Page 1 *Hon.DA Manual del Propietario Owner`s Manual C R F 15

Page 1 *Hon.DA Manual del Propietario Owner`s Manual C R F 15
Manual del Propietario
Owner’s Manual
CRF150F
Owner's Manual
CRF150F
2 Owner 's Manual
Important Information
e OPERATOR ONLY. NO PASSENGER
This motorcycle is designed and constructed as an operator-only model. The seating configuration does not
safely permit the carrying of a passenger. Do not exceed the maximum weight capacity.
e FOR OFF-ROAD USE ONLY
This motorcycle is designed and manufactured for off-road use only.
« 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 “A Few Words About Safety” section (page 5).
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when
it is resold.
Owner's Manual 3
Welcome
Your new motorcycle presents you with an invitation to adventure and a challenge to master the machine. Your
safety depends not only on your own alertness and familiarity with the motorcycle, but also the motorcycles
mechanical condition. A pre-ride inspection before every outing and regular maintenance are essential.
To help meet the challenges safely and enjoy the adventure fully, 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 NOTICE 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!
4 Owner's Manual
» The specifications may vary with each locale.
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.
Owner's Manual 5
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:
e Safety Labels — on the motorcycle.
* Safety Messages — preceded by a safety alert symbol Ak and one of three signal words:
DANGER, WARNING or CAUTION.
These signal words mean:
on
Owner ’s Manual
Á DANGER
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.
A 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.
e Instructions — how to use this motorcycle correctly and safely.
This entire manual is filled with important safety information — please read it carefully.
Owner's Manual
OPERATION ESSENTIAL INDIVIDUAL COMPONENTS oo...
- Ignition Switch ee narran
MOTORCYCLE SAFETY ooo 9 Ser ri BN
Important Safety Information ............................. 9 ngine PO
Protective Apparel... as 10 FEATURES nine
Load Limits and Guidelines ................................. 12 (Not required for operation)
Left Side Cover... eee rrrerenos
PARTS LOCATION ooo e arrererreoeeererererers 14 Right Side Cover
MAJOR COMPONENTS... 17 OPERATION ан,
(Information you need to operate
this motorcycle) Pre-ride inspection... a ee re
Brakes oo arren eee acer rare 17 Starting the Engine ooo,
Cluteh e 19 RUNNING-IN .... eee reee anna onanrerraa ranas
Fuel ee aa 51 RidiNnGg eee
Engine Oil oe 23 Braking I nn
TY TOS eee eee 24 Parking ........
Anti-theft Tips eee nr cnrs
8
Owner's Manual
MAINTENANCE ...... cena nan ses e ecran
The Importance of Maintenance ie
Maintenance Safety ar EEK
Safety Precautions ci
Maintenance Schedule ................ es
Competition Inspection een
Tool Kit .......... eee een icniiaric Dr DDR ent
Serial Numbers .....................essreeereeeeeeeereeeecanene
Colour Label ........
Air Cleaner ..............———e=..e....
Crankcase Breather e
Engine Oil... enn
Spark PIUQ 2er rer cernes
Idle Speed o.oo nrer essences
Throttle Operation men
Spark Arrester o.oo
Drive Chain ere
Wheel Rims and Spokes ......................
Wheel Removal ...oooooeeeeeieiiiiiiicc iin ESEL EHG
Brake Pad Wear ..….…..…...…........…rrsrccccacc care cn nanas assure
Brake Shoe Wear ieee
Battery …....…......….ccsseseeeececererrece scene ee eee
Fuse Replacement ovr,
Front Suspension ..................e0eeee e
Rear Suspension ....................
Side Stand o.oo
CLEANING ..…...…........….cesrra rene er sense na cases anse arr rer 60
STORAGE GUIDE ........... 0000000000. 61
Storage ee rre eee cesser 61
Removal from Storage ooo, 62
SPECIFICATIONS ........................ 63
Owner’s Manual
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 you can meet
while riding.
There is much that you can do to protect yourself
when you ride. You'll find many helpful
recommendations throughout this manual. Foliowing are
a few that we consider most important.
Always Wear a Helmet
It's a proven fact: helmets significantly reduce the
number and severity of head injuries. So always wear
an approved motorcycle helmet. We also recommend
that you wear eye protection, sturdy boots, gloves and
other protective gear (page 10).
Never Carry a Passenger
Your motorcycle is designed for one person only.
There are no handholds, footrests, or seat for a
second person — so never carry a passenger.
A passenger could interfere with your ability to move
around to maintain your balance and control of the
motorcycle.
Ride Off-Road Only
Your motorcycle is designed and manufactured for
off-road use only. The tyres are not made for
pavement, and the motorcycle does not have turn
signals and other features required for use on public
roads. If you need to cross a paved or public road, get
off and walk your motorcycle across.
Take Time to Learn and Practice
Developing off-road riding skills is a gradual,
step-by-step process. Start by practicing at low
speeds in a safe area and slowly build your skills.
Personal instruction from an experienced rider can
also be valuable.
If you need assistance, ask your dealer about riding
groups in your area.
Be Alert for Off-Road Hazards
The terrain can present a variety of challenges when
you ride off-road.
Continually “read” the terrain for unexpected turns,
drop-offs, rocks, ruts, and other hazards. Always keep
your speed low enough to allow time to see and react
to hazards.
Do not Ride at Night
Your motorcycle is not equipped with lights.
So do not ride at night.
10
Owner ’s Manual
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.
Don’t Drink and Ride
Alcohol and riding don't mix. Even one drink can
reduce your ability to respond to changing conditions,
and your reaction time gets worse with every additional
drink. So don't drink and ride, and don't let your friends
drink and ride either.
Keep Your Bike in Safe Condition
It's important to keep your motorcycle properly
maintained and in safe riding condition. Having a
breakdown can be difficult, especially if you are
stranded off-road far from your base. To help avoid
problems, inspect your motorcycle before every ride
and perform all recommended maintenance.
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 jersey, 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.
A WARNING
Not wearing a helmet increases the chance of
serious injury or death in a crash.
Be sure you always wear a helmet, eye protection
and other protective apparel when you ride.
Owner's Manual
11
Helmets and Eye Protection
Your helmet is your most important piece of riding gear
because it offers the best protection against head
injuries. A heimet should fit your head comfortably and
have a chin strap that can be tightened securely.
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 off-road motorcycle boots to help protect
your feet, ankles, and lower legs.
= Off-road motorcycle gloves to help protect your hands.
* Riding pants with knee and hip pads, a riding jersey
with padded elbows, and a chest/shoulder protector.
12
Owner's Manual
Load Limits and Guidelines
Your Honda was designed as a rider-only motorcycle. It
was not designed to carry a passenger or cargo. A
passenger or cargo could interfere with your ability to
move around to maintain your balance and control of
the motorcycle.
