuel cock (1) is under the left side of the
fuel tank. Set it to ON for normal operation
or RES when you start to run out of the
main fuel supply. The OFF setting is only
for long term storage or servicing of fuel
system components.
• To avoid running out of fuel that may
result in a sudden stop, learn how to
operate the fuel cock when riding the
motorcycle.
NOTE:
• Remember to check that the fuel cock is
in the ON position each time you refuel. If
the cock is left in the RES position, you
may run out of fuel with no reserve.
Reserve Fuel
When the main fuel supply is gone, turn the
fuel cock to RES. Refill the tank as soon as
possible after switching to RES, then switch
the cock back to ON.
The reserve fuel supply is :
2.7 I (0.7 US gal, 0.6 lnip gal)
(1) Fuel cock
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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. Use unleaded or lowlead 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.
Fuel Tank
The fuel tank capacity including the reseNe
supply is :
10.5 I (2.8 US gal, 2.3 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.
'ljC;;zG(3
i ~.~ ~~~.
1
CAUTION:
~ ~ . ., . . . .
• 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 authorized Honda dealer. Failure
to do so is considered misuse, and
damage caused by misuse is not
covered by Honda's Limited Warranty.
(2)--~~
(1 )
(1) Fuel fill cap
(2) Ignition key
(3) Filler neck
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AWARNING
• Petrol is extremely flammable and is
explosive under certain conditions.
Refuel in a well-ventilated area with the
engine stopped. Do not smoke or allow
flames or sparks in the area where petrol
is stored or where the fuel tank is
refueled.
• Do not overfill the tank (there should be
no fuel in the filler neck (3). After
refueling, make sure the fuel fill cap is
closed securely.
• Be careful not to spill fuel when
refueling. Spilled fuel or fuel vapor may
ignite. If any fuel is spilled, make sure
the area is dry before starting the
engine.
• Avoid repeated or prolonged contact
with skin or breathing of vapor. KEEP
OUT OF REACH OF CHILDREN.
(3) Filler neck
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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 cosol-vents and
corrosion inhibitors for methanol. Never
use petrol containing more than 5%
methanol, even if it has cosolvents and
corrosion inhibitors.
NOTE:
• Fuel system damage or engine
performance problems resulting from
the use of fuels that contain alcohol is
not covered underthewarranty. Honda
cannot endorse the use of fuels
containing methanol since evidence of
their suitability is as yet incomplete.
• Before buying fuel from an unfamiliar
staion, 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.
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To fill, remove the front seat (page 36),
remove the oil tank cap (1), and fill with the
recommended oil up to the UPPER LEVEL
ridge (2).
Oil capacity : 1.2 I
ENGINE OIL
Oil Level
When the low oil level indicator lights, it means
the oil level in the oil tank is low; stop the engine
and fill the oil tank as soon as possible.
AWARNING
•
(1 )
If the low oil level indicator comes on
while riding, stop riding and shut the
engine off. Fill the oil tank to the UPPER
level ridge with the recommended oil (see
page 28). Continuing to ride with a low oil
level may lead to engine failure that could
result in an accident.
CAUTION:
•
If the engine has been run after the low oil
level indicator has come on, the
motorcycle must be taken to an authorized
Honda dealer for inspection and bleeding
of the oil system. Failure to do this will
result in serious engine damage.
(1) Oil tank cap
(2) Upper level ridge
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Oil Recommendation:
USE HONDA 2-STROKE OIL OR AN
EQUIVALENT
CAUTION:
• The use of improper oils may cause
excessive and/or premature carbon
buildup in the engine and exhaust
system, resulting in loss of power
and possible engine damage.
Genuine Honda 2-stroke Oil has been
specifically designed and tested in
Honda scooters and is a proper oil.
NOTE:
• When filling, do not let dirt or other
foreign materials enter the tank.
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TUBELESS TYRES
Tyre size
This motorcycle is equipped with tubeless
tyres, valves, and wheel rims. Use only
tyres marked "TUBELESS" and tubeless
valves on rims marked "TUBELESS TYRE
APPLICABLE" .
Proper air pressure will provide maximum
stability, riding comfort and tyre life.
Check tyre pressure frequently and adjust
if necessary.
Front 90/80 - 17 46S
Rear 120/80 - 17 61 S
Rider only
Cold tyre
pressure
kPa
(kgf/cm2, psi)
NOTE:
• Tyre pressure should be checked before
you ride while the tyres are "cold".
• Tubeless tyres have some degree of
selfsealing ability if they are punctured,
and leakage is often very slow. Inspect
very closely for punctures, especially if
the tyre is not fully inflated.
Front 200 (2.0, 29)
Rear 200 (2.0, 29)
Rider and passenger
Front 200 (2.0, 29)
Rear 200 (2.0, 29)
IRe
Tyre brand
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Front NF46
Rear NR57
Check the tyres for cuts, embedded nails
or other sharp objects. Check the rims for
dents or deformation. If there is any
Replace tyres before tread depth at the
center of the tyre reaches the following
limit:
damage, see your authorized Honda
Minimum tread depth
dealer for repair, replacement, and
balancing.
AWARNING
Front:
1.5 mm (0.06 in)
Rear:
2.0 mm (0.08 in)
• Improper tyre inflation will cause
abnormal tread wear and create a
safety hazard. Underinflation may
result in the tyre slipping on, or
coming off of the rim causing tyre
deflation that may result in a loss
of vehicle control.