In addition, exceeding the weight limits or carrying an
unbalanced load can seriously affect your
motorcycle's handling, braking, and stability. Adding
accessories or making modifications that change this
motorcycle's design and performance can also make |
unsafe. Also, the weight of any accessories will reduce
the maximum load the motorcycle can carry.
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. If you decide
to carry cargo, you should be aware of the following
information.
À WARNING
Overloading or carrying a passenger 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:
100 kg (220 Ibs)
Includes the weight of the rider and any accessories.
The weight of added accessories will reduce the
maximum cargo weight you can carry.
Loading Guidelines
As previously discussed, we recommend that you do
not carry any cargo on this motorcycle. However, if
you decide to carry cargo, ride at reduced speeds and
follow these common-sense guidelines:
e Keep cargo small and light. Make sure it cannot
easily be caught on brush or other objects, and that
it does not interfere with your ability to shift position
to maintain balance and stability.
e Place weight as close to the center of the
motorcycle as possible.
e Do not attach large or heavy items (such as a
sleeping bag or tent) to the handlebar, fork, or front
fender.
« Make sure that all cargo is tied down securely.
e Never exceed the maximum weight limit.
e Check that both tyres are inflated properly.
Owner's Manual
Accessories 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.
A WARNING
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:
* Make sure the accessory does not reduce ground
clearance and lean angle, limit suspension travel or
steering travel, alter your riding position, or interfere
with operating any controls.
13
* Be sure electrical equipment does not exceed the
motorcycle's electrical system capacity (page 64).
A blown fuse can cause a loss of lights or engine
power.
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 exhaust system (such as
the spark arresters or mufflers) or other equipment can
also make your motorcycle illegal.
Owner 's Manual
14
PARTS LOCATION
Front brake fluid reservoir
tgnitilon switch
Front brake lever
Clutch lever
=.
S
Throttle grip
Start button
Engine stop button
Fuel fill cap
Owner's Manual 15
Engine oil filler cap/dipstick
Engine idle speed
Air cleaner Spark plug
Spark arrester
Rear brake pedal
16 Owner's Manual
uel valve Choke lever
Battery/Main fuse
7
Crankcase breather tube
Engine oil drain bolt Shift pedal
Front brake caliper
Drive chain
Owners Manual
17
MAJOR COMPONENTS
(Information you need to operate this motorcycte)
Brakes
Front Brake
This motorcycle has a hydraulic front disc brake.
As the brake pads wear, 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 free travel becomes excessive and
the brake pads are not worn beyond the recommended
limit (page 55), there is probably air in the brake
system and it must be bled. See your Honda dealer for
this service,
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, check
the brake pads for wear (page 55).
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.
Front
(1) Lower level mark
Front brake lever
Never use adjusters other than those designed for this
motorcycle. Install a new adjuster from the lever side
with the lock nut under the head of the adjuster.
1. Pull back the rubber dust cover (2).
2. Loosen the lock nut (3).
3. To position the brake lever farther away from the
handgrip, turn the adjuster (4) clockwise.
To position the brake lever closer to the handgrip,
turn the adjuster counterclockwise.
4. Tighten the lock nut. Return the dust cover to its
normal position,
18
5. Apply the brake, release it, then spin the wheel and
check that it rotates freely. Repeat this procedure
several times.
6. Check free play by pulling in slowly on the front
brake lever until the brake starts to engage.
Free play:
10 — 20 mm (0.4 — 0.8 in)
If brake lever free play is not within this range, see
your Honda dealer.
(2) (1) Front brake lever
| кк) (2) Dust cover
| woe ST (3) Lock nut
у (4) Adjuster
Other checks
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
Owner's Manual
Rear Brake
Pedal height adjustment
1. Place the motorcycle on its side stand.
2. The stopper bolt (1) is provided to allow adjustment
of the pedal height.
To adjust the pedal height, loosen the lock nut (2)
and turn the stopper bolt. Tighten the lock nut.
(1) Stopper bolt
(2) Lock nut
(3) Rear brake pedal
Owner 's Manual
19
Brake adjustment
1. Place the motorcycle on its side stand.
2. Measure the distance the rear brake pedal (3)
moves before the brake starts to take hold.
Free play should be: 20 — 30 mm (0.8 — 1.2 in)
3. If adjustment is necessary, turn the rear brake
adjusting nut (4).
(4) Adjusting nut
(5) Arm pin
(A) Decrease tree play
(B) Increase free play
* Make sure the cut-out on the adjusting nut is seated
on the brake arm pin (5) after making final free play
adjustment.
* |f proper adjustment cannot be obtained by this
method, see your Honda dealer.
4. Apply the brake several times and check for free
wheel rotation after the brake pedal is released.
Other checks
Make sure the brake rod, brake arm, spring and
fasteners are in good condition.
Clutch
Clutch adjustment may be required if the motorcycie
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
upper clutch cable adjuster (4) at the lever (1).
Normal clutch lever free play is:
10 - 20 тт (0.4 — 0.8 in)
(1) Clutch lever
(1
mw
NOS
Te
SES
)
RT
cd, e
Те ъ
+
1. Pull back the rubber dust cover (2).
2. Loosen the upper lock nut (3) and turn the upper
clutch cable adjuster (4) to obtain the specified free
play. Tighten the lock nut and check the adjustment.
Return the dust cover to its normal position.
20
Owner ’s Manual
Dust cover
Upper lock nut
Upper clutch cable
adjuster
Increase free play
Decrease free play
ETD
=
=
. If the adjuster is threaded out near its limit or if the
correct free play cannot be obtained, loosen the upper
lock nut (3) and turn in the upper clutch cable adjuster
(4) completely. Tighten the upper lock nut and pull the
dust cover (2) back to its normal position.
. Hold the lower adjusting nut (5) and loosen the lower
lock nut (6) at the lower end of the cable. Turn the
lower adjusting nut to obtain the specified free play.
Tighten the lower lock nut and check the
adjustment.
DT TT (5) Lower adjusting nut
(6) Lower lock nut
(A) Increase tree play
(B) Decrease free play
5. 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 motorcycie should
begin to move smoothly and accelerate gradually.
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.
Owners Manual
21
Fuel
Fuel Valve
The three way fuel valve (1) is on the left side below
the fuel tank.
OFF
With the fuel valve in the OFF position, fuel cannot
flow from the tank to the carburetor. Turn the valve
OFF whenever the motorcycle is not in use.
ON
With the fuel valve in the ON position, fuel will flow
from the main fuel supply to the carburetor.
RES
With the fuel valve in the RES position, fuel will flow
from the reserve fuel supply to the carburetor. Use the
reserve fuel only when the main supply is gone. Refill
the tank as soon as possible after switching to RES.
The reserve fuel supply is:
1.5 Ё (0.40 US gal, 0.33 Imp gal)
Remember to check that the fuel valve is in the ON
position each time you refuel. If the valve is left in the
Fuel Tank
The fuel tank capacity including the reserve supply is:
8.2 Ё (2.17 US gal, 1.80 Imp gal)
To open the fuel fill cap (1), pull out the breather tube
(2) from the steering stem nut (3). Then turn the fuel
fill cap counterclockwise.
Do not overfill the tank. There should be no fuel in the
filler neck (4).
After refueling, be sure to tighten the fuel fill cap firmly
by turning it clockwise. Insert the breather tube into
the steering stem nut.
(1) Fuel fill cap
(2) Breather tube
(3) Steering stem nut
{4) Filler neck
22
Owner ’s Manual
A WARNING
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.
« Refuel only outdoors.
es Wipe up spills immediately.
Use unleaded petro! with a research octane number of
98 or higher.
NOTICE
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 “gasoho!”: 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 aicohol 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.
Owner's Manual
23
Engine Oil
Engine Oil Level Check
Check the engine oil level each day before operating
the motorcycle.
The oil filler cap/dipstick (1) is at the rear of the right
crankcase cover and contains a dipstick for measuring
the oil level. Oil level must be maintained between the
upper (2) and lower (3) level marks on the oil filler cap/
dipstick (1).
1. Hold the motorcycle upright on firm level ground.
2. Start the engine and let it idle for 3 — 5 minutes.
(1) Oil filler cap/dipstick
: (2) Upper level mark
(3) Lower level mark
3. Stop the engine. After 2 — 3 minutes, remove the oil
filler cap/dipstick (1), wipe it clean, and reinsert the
oil filler cap/dipstick without screwing it in. Remove
the oil filler cap/dipstick. The oil level should be
between the upper (2) and lower (3) level marks on
the oil filler cap/dipstick.
4. If required, add the specified oil (see page 44) up to
the upper level mark. Do not overfill.
5. Reinstall the oil filler cap/dipstick. Check for oil
leaks.
NOTICE
Running the engine with insufficient oil can cause
serious engine damage.
24
Tyres
To safely operate your motorcycle, the tyres must be
the proper type (off-road) and size, in good condition
with adequate tread, and correctly inflated.
A WARNING
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 owner's manual
regarding tyre inflation and maintenance.
Air Pressure
Properly inflated tyres provide 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. Underinflated tyres can also cause wheel
damage in rocky terrain. Overinfiated tyres make your
motorcycle ride harshly, are more prone to damage
from surface hazards, and wear unevenly.
Make sure the valve stem caps are secure.
If necessary, install a new cap.
Owner 's Manual
Always check air pressure when your tyres are “cold.”
If you check air pressure when your tyres are “warm” —
even if your motorcycle has only been ridden for a few
miles — the readings will be higher. if you let air out of
warm tyres to match the recommended cold pressures,
the tyres will be underinflated.
The recommended “cold” tyre pressures are:
Front Rear
Cold tyre pressures 100 100
kPa (kgf/cm*, psi) (1.0, 15) (1.0, 15)
Inspection
Whenever you check the tyre pressures, you should
also examine the tyre treads and sidewalls for wear,
damage, and foreign objects:
Look for:
« 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.
» 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.
Owner ’s Manual
25
Tread Wear
Replace tyres before tread depth at the center of the
tyre reaches the following limit:
Minimum tread depth
Front 3.0 mm (0.12 in)
Rear 3.0 mm (0.12 in)
(1) Tyre tread depth
Tube Repair and Replacement
If a tube is punctured or damaged, you should replace
it as soon as possible. A tube that is repaired may not
have the same reliability as a new one, and it may fail
while you are riding.
If you need to make a temporary repair by patching a
tube or using an aerosol sealant, ride cautiously at
reduced speed and have the tube replaced before you
ride again. Any time a tube is replaced, the tyre should
be carefully inspected as described on page 24.
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.
À WARNING
Installing 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 motorcycie are:
Front: 70/100 — 19 NHS 42M
Rear: 90/100 — 16 NHS 51M
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.
Also remember to replace the inner tube whenever you
replace a tyre. The old tube will probably be stretched,
and if installed in a new tyre, it could fail.
26
ESSENTIAL INDIVIDUAL COMPONENTS
Ignition Switch
The ignition switch (1) is located in front of handlebar.
The ignition switch is used to prevent unauthorized
use of the motorcycle.
Before riding, insert the key and turn it to the ON
position. After parking the motorcycle, remove the key.
Owner s Manual
(1) Ignition switch
Key position Function Key removal
OFF The engine cannot be operated. Key can be removed.
ON With the transmission in neutral, Key cannot be removed.
the engine can be started.
Owner's Manual 27
Start Button Engine Stop Button
The start button (1) is next to the throttle grip. The engine stop button (1) is next to the left handlebar
When the start button is pressed, the starter motor grip.
cranks the engine. See page 30 for the starting Push the button in and hold it in until the engine stops
procedure. completely.
(1) Start button | | (1) Engine stop button
28
FEATURES
(Not required for operation)
Left Side Cover
Removal
1. Remove the screw (1), bolt A (2) and bolt B (3).
2. Pull both side cover prongs (4) out of the rubber
grommets (5).
Installation
1. Slide the top of the side cover under the bottom
edge of the seat.
2. Align the side cover prongs with the rubber
grommets. Press the side cover into position.
3. Install the securing screw and bolts and tighten
them.
] Screw
) Bolt À
(3) Boll B
(4) Prongs
(5) Rubber grommets
Owner ’s Manual
Right Side Cover
Removal
1. Remove the screw (1).
2. Pull both side cover prongs (2) out of the rubber
grommets (3).
Installation
1. Slide the top of the side cover under the bottom
edge of the seat.
2. Align the side cover prongs with the rubber
grommets. Press the side cover into position.
3. Install the securing screw and tighten it.
(1) Screw
(2) Prongs
(3) Rubber grommets
Owners Manual
29
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.
Á WARNING
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 23). Check for leaks.
2. Fuel level — fill fuel tank when necessary (page 21).
Check for leaks.
3. Front and rear brakes — check operation; make sure
there is no brake fluid leakage. Adjust free play if
necessary (pages 17 — 19).
Tyres — check condition and pressure
(pages 24 and 25).
Spokes and rim locks — check and tighten if
necessary (page 53).
Drive chain — check condition and slack (page 49).
Adjust and lubricate if necessary.
Chain slider — check slider wear {page 50).
Throttle — check for smooth opening and full
closing in all steering positions. Adjust free play if
necessary (page 48).
Clutch — check operation, and adjust if necessary
(pages 19 and 20).
. Spark plug and high tension terminal — check for
looseness.
. Engine stop button — check for proper function
{page 27).
. Nuts, bolts, fasteners — check the front wheel to
see that the axle nut and axle holder nuts are
tightened securely. Check security of all other
nuts, bolts, and fasteners.
30
Starting the Engine
Always follow the proper starting procedure described
below.