• Operation with excessively worn
tyres is hazardous and will adversely
affect traction and handling.
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Tyre Repair/Replacement:
See your authorized Honda Dealer.
AWARNING
• To avoid possible repair failure and
tyre deflation that may result in a loss of
vehicle control, do not exceed 80 km/h
(50 mph) for the first 24 hours, or 130
km/h (80 mph) at any time, after tyre
repair.
• Replace the tyre if the sidewall is
punctured or damaged. Sidewall flexing
may cause repair failure and tyre
deflation that may result in a loss of
vehicle control.
AWARNING
• The use of tyres other than those listed on
the tyre information label may adversely
affect handling.
• Do not install tube-type tyres on tubeless
rims. The beads may not seat and the tyres
could slip on the rims, causingtyre deflation
that may result in a loss of vehicle control.
• Do not install a tube inside a tubeless tyre.
Excessive heat build-up may cause the
tube to burst resulting in rapid tyre deflation
that may result in a loss of vehicle control.
• Proper wheel balance is necessary for
safe, stable handling of the motorcycle.
Do not remove or change any wheel
balance weights. When wheel balancing
is required, see your authorized Honda
dealer. Wheel balancing is required after
tyre repair or replacement.
CAUTION:
•
Do not try to remove tubeless tyres
without special tools and rim protectors.
You may damage the rim sealing surface
or disfigure the rim.
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ESSENTIAL INDIVIDUAL
COMPONENTS
IGNITION SWITCH
The ignition switch (1) is below the indicator panel.
(1 )
'I
\
.
(1) Ignition switch
Key Position
Function
LOCK
(steering lock)
Steering is locked. Engine and lights
cannot be operated.
Key can be removed
OFF
Engine and lights cannot be operated.
Key can be removed
ON
Engine and lights can be operated.
Key cannot be removed
Key Removal
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RIGHT HANDLEBAR CONTROLS
(1 )
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 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.
(1) Engine stop switch
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LEFT HANDLEBAR CONTROLS
Turn Signal Switch (4)
Moveto <III! to signal a left turn, .. to signal
a right turn. Press to turn signal off.
Headlight Switch (1)
The headlight switch (1) has two positions: H
and OFF, marked by a white dot under H.
Horn Button (5)
Press the button to sound the horn.
H : Headlight, taillight, position
light and meter lights on.
OFF (dot) : Headlight, taillight, position
light and meter lights off.
(1)
Headlight Dimmer Switch (2)
Push the dimmer switch to "HI" to select
high beam or to "LO" to select low beam.
(3)
(4) -~;::!g~,:,,-/
Passing Light Control Switch (3)
When this switch is pressed, the headlight
flashes on to signal approaching cars or
when passing.
(5)
(1)
(2)
(3)
(4)
(5)
Headlight switch
Headlight dimmer switch
Passing light control switch
Turn signal switch
Horn button
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(2)
FEATURES
(Not required for operation)
(1 )
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.
AWARNING
• Do not turn the key to LOCK while
riding the motorcycle; loss of vehicle
control will result.
(1) Ignition key
(A) Push in
(8) Turn to LOCK
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SEAT
Front seat
Rear seat
Removal:
1. Remove the rear seat.
2. Pull the seat lock lever (1) up. Then pull
the front seat (2) up and back.
Removal:
1. Insert the ignition key into the seat lock
(1) and turn it clockwise.
2. Pull the rear seat (2) back and up.
Installation:
1. Insert the tab (3) into the recess under
the frame.
2. Push down on the rear of the front seat.
Installation :
1. Insert the tab (3) into the recess under
the frame. Push down on the rear of the
rear seat.
(1) Seat lock lever
(2) Front seat
(3) Tab
(2) Rear seat
(3) Tab
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HELMET HOLDER
(1 )
The helmet holders are located below the
rear seat.
Remove the rear seat (page 36).
Hang the helmets on the holder hooks (1).
Install the rear seat and lock it securely.
AWARNING
• The helmet holder is designed for
helmet security while parked. Do not
ride with a helmet attached to the
holder; the helmet may interfere
with safe operation and result in loss
of control.
(1) Helmet holder hooks
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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
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SIDE COVER
<Left side cover>
Removal:
1. Remove the rear and front seat (page
36).
2. Remove the bolt (1) and screws (2).
3. Gently pull out two prongs (3), and pull
the two tabs (4) out of their slots.
4. Remove the side cover (5).
-~}
<Right side cover>
;~~~~\'},i/
(2)
',/
,
(2)(3)
/
f4J~~ F~~-:;/
(5)
(biJ\-ljr~
[de:
J (3)
(5)
(2)
(1) Bolt
(2) Screws
(3) Prong
(1)
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(3)
GI~(1)
'<J
(2)
(4) Tab
(5) Side cover
(1 )
MIDDLE FAIRING
Removal:
1. Remove the screws (1).
2. Pull down the middle fairing (2) and
remove it.
(2)
(1) Screws
(2) Middle fairing
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LOWER FAIRING
Removal:
1. Remove the screws (1).
2. Remove the tachometer cable (2) from
cable guide.
3. Remove the carburetor drain tube (3)
from guide hole.
(1 )
(1 )
(1) Screw
(2) Tachometer cable
(3) Tube
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(1 )
INNER COVER
Removal:
1. Remove two screws (1).
2. Remove the inner cover (2).
(1) Screws
(2) Inner cover
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4. Front and rear brakes - check operation;
make sure there is no brake fluid leakage
(page 15-18).