This motorcycle can be started with the transmission
in gear by disengaging the clutch before operating the
starter.
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 start button for
approximately 10 seconds before pressing it again.
Preparation
Before starting, insert the key and turn the ignition
switch ON.
Make sure that the transmission is in neutral. Turn the
fuel valve ON.
Owner's Manual
Starting Procedure
To restart a warm engine, follow the procedure for
“High Air Temperature.”
Normal air temperature:
10° — 35°C (50° — 95°F)
—
1. Pull the choke lever (1) up all the way to Fully ON (A).
(1) Choke lever
y (A) Fully ON
Ne (В) Detent position
(C) Fully OFF
|
|
I
;
i
1. With the throttle closed, press the start button.
2. Immediately after the engine starts, push the choke
lever (1) down to the Detent Position (B).
NOTICE
Extended use of the choke may impair piston and
cylinder wall lubrication and damage the engine.
4. Warm up the engine by opening and closing the
throttle slightly.
5. About a half minute after the engine starts, push the
choke lever (1) down all the way to Fully OFF (C).
Owner's Manual
6. If idling is unstable, open the throttle slightly.
High air temperature
35°C (95°F) or above
1. Do not use the choke.
2. Start the engine following step 2 under “Normal Air
Temperature”
Low air temperature
10°C (50°F) or below
1. Foliow steps 1 — 3 under “Normal Air Temperature”.
2. Warm up the engine by opening and closing the
throttle slightly.
3. Continue warming up the engine until it will idle
smoothly with the choke lever (1) pushed down all
the way to Fully OFF (C).
NOTICE
Extended use of the choke may impair piston and
cylinder wall lubrication and damage the engine.
Flooded Engine
If the engine fails to start after repeated attempts, it
may be flooded with excess fuel. To clear a flooded
engine, push the choke lever down to Fully OFF (C).
Open the throttle fully and press the start button for
5 seconds while pushing the engine stop button.
Release the engine stop button and follow the “High Air
Temperature” Starting Procedure.
31
Running-in
Help assure your motorcycle’s future reliability and
performance by paying extra attention to how you ride
during the first operating day or 25 km (15 miles).
During this period, avoid full-throttle starts and rapid
acceleration.
32 Owner's Manual
Riding — as
Review Motorcycle Safety (pages 9 — 13) before you
ride.
Make sure the side stand is fully retracted before
riding the motorcycle. 1t the stand is extended, it may
interfere with control during a left turn.
Make sure you understand the function of the side
stand mechanism. (See “Maintenance Schedule” on 1
page 36 and explanation for “Side Stand” on page 59). —
1. After the engine has been warmed up, the
motorcycle is ready for riding.
+ Do not downshift when traveling at a speed that
would force the engine to overrev in the next lower
2. While the engine is idling, pull in the clutch lever gear; the rear wheel may lose traction, resulting in a
and depress the shift pedal to shift into 1st (low) possible loss of vehicle control.
gear. « Do not shift gears without disengaging the clutch
3. Slowly release the clutch lever and at the same time and closing the throttle. The engine and drive train
gradually increase engine speed by opening the could be damaged by overspeed and shock.
throttle. Coordination of the throttle and clutch lever
: о » Do not tow the motorcycle or coast for long
will assure a smooth positive start.
distances while the engine is off. The transmission
4. When the motorcycle attains a moderate speed, will not be properly lubricated and damage may
close the throttle, pull in the clutch lever and shift result.
to 2nd gear by raising the shift pedal. e Do not run the engine at high rpm with the
This sequence is repeated to progressively shift to transmission in neutral or the clutch lever pulled in.
3rd. 4th and Sth (top) gear. Serious engine damage may result.
5. Raise the shift pedal to shift to a higher gear and
depress the shift pedal to shift to a lower gear.
Each stroke of the shift pedal engages the next
gear in sequence. The shift pedal automatically
returns to the horizontal position when released.
Owners Manual
33
Braking
For normal braking, gradually apply both the front and
rear brakes while downshifting to suit your road speed.
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.
Important safety reminders
* Independent operation of only the brake lever or
brake pedal reduces stopping performance.
Extreme application of the brake controls may cause
wheel 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.
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.
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.
Parking
1. After stopping the motorcycle, shift the transmission
into neutral and turn the fuel valve OFF. Push the
engine stop button in and hold it in until the engine
stops completely.
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. Turn the ignition switch OFF and remove the key.
34
Anti-theft Tips
1. Be sure the registration information for your
motorcycle is accurate and current.
2. Park your motorcycle in a locked garage whenever
possible.
3. Use an additional anti-theft device of good quality.
4. Put your name, address and phone number in this
Owner's Manual and keep it on your motorcycle at
all times. Many times stolen motorcycles are
identified by information in the Owner's Manuals
which are stili with them.
Name:
Address:
Phone no.:
Qwner's Manual
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. Careful pre-ride inspections and
good maintenance are especially important because
your motorcycle is designed to be ridden over rough
off-road terrain.
To help you properly care for your motorcycle, this
section of the manual provides a Maintenance
Schedule.
The service intervals in this schedule are based on
average riding conditions.
More frequent service is needed if you subject your
motorcycle to severe use (such as competition) or ride
in unusually wet or dusty areas.
Frequent servicing of the air cleaner is especially important
to help you avoid a possible costly engine repair.
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.
À WARNING
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.
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 normaily 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.
A WARNING
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,
35
Safety Precautions
* 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.
Read the instructions before you begin, and make
sure you have the tools and skills required.
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.
To reduce the possibility of a fire or explosion, be
careful when working around petrol. Use only
nonflammable solvent, not petrol, to clean parts.
Keep cigarettes, sparks and flames away from 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.
36 Owners Manual
Maintenance Schedule
Perform the Pre-ride Inspection (page 29) 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 proper tools and service data and is
mechanically qualified. Refer to the Official Honda Shop Manual.
x* 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.
NOTE:
1. Service more frequently when ridden in wet or dusty conditions.
2. Replace every 2 years. Replacement requires mechanical skill.
Owner's Manual
Whichever — Initial Regular maintenance interval
Frequency comes Maint.
first km 150 | 1,000 | 2,000 | 3,000 | 4,000
| Refer
mi 100 600 1,200 | 1,800 | 2400 to
Items Note Month 1 12 18 24 page
* | Fuel line | | —
* | Throttle operation | |
Air cleaner Note (1) C C С С 41
Crankcase breather | | | I 43
Spark plug ! ! | |
* | Valve clearance | | | ! | —
Engine oil R R R R R 44
** | Engine oil strainer screen C C —
** | Engine oil centrifugal filter C С —
** | Engine idle speed | | | I | 47
Drive chain Note (1) IL every 500 km (300 mi) or 49
every 3 months: I, L
Drive chain slider | i | | 50
Brake fluid Note (2) I | ! | 17
Brake shoe/pad wear | | | | 55, 56
Brake system ! | | | | 17,55, 56
Clutch system | | | | | 19
Side stand | | 29
* | Suspension | | 58,59
* | Sparkarrester every 1,600 km (1,000 mi) or 49
every 100 operating hours: C
* Nuts, bolts, fasteners | | | —
** | Wheels/tyres | } | I I 24,53
** | Steering head bearings I I | -
38 Owner s Manual
Competition Inspection
All items should be checked before each competition event. See your Honda dealer unless you are mechanically
qualified and have the proper tools.
NOTE:
Refer to the Maintenance Schedule (page 36) for regular service intervals.
No. Items Inspection for Action Refer to page
1 All Pre-ride Inspection items | As listed 29
2 Engine oil Contaminants Change 23, 44 — 46
3 Fuel line Deterioration, damage or leakage Replace —
4 Valve clearance Correct clearance Adjust —
5 Engine idle speed Correct idle speed Adjust 47
6 Carburetor choke Proper operation — —
7 Clutch discs Proper operation, see NOTE 1 Replace —
8 Air cleaner Contamination or tears Clean or replace 41 — 43
9 Spark plug Gap, tightness, proper heat range, Tighten, replace 46 and 47
and high-tension terminal security or secure
10 Steering head bearings Free rotation of handlebar and Adjust or —
steering stem nut tightness retighten
NOTE 1:
Competition use may cause more rapid clutch disc wear.
Refer to the official Honda Shop Manual, or see your Honda dealer for clutch disassembly and wear inspection.
Owner's Manual
39
No. Items Inspection for Action Refer to page
11 Front suspension Smooth operation, no oil leaks, good Replace or adjust 58
boot condition and oil volume
12 Rear suspension Smooth operation and no oil leaks Replace or adjust 59
13 Swingarm bearings Smooth operation Replace -
14 Rear suspension linkage Wear Replace —
bushings
15 Brake pads Wear beyond service limit Replace 55
16 Drive chain: max. length/pins | 637 mm (25.1 in) / 41 Replace 49 — 52
17 Sprockets Wear and secure installation Replace or tighten 51
18 Seat Security Tighten —
19 Control cables Smooth operation, kinks and correct Lubricate or —
routing replace
20 Engine mounting bolts
Tightness
Tighten
40
Owner's Manual
Tool Kit
The spark plug wrench (1) and its handle (2) are stored
in the tool bag (3).
|
1 (1) Spark plug wrench
(7) Handle
3) Tool bag
(1) |
(2)
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) Frame number
The frame number (1) is stamped on the right side of
the steering head.
ENGINE NO.
(2) Engine number
The engine number (2) is stamped on the left side of
the engine.
Owner ’s Manual
41
Colour Label
The colour label (1) is attached to the frame behind the
left side cover (page 28).
It is helpful when ordering replacement parts. Record
the colour and code here for your reference.
COLOUR
CODE
(1) Colour labe
Air Cleaner
(Refer to the Safety Precautions on page 35.)
The air cleaner should be serviced at regular intervals
(page 36). Service more frequently when riding in
unusually wet or dusty areas.
1. Remove the right side cover (page 28).
2. Remove the screws (1) and air cleaner housing
cover (2).
(1) Screws
(2) Air cleaner housing
cover
3. Unhook the set spring (3), take care to avoid
bending the set spring and set spring holder (4).
4. Remove the air cleaner (5).
(3) Set spring
(4) Set spring holder
(5) Air cleaner
Owner ’s Manual
5. Remove the air cleaner holder (6) from the air
cleaner (5).
6. Wash the air cleaner in clean, nonflammable or high
ftash point solvent and let it dry thoroughly.
Never use petrol or low flash point solvents for
cleaning the air cleaner. A fire or explosion could
result.
7. Soak the air cleaner in gear oil {SAE 80 — 90) until
saturated, then squeeze out the excess oil.
8. Assemble the air cleaner and holder. Insert the tabs
(7) in the air cleaner holes (8).
(5) Air cleaner
(6) Air cleaner holder
(7) Tabs
(8) Holes
Owner's Manual
9.
10.
11.
12.
13.
Clean the inside of the air cleaner housing.
Apply a thin coat of grease to the sealing surface
of the air cleaner.
Install the air cleaner assembly by inserting the
upper tab (7) on the cleaner into the upper hole (9)
in the air cieaner housing, and the lower tab (7)
into the lower hole (10).
Hook the set spring.
Check that the air cleaner is properly seated.
Install the air cleaner housing cover and screws.
Install the right side cover (page 28).
(7) Tabs
(9) Upper hole
(10) Lower hole
43
Crankcase Breather
(Refer to the Safety Precautions on page 35.)
Service more frequently if your motorcycle is ridden in
the rain or often at full throttle.
Service the breather if you can see deposits in the
transparent section of the drain tube.
* Drain the deposits by pinching the plug (1).
(1) Crankcase breather plug
44
Engine Oil
(Refer to the Safety Precautions on page 35.)
Oil Recommendation
API SG or higher except oils labeled
classification as energy conserving on the
circular API service label
Viscosity SAE 10W-40
JASO T 903 MA
standard
Honda “4-STROKE MOTORCYCLE
OIL” or equivalent
Suggested oil
e Your motorcycle does not need oil additives.
Use the recommended oil.
e Do not use oils with graphite or molybdenum additives.
They may adversely affect clutch operation.
» Do not use API SH or higher oils displaying a circular
API “energy conserving” service label on the
container. They may affect lubrication and clutch
performance.
NOT RECOMMENDED
Owner ’s Manual
s Do not use non-detergent, vegetable, or castor
based racing oils.
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.
30 20 -10 0 10 20 30 40 50°C
Chel e .
20 0 20 40 60 80 100 120°F
JASO T 903 standard
The JASO T 903 standard is an index for engine oils
for 4-stroke motorcycle engines.
There are two classes: MA and MB.
Oil conforming to the standard is labeled on the oil
container. For example, the following label shows the
MA classification.
(1) Code number of the
sales company of the
ail
(2) Oil classification
PRODUCT MEETING JASO T 803
COMPANY GUARANTEEING THIS MA PERFORMANCE:
Owner's Manual
45
Engine Oi
Engine oil quality is the chief factor affecting engine
service life. Change the engine oil as specified in the
maintenance schedule (page 36).
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 possible
after handling used oil.
Changing the oil requires a torque wrench. If you do
not have it 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. Remove the engine guard (1) by removing the bolt A
(2), collar (3) and bolts B (4).
2. If the engine is cold, start it and let it idle for 3-5
minutes. Turn the engine off. Wait 2-3 minutes for
the oil to settle.
3. Park your motorcycle on its side stand on a firm,
level surface.
4. Place a drain pan under the crankcase.
5. To drain the oil, remove the oil filler cap/dipstick, oil
drain bolt (5), and sealing washer (6).