5. Tyres - check condition and pressure
(page 29-31).
6. Drive chain - check condition and slack
(page 69). 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 (page 33).
1O. Battery electrolyte - check the level and
add if necessary (page 83).
OPERATION
PRE-RIDE INSPECTION
AWARNING
• If the Pre-ride Inspection is not performed, severe personal injury or
vehicle damage may result.
Inspect your motorcycle every day before
you ride it. The items listed here will only take
a few minutes to inspect, and in the long run
they can save time, expense, and possibly
your life.
1. Engine oil level - add engine oil if required
(page 27). Check for leaks.
2. Fuel level - fill fuel tank when necessary
(page 23). Check for leaks.
3. Coolant level - add coolant if required.
Check for leaks (page 21-22).
Correct any discrepancy before you ride.
Contact your authorized Honda dealer for
assistance if you cannot correct the problem.
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Preparation
Before starting, insert the key, turn the
ignition switch ON and confirm the
following;
• The Transmission is in NEUTRAL
(neutral indicator ON).
• The engine stop switch is at RUN.
• The fuel cock is ON.
STARTING THE ENGINE
Always follow the proper starting procedure described below.
AWARNING
• Never run the engine in an enclosed
area. The exhaust contains poisonous
carbon monoxide gas that can cause
loss of consciousness and lead to
death.
• Do not try to start the motorcycle
with the transmission in gear. You
may injure yourself or damage the
motorcycle.
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Starting Procedure
Warm engine:
1. Do not use the choke.
2. Open the throttle 1/8 - 1/4 turn.
3. Operate the kickstarter.
Cold engine:
1. Pull the choke knob (1) up all the way to
Fully ON (A).
2. With the throttle closed, operate the
kick starter with the right foot, starting
from the top of the stroke and following
through to the bottom with a rapid and
continuous motion.
(If you cannot start the engine; follow the
"Warm engine" starting procedure.)
(1 )
CAUTION:
• Do not operate the kickstarter pedal
white the engine is running as engine
damage could result. Do not apply
excessive force on the starter pedal.
• Fold up the kickstarter pedal after the
kickstarter is returned to the pedal stop.
3. Warm up the engine until it runs smoothly
with the choke knob Fully OFF (8).
(1) Choke knob
(A) Fully ON
(8) Fully OFF
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Flooded Engine
If the engine fails to start after several
repeated attempts, it may have become
flooded with excess fuel. To clear the
engine, turn the engine stop switch OFF
and push the choke knob to Fully OFF (8).
Open the throttle fully and crank the
engine several times with the kickstarter.
Turn the engine stop switch to RUN and
open the throttle slightly; start the engine.
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3. Increase the maximum continuous engine
speed by 2,000 min (rpm) between
odometer readings of 1,000 km (600
miles) and 1,600 km (1,000 miles). Drive
briskly, vary speeds frequently and use
full throttle for short bursts only. Do not
exceed 10,000 min- 1 (rpm).
4. Upon reaching an odometer reading of
1,600 km (1,000 miles), you can subject
the motorcycle to full throttle operation.
However, do not exceed 11 ,000 min (rpm)
indicated by the beginning of the
tachometer red zone. (Do not let the
tachometer needle enter the red zone.)
RUNNING-IN
During initial running-in newly machined
surfaces will be in contact with each other
and these surfaces will wear in quickly.
Running-in maintenance at 1 ,000 km (600
miles) is designed to compensate for this
initial minor wear. Timely performance of
the running-in maintenance will ensure
optimum service life and performance from
the engine.
The general rules as follows:
1. Never labour the engine with full throttle
at low engine speeds. This rule is
applicable not only during running-in
but at all times.
2. Maximum continuous engine speed
during the first 1,000 km (600 miles)
must not exceed 8,000 min- 1 (rpm).
CAUTION:
• Running the engine beyond recommended maximum engine speed (the
beginning ofthe tachometer red zone)
can damage the engine.
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RIDING
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 progressively shift to 3rd, 4th, 5th and
6th (top) gear.
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.
AWARNING
•
Review Motorcycle Safety (pages 1-5)
before you ride.
NOTE:
• Make sure you understand the function
of the side stand mechanism. (See
MAINTENANCE SCHEDULE on page
54 and explanation for SIDE STAND on
page 74).
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.
£?
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BRAKING
A.WARNING
1. For normal braking, gradually apply both
the front and rear brakes while downshifting to suit your road speed.
2. For maximum deceleration, close the
throttle and apply the front and rear
brakes firmly. Pull in the clutch lever
before coming to a complete stop to
prevent stalling the engine.
•
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, accelera-ting or turning.
• When descending a long, steep grade,
use engine compression braking by
downshifting, 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 hands on the brake lever
may actuate the brakelight, giving a
false indication to other drivers. It may
also overheat the brake, reducing
effectiveness.
A.WARNING
•
Independent use of only the front or
rear brake reduces stopping performance. Extreme braking may cause
either wheel to lock, reducing control
of the motorcycle.
• 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.
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PARKING
1. After stopping the motorcycle, shift the
transmission into neutral, turn the fuel
cock OFF, 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.
CAUTION:
• 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 35).
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ANTI-THEFT TIPS
NAME : _ _ _ _ _ _ _ __
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 stili with them.
ADDRESS :_ _ _ _ _ _ _ _ __
PHONE NO :_ _ _ _ _ _ _ _ __
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MAINTENANCE
• The Required Maintenance Schedule specifies how often you should have your
motorcycle served, and what things need attention. It is essential that your
motorcycle be served as scheduled to retain its high level of safety, dependability, and
emission control performance.
• 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 of dusty conditions, will require more frequent service than specified
in the MAINTENANCE SCHEDULE. Consult your authorized Honda dealer for
recommendations applicable to your individual needs and use.
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MAINTENANCE SCHEDULE
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 authorized Honda dealer meets all of these requirements.
Perform the Pre-ride Inspection (page 43) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACEMENT IF NECESSARY
C: CLEAN
R: REPLACE
A: ADJUST
L: LUBRICATE
~
ITEM
WHICHEVER --+
COMES
x1 ,000 km
FIRST
x1 ,000 mi
1
NOTE
ODOMETER READING (NOTE 1)
1
4
8
12
0.6
2.5
5
7.5
18
MONTH
REFER TO
PAGE
6
12
*
FUEL LINE
I
I
I
-
*
FUEL STRAINER SCREEN
C
C
C
66
*
THROTILE OPERATION
I
I
I
**
OIL PUMP AND OIL LINE
I
I
I
-
*
AIR CLEANER
C
C
C
-
(NOTE 2)
SPARK PLUG
**
EVERY 2,000 km = C, EVERY 4,000 km = R
DECARBONIZING
C
ENGINE IDLE SPEED
RADIATOR COOLANT
I
(NOTE 3)
COOLING SYSTEM
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I
I
64
-
I
68
I
21
I
-
~
ITEM
WHICHEVER .....
COMES
x1 ,000 km
FIRST
x1 ,000 mi
1
NOTE
ODOMETER READING (NOTE 1)
1
4
8
12
0.6
2.5
5
7.5
6
12
18
MONTH
TRANSMISSION OIL
R
DRIVE CHAIN
EVERY 1,000 km (600 mil I,L
I
I
I
73
BATIERY
I
I
I
81
I
I
I
15
I
I
I
75
(NOTE 3)
BRAKE PADS WEAR
BRAKE SYSTEM
I
I
I
15,75
BRAKE LIGHT SWITCH
I
I
I
I
90
HEADLIGHT AIM
I
I
I
-
I
I
I
19
CLUTCH SYSTEM
..
61
69
DRIVE CHAIN SLIDER
BRAKE FLUID
..
REFER TO
PAGE
I
SIDE STANO
I
I
I
74
SUSPENSION
I
I
I
-
I
-
I
-
NUTS,BOLTS,FASTENERS
I
WHEELSfTYRES
I
I
STEERING HEAD BEARING
I
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I
-
* SHOULD BE SERVICES BY YOUR AUTHORIZED HONDA DEALER, UNLESS THE
OWNER HAS 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 SERVICES ONLY
BY YOUR AUTHORIZED HONDA DEALER.
Honda recommends that your authorized 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 when riding in unusually wet or dusty areas.
3. Replace every 2 years, replacement requires mechanical skill.
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TOOL KIT
Tool kit (1) is in the tool box (2) under the
rear seat (page 36).
Some roadside repairs, minor adjustments
and parts replacement can be performed
with the tools contained in the kit.
• 8x10 mm open end wrench
• 1Ox12 mm open end wrench
• 14x17 mm open end wrench
• 19 mm box end wrench
• 22 mm box end wrench
• 5 mm hex wrench
• Standard/Phillips screwdriver
• Pliers
• Spark plug wrench/screwdriver
handle
• Pin spanner
• Extension bar
• Tool bag
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The frame number (1) is stamped on the
right side of the steering head.
The engine number (2) is stamped on the
right side of the crankcase.
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.
FRAMENO. __________________
ENGINE NO. _________________
(1) Frame number
(2) Engine number
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MAINTENANCE PRECAUTIONS
AWARNING
• Stop the engine and support the
motorcycle securely on a firm, level
surface before performing any
maintenance.
AWARNING
• If your motorcycle is overturned or
involved in a collision, inspect control
levers, cables, brake hoses, calipers,
accessories, and other vital parts for
damage. Do not ride the motorcycle if
damage impairs safe operation. Have
your authorized Honda dealer inspect
the major components, including frame,
suspension and steering parts, for misalignment and damage that you may
not be able to detect.
• Use new, genuine Honda parts or their
equivalent for maintenance and repair.
Parts which are not of equivalent quality
may impair the safety of your
motorcycle and the effective operation
of the emission control systems.
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To install :
1. Support the motorcycle on a firm, level
ground using the side stand.
2. Install the maintenance stand on the
motorcycle as follows:
MAINTENANCE STAND
Use two people to place the motorcycle
on the maintenance stand.
AWARNING
CD Align the top ends of the maintenance
• Improper use of the maintenance
stand may cause injury.
- Be sure the maintenance stand is
placed on a firm, level ground.
- Never ride the motorcycle on the
maintenance stand or run the
engine while the motorcycle is on
the maintenance stand.
- Be sure the maintenance stand is
fully engaged and the attaching
bolt is fastened securely before
working on the motorcycle.
stand (1) with the rear axle nut (2).
® Turn the attaching bolt (3) in until
resistance is felt.
(1) Maintenance stand
(2) Rear axle nut
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3. Raising the motorcycle onto the stand as
follows:
CD
®
®
@
While holding the handlebars, support
the motorcycle upright and retract
the side stand.
Have an assistant check that the
attaching bolt is tightened securely and
is aligned with the rear axle nut properly.