6. Pour the drained oil into a suitable container and
dispose of it in an approved manner.
) Engine guard
) Bolt A
) Collar
) Bolts B
) Oil drain bolt
Y Sealing washer
NOTICE
Running the engine with insufficient oil can cause
serious engine damage.
46
Owner ’s Manual
7. Check the condition of the sealing washer on the
oil drain bolt. Replace the washer every other time
the oil is changed.
Install the oil drain bolt and tighten to the specified
torque:
30 N-m (3.1 kgf-m, 22 Ibf-ft)
8. Pour the recommended oil into the crankcase,
approximately:
1.0 2 (1.1 US qt, 0.9 Imp qt)
9. Install the oil filler cap/dipstick securely.
10. Start the engine and let it idle for 3-5 minutes.
Stop the engine. Wait 2-3 minutes.
11. With the motorcycle held upright on level ground,
check the oil level.
If needed, add oil (page 23) until it reaches the
upper level mark. (Do not overfill.)
12. Check for oil leaks.
13. Install the engine guard.
Spark Plug
(Refer to the Safety Precautions on page 35.)
Recommended plugs:
Standard: CPRBEA — 9 (NGK)
For extended high speed riding:
CPR9EA - 9 (NGK)
NOTICE
Never use a spark plug with an improper heat range.
Severe engine damage could result.
1. Clean any dirt from around the spark plug base.
2. Disconnect the spark plug cap from the spark plug.
3. Remove the spark plug with the spark plug wrench
(1) and handie provided in the tool bag.
г DEF RP — | (1) Spark plug wrench
4. Visually inspect the spark plug electrodes for wear.
The center electrode (2) should have square edges
and the side electrode (3) should not be eroded.
5. Discard the spark plug if there is apparent wear or if
the insulator is cracked or chipped.
Owner ’s Manual
47
6. Check the spark plug gap (4) using a wire-type
feeler gauge. If adjustment is necessary, bend the
side electrode carefully.
The gap should be: 0.8 — 0.9 mm (0.03 — 0.04 in)
CT (2) Center electrode
(3) Side electrode
(4) Spark plug gap
7. Make sure the plug washer is in good condition.
8. With the plug washer attached, thread the spark
plug in by hand to prevent cross-threading.
9. Tighten the spark plug:
s If the old plug is good:
1/8 turn after it seats.
е If installing a new plug, tighten it twice to prevent
loosening:
a) First, tighten the plug:
NGK: 1/2 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
NOTICE
An improperly tightened spark plug can damage the
engine. If a plug is too loose, a piston may be damaged.
If a plug is too tight, the threads may be damaged.
10. Reinstall the spark plug cap.
Idle Speed
(Refer to the Safety Precautions on page 35.)
The engine must be at normal operating temperature
for accurate idle speed adjustment. 10 minutes of
stop-and-go riding is sufficient.
Do not attempt to compensate for faults in other
systems by adjusting idle speed. See your Honda
dealer for regularly scheduled carburetor adjustments.
(1) Throttle stop screw
(A) Increase
(B) Decrease
E
EA
(ON
A} 4,
Los
1. Warm up the engine and hold the motorcycle
upright.
2. Connect a tachometer to the engine.
3. Adjust idle speed with the throttle stop screw (1).
Idle speed (In neutral):
1,400 + 100 min” (rpm)
48
Owners Manual
Throttle Operation
(Refer to the Safety Precautions on page 35.)
Cable inspection
1. Check for smooth rotation of the throttle grip from
the fully open to the fully closed position at both full
steering positions.
2. Inspect the condition of the throttle cables from the
throttle grip down to the carburetor. If the cables are
kinked, chafed or improperly routed, they should be
replaced and/or rerouted.
3. Check the cables for tension or stress at all
steering position. Lubricate the throttle cables with a
commercially available cable lubricant to prevent
premature wear and corrosion.
| (1) Throttle cables
Free play adjustment
Measure the throttle grip free play at the throttle grip
flange.
The standard free play should be approximately:
2 — 6 mm (0.1 — 0.2 in)
To adjust free play, pull the rubber dust cover (2) back.
Loosen the lock nut (3) and turn the adjuster (4).
Tighten the lock nut and return the dust cover to its
normal position.
After adjustment, check for smooth rotation of the
throttle grip from the fully closed to the fully open
position in all steering positions.
If proper throttle free play cannot achieved, contact
your Honda dealer.
(1) Free play
TT] (2) Rubber dust cover
(3) Lock nut
(4) Adjuster
(A) Increase tree play
(B) Decrease free play
Owner's Manual
49
Spark Arrester
(Refer to the Safety Precautions on page 35.)
The exhaust system spark arrester must be purged of
accumulated carbon periodically (see Maintenance
Schedule for servicing period, page 36).
The exhaust system becomes very hot during
operationand remainshotfora period of time after
stopping the engine. Allow the exhaust system to cool
before performing this operation.
1. Remove the three bolts (2), the spark arrester (1)
and the gasket (3) from the muffler (4).
2. Use a brush to remove carbon deposits from the
spark arrester screen. Be careful to avoid damaging
the spark arrester screen. The spark arrester must
be free of breaks and holes. Replace, if necessary.
Check the gasket. -
Replace, if necessary.
3. Install the spark arrester
and the gasket in the
muffler and tighten the
three bolts securely.
Drive Chain
(Refer to the Safety Precautions on page 35.)
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 29). 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, raise the rear wheel off the
ground by placing a support under the engine, 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:
20 — 30 mm (0.8 — 1.2 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.
50
NOTICE
Excessive chain slack may allow the drive chain to
damage the engine cases.
(1) Drive chain
4. Check the chain slider (2), chain guide slider (3).
chain roller (4) and lower slider (5) for wear.
If the chain slider and lower slider are worn to the
bottom of the cutouts (6), have your Honda dealer
replace the slider. Replace the chain guide slider if
the chain is visible through the wear inspection
window (7).
Replace the chain roller if it is smaller than:
18 mm (0.7 in)
Owner's Manual
0
i
: (6) .
a.
i J ka (9)
— 5 _
т — RN No EEE E Г oT
A Neme Y emg Uv
= EE +; Re
- E Tel ee |
|
(2) Chain slider
(3) Chain guide slider
(4) Chain roller
(5) Lower slider
(6) Cutouts
(7) Wear inspection window
5. Measure a section of the drive chain to determine
whether the chain is worn beyond its service limit.
Measure the distance between a span of pins from
pin center to pin center, If the distance exceeds the
service limit, the chain is worn out and should be
replaced.
New chain: 635 mm (25.0 in)
Service limit: 637 mm (25.1 in)
Span of pins measured: 41
Owner's Manual
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 dealer.
6. Inspect the sprocket teeth for possible wear or
damage. Replace if necessary.