If necessary, reinstall the maintenance
stand.
Have the assistant rest his right foot
on the maintenance stand and his
hands on the rear of the rear cowl.
Pull the motorcycle backward while
simultaneously, letting the assistant shift
his weight onto the maintenance stand.
To remove:
1. Retract the side stand.
2. Hold the handlebars and push the
motorcycle forward.
3. Lower the side stand and support the
motorcycle on it.
4. Remove the maintenance stand.
CAUTION:
•
Do not pull up on the rear cowl during
this operation.
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TRANSMISSION OIL
(Refer to the maintenance precautions on
page 58)
CD
Transmission Oil
Good transmission 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 transmission 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
2'0
(1) Single grade
(2) Multi grade
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10
4'0
20
6'0
30
8'0
40·C
Ion
OIL CHANGE
Transmission oil quality is the chief factor affection
engine service life. Change the transmission oil
when specified by the maintenance schedule.
(1)
NOTE:
• Change transmission oil with the engine at
normal operating temperature and the
motorcycle with upright position to assure
complete and rapid draining.
1. Start the engine and let it idle for a few
minutes.
2. Stop the engine, place an oil drain pan
under the crankcase. Remove the oil filler
cap (1) and drain plug (2).
AWARNING
•
A warmed-up engine and the oil in it are
hot; be careful not to burn yourself.
3. With the ignition switch OFF, operate the
kickstarter several times to drain any oil
which may be left in the engine.
(2)
(1) Oil filler cap
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(2) Drain plug
4. After the oil has completely drained, make
sure the sealing washer on the drain plug
is in good conditions.
5. Install the drain plug to the specified torque.
Drain plug torque:
CAUTION:
• Running the engine with insufficient oil
can cause serious engine damage.
NOTE:
• Please dispose of used transmission oil
in a manner that is compatible with the
environment. We suggest you take it in
a sealed container to your local service
station for reclamation. Do not throw it in
the rubbish or pour it on the ground.
21 N.m (2.1 kgf.m, 15 Ibf.ft)
6. Fill the crankcase with recommended
grade oil; approximately:
0.7 I (0.7 US qt, 0.8 Imp qt)
7. With the motorcycle upright on level
ground, start the engine and let it idle for
a few minutes. Stop the engine and
check that the oil level is at the upper level
mark in the inspection window with the
motorcycle upright position.
8. If required, remove the oil filler cap and
add the specified oil up to the upper level
mark. Do not over fill. Install the oil filler
cap.
Check for oil leaks.
',',.,"
/
,,;0/
f...~.'~
(3) Inspection window
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(1)
1. Disconnect the spark plug cap from the
spark plug.
2. Clean any dirt from around the spark
plug base. Remove the spark plug
using the plug wrench furnished in the
tool kit.
SPARK PLUG
(Refer to the maintenance precaution on
page 58)
Recommended plugs:
Standard:
B9ECS (NGK)
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CAUTION:
3. Inspect the electrode and center porcelain
for deposes, erosion or carbon fouling. If
the erosion or deposit is heavy, replace the
plug.
Clean a carbon or wet-fouled plug with a
plug cleaner, otherwise use a wire brush.
4. Check the spark plug gap (1) using a wire
type feeler gauge. If adjustment is necessary,
bend the side electrode (2) carefully.
The gap should be:
0.7-0.8 mm (0.028-0.031 in)
Make sure the plug washer is in good
condition.
5. With the plug washer attached, thread the
spark plug in by hand to prevent cross
threading.
6. 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 seat.
7. Reinstall the spark plug cap.
• The spark plug must be securely
tightened. An improperly tightened
plug can become very hot and possibly
damage the engine. Never use a spark
plug with an improper heat range.
Severe engine damage could result.
(2)
~
~
~========== (1)
(1) Spark plug gap
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(2) Side electrode
THROTTLE OPERATION
(Refer to the maintenance precaution on
page 58)
1. Checkforsmooth 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
approx:
2-6 mm (0.08-0.24 in)
(2)
To adjust the free play, loosen the lock nut
(1) and turn the adjuster (2).
(1) Lock nut
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(2) Adjuster
3. Check for correct synchronization of
the oil pump (3). Check the reference
mark (4) aligns with the index mark (5)
with the throttle fully opened. See your
authorized Honda dealer if any
misalignment occurs.
CAUTION:
• Failure to perform oil pump synchroni
zation may result in serious engine
damage.
(3)
(3) Oil pump
(4) Reference mark
(5) Index mark
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3. Adjust idle speed with the throttle stop
screw (1).
Idle speed (In neutral):
1,300 ± 100 rpm
IDLE SPEED
(Refet to the maintenance precaution on
page 58)
The idle speed adjustment procedure given
here should only be used when changes in
altitude affect normal idle speed as set by
your dealer. See your authorized Honda
dealer for regularly scheduled carburetor
adjustments, including individual carburetor
adjustment and synchronization.
(1 )
/
NOTE:
• The engine must be at normal operating
temparature for accurate idle speed
adjustment. Ten minutes of stop-andgo riding is sufficient.
1. Warm up the engine, shift to neutral and
place the motorcycle on its stand.
2. The throttle stop screw (1) is behind the
seal rubber in the left side cover.
Push in the rubber.
o
II
,
(1) Throttle stop screw
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/
'\'
(A) Increase
(8) Decrease
3. Roll the motorcycle forward. Stop. Check
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.
DRIVE CHAIN
(Refer to the maintenance precaution on page 58)
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 43).
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:
30-40 mm (1 .2-1 .6 in)
(1) Drive chain
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4. Roll the motorcycle forward. Stop and
place it on its side stand. Inspect the drive
chain and sprockets for any of the following
conditions:
DRIVE CHAIN
• Damaged Rollers
• Loose Pins
• Dry or Rusted Links
• Kinked or Binding Links
• Excessive Wear
• Improper Adjustment
• Missing O-rings
SPROCKETS
• Excessively Worn Teeth
• Broken or Damaged Teeth
A drive chain with damaged rollers, loose pins,
or missing O-rings must be replaced. A chain
which appears dry, or shows signs of rust,
requires supplementary lubrication. Kinked or
binding links should be thoroughly lubricated
and worked free. If links cannot be freed, the
chain must be replaced.
Damaged Sprocket Teeth
Worn sprocket teeth
REPLACE /~REPLACE
(~J\;
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Normal Sprocket Teeth
GOOD
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Adjustment:
CAUTION:
Drive chain slackshould 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.
If the drive chain requires adjustment, the
procedure is as follows:
1. Turn the engine off, place the motorcycle on its
side stand and shift the transmission into neutral.
2. Loosen the bearing holder pinch bolt (1).
3. Turn the bearing holder (2) clockwise or
counterclockwise to obtain the proper chain slack
with the pin spanner (3).
4. Torque the bearing holder pinch bolt to:
73 N.m (7.4 kgf.m, 54 Ibf.ft)
5. Recheck chain slack.
•
Damage to the bottom part of the frame may
be caused by excessive drive chain slack of
more than:
50 mm (2.0 in)
/
~'-;f---T-n---
AWARNING
•
(2)
(3)
If a torque wrench was not used for
installation, see your authorized Honda
dealer as soon as possible to verify proper
assembly.
(1) Bearing holder pinch bolt
(2) Bearing holder
(3) Pin spanner
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(1)
Wear inspection:
Check the chain wear label when adjusting
the chain. If the red zone (4) on the label
aligns with the index mark (5) after the chain
has been adjusted to the proper slack, the
chain is excessively worn and must be
replaced. The proper slack is :
30-40 mm (1.2-1.6 in)
Lubrication and cleaning:
Lubricate every 1,000 km (600 miles) or
sooner if chain appears dry.
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 lubricants
may contain solvents which could damage
the rubber O-rings.
(4)
(5)
(4) Red zone
(5) Index mark
72
CAUTION:
• 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 serv.ice life. However, special
precautions must be taken when
adjusting, lubricating, washing, and
replacing the chain.
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DRIVE CHAIN SLIDER
(Refer to the maintenance precaution on
page 58)
Check the chain slider (1) for wear.
The chain slider must be replaced if it is
worn to the bottom of the cut out (2). For
replacement, see your authorized Honda
dealer.
(2)
(1) Chain slider
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(1)
(2) Cut out
SIDE STAND
(Refer to the maintenance precaution on
page 58)
Check the side stand spring for damage
and loss of tension, and the side stand
assembly for freedom of movement.
If the side stand is squeaky or stiff, clean
the pivot area and lubricate the pivot bolt
with clean engine oil.
(1 )
(1) Side stand
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BRAKE PAD WEAR
(FRONT BRAKE)
(Refer to the maintenance precaution on
page 58)
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 54).
Front Brake
Check the wear indicator mark (1) on each
pad.
If either pad is worn to the wear indicator
mark, replace both pads as a set. See
your authorized Honda dealer for this
service.
(1) Wear indicator mark
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(REAR BRAKE)
Rear Brake
Check the wear indicator mark (2) on each
pad.
If either pad is worn to the wear indicator
mark, replace both pads as a set. See
your authorized Honda dealer for this
service.
(2)
(2) Wear indicator mark
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WHEEL REMOVAL
(Refer to the maintenance precaution on
page 58)
Front Wheel Removal
1. Support the motorcycle with the
maintenance stand (page 59).
2. Raise the front wheel off the ground by
hoisting the top bridge.
3. Remove the speedometer cable (1) by
removing screw (2).
4. Remove the axle nut (3).
5. Remove the axle shaft (4) and the wheel.
(4)
(1 )
(2)
(3)
NOTE:
• Do not depress the brake lever when the
wheel is off the motorcycle. The caliper
pistons will be forced out of the cylinders
with subsequent loss of the brake fluid. If
this occurs, servicing of the brake system
will be necessary. See your authorized
Honda dealer for this service.
/
(1) Speedometer cable
(2) Screw
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(3) Axle nut
(4) Axle shaft
Installation notes:
Reverse the removal procedure.
Position the front wheel between the
fork legs and insert the axle shaft from
left side, through the left fork leg and
wheel hub.
Tighten the axle nut to the specified
torque.
Axle nut torque:
AWARNING
• If a torque wrench was not used for
installation, see your authorized
Honda dealer as soon as possible to
verify proper assembly. Improper
assembly may lead loss of braking
capacity.
59 N.m (6.0 kgf.m, 43 Ibf.ft)
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.
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Rear Wheel Removal
1. Place the motorcycle on its side stand.
2. With the rear wheel on the ground,
loosen the wheel nuts (1) while applying
the rear brake.
3. Raise the rear wheel off the ground with
the maintenance stand (page 59).
4. Remove the wheel nuts.
5. Remove the rear wheel (2).
(1) -'-H--~~~N<.
(1 )
(1) Wheel nuts
(2) Rear wheel
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Installation notes:
Reverse the removal procedure.
Tighten the wheel nuts to the specified
torque.
Wheel nut torque:
108 N.m (11.0 kgf.m, 80 Ibf.ft)
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.
AWARNING
• If a torque wrench was not used for
installation, see your authorized
Honda dealer as soon as possible
to verify proper assembly. Improper
assembly may lead loss of braking
capacity.
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BATTERY
CAUTION:
(Refer to the maintenance precautions on
page 58)
If the motorcycle is operated with
insufficient battery electrolyte, sulufation
and battery plate damage will occur.
If rapid loss of electrolyte is experienced, or
if your battery seems to be weak, causing
slow starting or other electrical problems,
see your authorized Honda dealer.
• When checking the battery electrolyte
level or adding distilled water, make
sure the breather tube is connect to
the battery breather outlet.
• Use only distilled water in the battery.
Tap water will shorten the service
Iife of the battery.
• Filling the battery above the UPPER
LEVEL line may cause the electrolyte
to overflow, resulting in corrosion to
engine or frame parts. Immediately
wash off any spilled electrolyte.
• The battery breather tube must be
routed as shown on the label. Do not
bend or twist the breather tube. A
bent or kinked breather.
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AWARNING
• The battery gives off explosive gases;
keep sparks, flames, and cigarettes
away. Provide adequate ventilation
when charging or using the battery in
an enclosed space.
• The battery contains sulfuric acid
(electrolyte). Contact with skin or eyes
may cause serve burns. Wear protective clothing and a face shield.
- If electrolyte gets on your skin, flush
with water.
- If electrolyte gets in your eyes, flush
with water for at least 15 minutes and
call a physician immediately.
• Electrolyte "is poisonous.
- If swallowed, drink large quantities
of water or milk of magnesia or
vegetable oil and call a physician.
•
KEEP OUT OF REACH OF CHILDREN.
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Battery electrolyte :
The battery (1) is behind the right side cover.
Check the electrolyte level with the motorcycle in
an upright position on level ground. Theelectrolyte
must be maintained between the UPPER (2) and
LOWER (3) level marks on the side of the battery.
If the electrolyte level is low, remove the battery
and remove the battery filler caps.
Carefully add distilled water to the UPPER level
mark, using a small syringe or plastic funnel.
Battery removal :
1. Remove the right side cover (page 39)
2. Disconnect the negative (-) terminal lead (4)
from the battery.
3. Open the terminal cover (5), then disconnect
the positive (+) terminal lead (6).
4. Remove the battery band (7) and open the
battery cover (8).
5. Remove the battery (1).
.. / ( 5 )
(1 )
_~~
J :.}~i:
~:'"''
~
(6)
~'J'
{I',\ \ .\.'~ ". ~ -'I
(2)-----'~
·,'X\~·
/',:,
(8)
-\(3)
(1) Battery
(3) LOWER level mark
(4)
(4) Negative (-) terminal lead
(5) Terminal cover
(6) Positive (+) terminal lead
(2) UPPER level mark
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-+---(1)
(7)
(7) Battery band
(8) Battery cover
FUSE REPLACEMENT
AWARNING
(Refer to the maintenance precaution on
page 58)
When frequent fuse failure occurs, it usually
indicates a short circuit or an overload in
the electrical system. See your authorized
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.
CAUTION:
Blown fuse
• Turn the ignition switch OFF before
checking or replacing fuses to prevent
accidental short-circuiting.
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Fuse box:
The fuse box is located under the right
inner cover.
The specified fuses are:
10A,20A
1. Remove the inner fairing (page 42).
2. Open the fuse box cover (1).
3. Pull out the old fuse and install a new
fuse.
4. The spare fuses (2) are located in the
fuse box.
5. Close the fuse box cover and install the
inner cover.
(1) Fuse box cover
(2) Spare fuses
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BULB REPLACEMENT
NOTE:
(Refer to the maintenance precaution on
page 58)
• Be sure to turn the ignition switch OFF
when replacing the bulb.
• Do not use bulbs other than that specified.
• After installing a new bulb, check that the
light operates properly.
AWARNING
• The light bulb becomes very hot while
the light is ON, and remain hot for a
while after it is turned OFF. Be sure to
let it cool down before servicing.
CAUTION:
• 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.
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Headlight Bulb
1. Pull back the rubber cover (1).
2. Slightly press the socket (2) and turn it
counterclockwise, then remove the
socket.
3. Pullout the bulb (3).
4. Install a new bulb in the reverse order of
removal.
t=J~~\ \~r\~
, "l~/ ~~':,,~cc-·/
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(2)
(1) Cover
(2) Socket
(3) Bulb
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(1)
(3)
Front/Rear Turn Signal Bulb
1. Remove the turn signal lens (1) by
removing screw (2).
2. Pull out the turn signal bulb (3).
3. Install a new bulb in the reverse order of
removal.
(3)
(1 )
(1) Lens
(2) Screw
(3) Bulb
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Stoprrail Light Bulb
1. Remove the right side cover (page 39).
2. Remove the tail cover (1) by removing
screws (2).
3. Remove the taillight lens (3) by removing
screw (4).
4. Slightly press the bulb (5) and turn it
counterclockwise.
5. Install a new bulb in the reverse order of
removal.