Damaged sprocket Worn sprocket
e
Replace
Sort
Normal sprocket Teeth
GOOD
Standard sprocket sizes:
Driven sprocket
(rear wheel)
Drive sprocket
(engine)
50 teeth
13 teeth
If the drive chain or sprockets are excessively worn or
damaged, they should be replaced. Never use a new
chain with worn sprockets; rapid chain wear will resuit.
51
Adjustment
If the drive chain requires adjustment, the procedure is
as follows:
1. Place a support block under the engine to raise the
rear wheel off the ground.
2. Loosen the rear axle nut (1) while holding the axle.
3. Turn both the right and left adjusters (2) equally to
increase or decrease chain slack.
4. After adjusting, be sure the same adjuster index
marks (3) align with the stopper pins (4) on both
sides of the swingarm.
If the drive chain slack is excessive when the rear
axle is moved to the furthest limit of adjustment, the
drive chain is worn and must be replaced.
5. Tighten the rear axle nut to:
108 N-m (11.0 kgf-m, 80 Ibf.ft)
It a torque wrench is not used for this installation, see
your Honda dealer as soon as possible to verify proper
assembly.
6. Recheck drive chain slack.
7. Rear brake pedal free play is affected when
repositioning the rear wheel to adjust drive chain
slack. Check rear brake pedal free play and adjust
as necessary (page 19).
o (1) Axle nut
(2) Chain adjuster
(3) Index mark
(4) Stopper pin
Lubrication and cleaning
Lubricate every 500 km (300 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.
Owner's Manual
Removal, cleaning and replacement
Your motorcycle has an endless (reveted master link)
type chain. it should only be removed or replaced by
your Honda dealer.
When the drive chain becomes dirty, it should be
removed and cleaned prior to lubrication.
1. Clean the side surfaces of the chain with a dry
cloth. Do not brush the rubber O-rings. Brushing will
damage them. Use of a solvent may also damage
the O-rings.
2. Inspect the drive chain for possible wear or damage.
Replace any chain that has damaged rollers, loose
fitting links, or otherwise appears unserviceable.
Replacement chain:
D.1.D. 520VD
Never use petrol or low flash point solvents for
cleaning the drive chain. A fire or explosion could
result.
3. Inspect the sprocket teeth for possible wear or
damage. Replace if necessary.
4, Lubricate the drive chain.
Owners Manual
Wheel Rims and Spokes
(Refer to the Safety Precautions on page 35.)
1. Inspect the wheel rims (1) and spokes (2) for
damage.
2. Tighten any loose spokes and rim locks (3).
3. Check wheel rim runout. ' runout is noticeable, see
your Honda dealer for inspection.
Maintenance of spoke tension and wheel trueness are
critical to safe motorcycle operation. During the first
150 km (100 miles), spokes will loosen more rapidly
due to initial seating of parts. Excessively loose
spokes may result in high speed instability and
possible loss of control.
(1) Wheel rim
(2) Spoke
(3) Rim lock
53
Wheel Removal
(Refer to the Safety Precautions on page 35.)
Front Wheel Removal
1. Raise the front wheel off the ground by placing a
support block under the engine.
2. Loosen the axle holder nuts (1).
3. Unscrew the axle (2). Remove the wheel.
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 brake fluid. If
this occurs, servicing of the brake system will be
necessary. See your Honda dealer for this service.
« (1) Axle holder nuts
(2) Front axle
54
Owner s Manual
Installation
1. Reverse the removal procedure. Insert the axle
through the wheel hub and left fork leg.
2. Tighten the axle.
Axle torque:
74 N-m (7.5 kgf-m, 54 Ibf.ft)
3. First tighten the upper holder nuts until lightly
seated, then tighten the lower axle nuts until lightly
seated.
4. Operate the front brake and pump the fork several
times.
5. First tighten the upper axle holder nuts to the
specified torque, then tighten the lower axle holder
nuts to the same torque:
12 N-m (1.2 kgf-m, 9 Ibf-ft)
6. 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.
Check front brake adjustment (page 17).
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. Unscrew the rear brake adjuster (1).
3. Press and release the rear brake pedal and
disconnect the brake rod (2) from the brake arm (3).
ile holding the axle.
—
par
Adjuster
(2) Brake rod
3) Brake arm
(4) Axle nut
(5) Chain adjusters
5. Turn both adjusters (5) so the rear wheel can be moved
all the way forward for maximum drive chain slack.
6. Move the rear wheel forward. Derail the drive chain
from the driven sprocket.
7 Remove the axle nut, chain adjusters, washer, side
collar, axle (6) and rear wheel from the swingarm.
po
(5) Chain adjusters
(6) Axle
Owner ’s Manual
Installation
1. Reverse the removal procedure. Make sure that the
lug (7) on the swingarm is located in the slot (8) in
the brake panel (9).
2. Adjust the drive chain (page 51).
3. Tighten the axle nut to:
108 N-m (11.0 kgf-m, 80 Ibf.ft)
4. Adjust the brake (page 18).
5. Apply the brake several times and check for free
wheel rotation after the brake pedal is released.
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.
| ©) Lug
(8) Slat
(9) Brake panel
55
Brake Pad Wear
(Refer to the Safety Precautions on page 35.)
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 36).
Front Brake
Check the cutout (1) in each pad.
If either pad is worn to the cutout, replace both pads
as a set. See your Honda dealer for this service.
FRONT BRAKE
56
Owner ’s Manual
Brake Shoe Wear
(Refer to the Safety Precautions on page 35.)
The rear brake is equipped with a brake wear indicator.
When the brake is applied, an arrow (1) attached to
the brake arm (2) moves toward a reference mark (3)
on the brake panel (4). If the arrow aligns with the
reference mark on full application of the brake, the
brake shoes must be replaced.
See your Honda dealer for this service.
When the brake service is necessary, see your Honda
dealer. Use only genuine Honda parts or its equivalent.
REAR BRAKE
PO (1) Arrow
| (2) Brake arm
pe e a ST Le (
Battery
(Refer to the Safety Precautions on page 35.)
lt 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.
NOTICE
Your battery is a maintenance-free type and can be
permanently damaged if the cap strip is removed.
À WARNING
The battery gives off explosive hydrogen gas during
normal operation.
A 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.
Owner ’s Manual
Battery Removal
The battery (4) is in the battery compartment behind
the left side cover.
Removal
1. Make sure the ignition switch is OFF.
2. Remove the left side cover (page 28).
3. Remove the battery holder (1).
4. Disconnect the negative (-) terminal lead (2) from
the battery first, then disconnect the positive (+)
terminal lead (3).
5. Pull out the battery (4) from the battery box.
Installation
1. Reinstall in the reverse order of removal. Be sure to
connect the positive (+) terminal first, then the
negative (-) terminal.