(1) Tail cover
(3) Lens
(5) Bulb
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(2) Screw
(4) Screw
STOPLIGHT SWITCH ADJUSTMENT
(Refer to the maintenance precaution on
page 58)
Check the operation of the stoplight
switch (1) at the right side behind the
engine from time to time.
Adjustment is done by turning the
adjusting nut (2). Turn the nut in the
direction (A) if the switch operates too late
and in direction (8) if the switch operates
too soon.
(2)
(1 )
(1) Stoplight switch
(2) Adjusting nut
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CLEANING
NOTE:
Clean your motorcycle regularly to protect
the surface finishes and inspect for damage,
wear and oil, coolant or fluid (brake and clutch)
leakage.
• 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.
2. Dry the motorcycle, start the engine, and let
it run for several minutes.
3. Test the brakes before riding the motorcycle. Several applications may be necessary
to restore normal braking performance.
CAUTION:
•
High pressure water (or air) can damage
certain parts of the motorcycle.
Avoid spraying high pressure water (typical in
cOinoperated car washes) at the following areas:
Ignition Switch
Instruments
Carburetors
Wheel Hubs
Drive Chain
Muffler Outlets
Under Seat
Under Fuel Tank
Handlebar Switches
Brake Master Cylinder
Clutch Master Cylinder
1. After cleaning, rinse the motorcycle
thoroughly with plenty of clean water. Strong
detergent residue can corrode alloy parts.
AWARNING
•
Braking efficiency may be temporarily
impaired immediately after washing the
motorcycle. AntiCipate longer stopping
distance to avoid a possible accident.
4. Lubricate the drive chain immediately after
washing and drying the motorcycle.
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Painted Aluminum Wheel Maintenance
Aluminum may corrode from contact with
dirt, mud or road salt. Clean the wheels
after riding through any of those
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.
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STORAGE GUIDE
AWARNING
Extended storage, such as for winter, requires
that you take certain steps to reduce the effects
of deterioration from non-use ofthe 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
Petrol is extremely flammable and is
explosive under certain conditions.
Perform this operation in a well-ventilated
area with the engine stopped. Do not
smoke or allow flames or sparks in the
area where petrol is drained or stored
and where the fuel tank is refueled.
1. Change the engine oil and filter.
2. Make sure the cooling system is filled with a
50/50% antifreeze solution.
3. Drain the fuel tank and carburetor into an
approved petrol container. Spray the inside of
the fuel tank with an aerosol rust -inhibiting oil.
Reinstall the fuel fill cap on the tank.
NOTE:
•
If storage will last more than one month,
carburetor draining is very important, to
assure proper performance after storage.
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4. To prevent rusting in the cylinders,
perform the following:
• Remove the spark plug caps from
the spark plugs. Using tape or string,
secure the caps to any convenient
plastic body part so that they are
positioned away from the spark plugs.
• Remove the spark plugs from the
engine and store them in a safe
place. Do not connect the spark
plugs to the spark plug caps.
• Pour a tablespoon (15-20 cc) of clean
engine oil into each cylinder and cover
the spark plug holes with a piece of
cloth.
• Crank the engine several times to
distribute the oil.
• Reinstall the spark plugs and spark
plug caps.
5. Remove the battery. Store in an area
protected from freezing temperatures
and direct sunlight.
Check the electrolyte level and 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 72).
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 tem perature
variation. Do not store the motorcycle
in direct sunlight.
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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 43). Test ride the motorcycle at
low speeds in a safe riding area away
from traffic.
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SPECIFICATIONS
DIMENSIONS
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
1,970 mm (77.5 in)
685 mm (27.0 in)
1,060 mm (41.7 in)
1,335 mm (52.5 in)
142 mm (5.6 in)
WEIGHT
Dry weight
122.4 kg (269.8 Ibs)
CAPACITIES
2-stroke engine oil
Transmission oil
Fuel tank capacity
Fuel reserve capacity
Passenger capacity
1.2 I
0.8 I (After disassembly)
0.7 I (After draining)
10.51
2.71
Operator and one passenger
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ENGINE
59X54.5 mm (2.3X2.15 in)
6.8: 1
149 cm 3 (9.1 cu-in)
Bore and stroke
Compression ratio
Displacement
Spark plug
Standard
Spark plug cap
Idle speed
B9ECS (NGK)
0.7 - 0.8 mm (0.028 - 0.031 in)
1,300 ± 100 rpm
CHASSIS AND SUSPENSION
Caster
Trail
Tyre size, front
Tyre size, rear
25° 36'
91 mm (3.6 in)
90/80 - 17 46S
120/80 - 17 61 S
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POWER TRANSMISSION
Primary reduction
Gear ratio, 18t
2nd
3rd
4th
5th
6th
Final reduction
2.954
2.916
1.937
1.470
1.210
1.043
0.916
2.857
ELECTRICAL
Battery
Generator
12V - 3AH
0.188 kW
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LIGHTS
Headlight
BrakelTaillight
Turn signal light Front
Turn signal light Rear
Instrument light
Neutral indicator
Turn signal indicator
High beam indicator
12V - 30/30 W
12V - 5/18 W
12V - 10 W
12V - 10 W
12V - 1.7 WX5
12V - 3.4 W
12V - 1.7 W
12V - 1.7 W
FUSE
Main fuse
Other fuses
20A
10A
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Memo
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---_._----
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----~--------
- - -
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~HONDA.
25111998
HONDA.
ASH 01/98
Printed on recycled paper
http://www.motorcycle.in.th
PRINTED IN THAILANI
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