2. Check all bolts and other fasteners are secure.
(1) Battery holder
(2) Negative (-) terminal lead
(3) Positive (+) terminal lead
(4) Battery
57
Fuse Replacement
(Refer to the Safety Precautions on page 35.)
When frequent fuse failure occurs, it usually indicates
a short circuit or an overload in the electrical system.
See your Honda dealer for repair.
NOTICE
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,
Blown fuse
CTT
58
Main fuse
The main fuse (1) is located behind the left side cover.
The specified fuse is:
7.5 A
1. To prevent an accidental short circuit, turn the
ignition switch OFF before checking or replacing the
fuse.
2. Remove the left side cover (page 28).
3. Remove the starter magnetic switch (2) from the
battery box (3).
4 Disconnect the wire connector (4) of the starter
magnetic switch.
5. Pull out the fuse. If the fuse is blown install a new
main fuse (5).
6. Reconnect the wire connector.
7. Install the starter magnetic switch.
8. Install the left side cover.
Main fuse
Starter magnetic switch
Battery box
Wire connector
Spare main fuse
Owner's Manual
Front Suspension
(Refer to the Safety Precautions on page 35.)
Check the fork operation by locking the front brake
and pumping the forks up and down several times. The
suspension should function smoothly, with no oil
leakage from the fork legs. Damaged, binding, or
leaking fork should be repaired before the motorcycle
is operated. Check security of all fork and handlebar
mounting bolts (1).
loe A le
PR EA За
: Ns N
‘
(1
(1) Mounting bolts
—
|
| (ftustration only for reference)
Operating the motorcycle with loose, worn, or damaged
steering or front suspension components may
adversely affect vehicle handling and stability.
If any suspension components appear worn or
damaged, consult your Honda dealer for further
inspection. The suspesion components are directly
related to safety and your Honda dealer is qualified to
determine whether or not replacement parts or repairs
are needed.
Owner's Manual
Rear Suspension
(Refer to the Safety Precautions on page 35.)
Check the rear suspension periodically by careful
visual examination. Note the following items:
1. Swingarm bearings (1) 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.
2. Check all suspension component attachment points
for security of their fasteners (2).
3. Check for oil leaks in the shock absorber units.
If any suspension components appear worn or
damaged, consult your Honda dealer for further
inspection. The suspension components are directly
related to safety and your Honda dealer is qualified to
determine whether or not replacement parts or repairs
are needed.
(1) Swingarm bearings
(2) Fasteners
59
Side Stand
(Refer to the Safety Precautions on page 35.)
Check the side stand spring (1) for damage and loss
of tension, and the side stand assembly for freedom of
movement.
It the side stand is squeaky or stiff, clean the pivot
area and lubricate the pivot bolt with clean engine oil.
DR ma a (1) Side stand spring
¡PS 5
A La 1 Ñ Ex Im
— rá я te SN
60
Owner's Manual
CLEANING
Clean your motorcycle regularly to protect the surface
finishes and inspect for damage, wear and oil 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).
NOTICE
High pressure water (or air) can damage certain parts
of the motorcycle.
High pressure washer spray can damage certain parts
of your motorcycle. If you use a high pressure washer,
avoid spraying the following areas:
* Wheel hubs
» Muffler outlet
e Under seat
e Engine stop button
* Under fuel tank
« Drive chain
e Carburetor
e Ignition switch
* Brake master cylinders
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 mutfler 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.
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.
Owners Manual
61
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.
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 clean the filter screen.
2. Drain the fuel tank and carburetor into an approved
petrol container. Reinstall the fuel fill cap on the
tank.
To assure proper performance after storage lasting
more than one month, it is important to drain the
carburetor.
62
Owner 's Manual
A WARNING
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.
3.
To prevent rusting in the cylinder, perform the
following:
e Remove the spark plug cap from the spark plug.
Using tape or string, secure the cap to any
convenient plastic body part so that it is
positioned away from the spark plug.
e Remove the spark plug from the engine and store
it in a safe place. Do not connect the spark plug
to the spark plug cap.
e Pour a tablespoon (15 - 20 cm”) of clean engine
oil into the cylinder and cover the spark piug hole
with a piece of cloth.
Crank the engine several times to distribute the oil.
¢ Reinstall the spark plug and spark plug cap.
. Remove the battery. Store in an area protected from
freezing temperatures and direct sunlight.
Slow charge the battery once a month.
. Wash and dry the motorcycle. Wax all painted
surfaces. Coat chrome with rustinhibiting oil.
. Lubricate the drive chain (page 52).
. Inflate the tyres to their recommended pressures.
Place the motorcycle on blocks to raise both tyres
off the ground.
. 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.
Removal from Storage
1.
2.
с сл SS GO
Uncover and clean the motorcycle.
Change the engine oil if more than 4 months have
passed since the start of storage.
. Charge the battery as required. Install the battery.
_ Fill the fuel tank with fresh petrol.
. Perform all Pre-ride Inspection checks (page 29).
. Test ride the motorcycle at low speeds in a safe
riding area away from traffic.
Owner's Manual
SPECIFICATIONS
63
Item
Dimensions
Overall length
1,945 mm (76.6 in)
Maximum weight capacity
Overall width 798 mm (31.5 in)
Overall height 1,111 mm (43.7 in)
Wheelbase 1,328 mm (52.3 in)
Capacities
Engine oil After draining 1.02 (1.1 qt, 0.9 Imp qt)
After disassembly | 1.2 € (1. 3 at, 1.1 Imp qt)
Fuel tank 8.2 8 (2.17 TA gal, 1.80 Imp gal)
Fuel reserve 1.5 £ (0.40 US gal, 0.33 Imp gal)
Passenger capacity Operator only; no passenger
100 kg (220 Ibs)
ENGINE
ltem
Bore and stroke
Compression ratio
Displacement
Spark plug Standard
For extended high speed riding
Idle speed
Valve clearance (Cold) Intake
Exhaust
(
© 0.08 mm (0.003 in)
| 0.12 mm (0.005 in)
57.3 x 57.8 mm (2.26 x 2.28 in)
9.51
149.2 cm“ (9.10 cu-in)
CPR8EA - 9 (NGK)
CPR9EA — 9 (NGK)
1,400 + 100 min* (rpm)
64 Owner's Manual
CHASSIS AND SUSPENSION
Item
Caster | 26°02"
Trail 88 mm (3.5 in)
Tyre size, front
Tyre size, rear
70/100 — 19 NHS 42M
90/100 — 16 NHS 51M
POWER TRANSMISION
Item
Primary reduction 3.350
Gear ratio 1st 2.786
2nd 1.875
3rd 1.409
4th 1.120
Sth 0.938
Final reduction 1 3.615
ELECTRICAL
Item
Battery 12 V - 4 Ah
Alternator 0.056 kW/5,000 min-' (rpm)
Main fuse 7.5A
HONDA
The Power of Dreams
Printed in Brazil
A0700-0506
D2203MAN 0428 AA
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising