Owner's manual | Honda CRF 70F Offroad Motorcycle OWNER’S MANUAL

OWNERS MANUAL
CRF70F
2007
Honda CRF70F
OWNER’S MANUAL
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FOR OFF-ROAD USE ONLY
This vehicle 1s designed and manufactured for off-road use only.
USA only:
It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety
Standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or
highways is illegal. The vehicle is equipped with a USDA qualified spark arrester. Obey local laws and
regulations.
It conforms to US EPA and California exhaust emission regulations for off-road motorcycles.
A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an
important responsibility. |
To help you make informed decisions about safety, we have provided operating procedures and
other information on labels and in this manual. This information alerts you to potential hazards that
could hurt you or others.
Of course, it is not practical or possible to warn you about all hazards associated with operating or
maintaining a motorcycle. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
* Safety Labels — on the motorcycle.
* Safety Messages — preceded by a safety alert symbol AA and one of three signal words:
DANGER, WARNING, or CAUTION.
These signal words mean:
Safety Messages
A Few Words About Safety
| ADANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
i CAUTION You CAN be HURT if you don’t follow instructions.
* Safety Headings — such as Important Safety Reminders or Important Safety Precautions.
A WARNING
* Safety Section — such as Motorcycle Safety.
* Instructions — how to use this motorcycle correctly and safely.
This entire book 15 filled with important safety information — please read it carefully.
Safety Messages
Contents
These pages give an overview of the contents
of your owner’s manual. The first page of each
section lists the topics covered in that section.
Introduction
Motorcycle Safety .......
Important safety information, a special
message for parents, precautions about
loading, accessories, and modifications,
and the location of safety labels.
Operating Controls
The location, function, and operation of
the throttle, brakes, and other basic
controls.
Before Riding ..
The importance of wearing a helmet
and other protective gear, plus how to
make sure you and your motorcycle are
ready to ride.
Contents
13
23
Basic Operation & Riding . 29
How to start and stop the engine, shift
gears, and brake. Also, riding
precautions.
Servicing Your Honda 39
Why your motorcycle needs regular
maintenance, what you need to know
before servicing your Honda, a
maintenance schedule, and instructions
for specific maintenance 1tems.
Contents
Tips
How to transport and store your
motorcycle, and how to be an
environmentally-responsible rider.
Taking Care of the Unexpected...............
What to do if you have a flat tire, your
engine won't start, etc.
Technical Information
ID numbers, technical specifications,
and other technical facts.
Consumer Information .
Information on warranties and how to
get Honda service manuals.
Table of Contents ...........
Sequential listing of topics in this
owner's manual.
107
117
125
141
152
Index
Quick Reference
Handy facts about fuel, engine oil, tire sizes,
and air pressures.
Contents
Introduction
Congratulations on choosing your Honda off-
road motorcycle.
When you own a Honda, you're part of a
worldwide family of satisfied customers —
people who appreciate Honda's reputation for
building quality into every product.
Your Honda was designed as a recreational
motorcycle for off-road use by one rider only.
It’s an ideal bike for younger, beginning riders.
Before riding, take time to get acquainted with
your motorcycle and how it works. To protect
your investment, we urge you to take
responsibility for keeping your motorcycle well
maintained. Scheduled service is a must, of
course. But it’s just as important to observe the
break-in guidelines, and perform all the pre-
ride and other periodic checks detailed in this
manual.
Introduction
We also recommend that you read the owner’s
manual before you ride. It’s full of facts,
instructions, safety information, and helpful
tips. To make it easy to use, the manual
contains a table of contents, a detailed list of
topics at the beginning of each section, and an
index at the back of the book.
As you read this manual, you will find
information that 1s preceded by a
symbol. This information is intended
to help you avoid damage to your Honda, other
property, or the environment.
Read the Warranties Booklet (page 145 )
thoroughly so you understand the coverages
that protect your new Honda and are aware
of your rights and responsibilities.
Introduction
Whenever you ride, tread lightly. By staying on
established trails and riding only in approved
areas, you help protect the environment and
keep off-road riding areas open for the future.
If you have any questions, or if you ever need a
special service or repairs, remember that your
Honda dealer knows your motorcycle best and
is dedicated to your complete satisfaction.
Please report any change of address or
ownership to your Honda dealer so we will be
able to contact you concerning important
production information.
You may also want to visit our website at
www.honda.com.
Happy riding!
California Proposition 65 Warning
WARNING: This product contains or emits
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
Introduction
This section presents some of the most
important information and recommendations to
help you ride your motorcycle safely. Please
take a few moments to read these pages. This
section also includes a special message for
parents and location information for the safety
labels on your motorcycle.
Motorcycle Safety
Important Safety Information .......................... 2
Important Message to Parents.......................... 5
Loading, Accessories & Modifications ………… 8
Loading ................eeeeeeererececrccec nece 8
Accessories & Modifications..............—.... 10
Safety Labels..…....….........…..….…….rrerererersoneneacees 12
Motorcycle Safety 1
Important Safety Information
Y our 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.
This motorcycle has been designed for younger
riders. However, not all youngsters are
physically or emotionally ready to ride.
Therefore, before parents allow any youngster
to ride this motorcycle, we urge them to
carefully read the Important Message to
Parents beginning on page 5 and the Parents,
Youngsters and Off-Highway Motorcycles
booklet that came with the motorcycle (USA
only).
There 1s much that you can do to protect
yourself when you ride. You'll find many
helpful recommendations throughout this
manual. The following are a few that we
consider most important.
2 Motorcycle Safety
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 24 ).
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.
Important Safety Information
Ride Off-Road Only
Your motorcycle is designed and manufactured
for off-road use only. The tires 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.
Also be sure to read the Tips & Practice Guide
for the Off-Highway Motorcyclist booklet that
came with your motorcycle (USA only).
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.
Ride within Your Limits
Pushing 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 judgments and ride safely.
Motorcycle Safety 3
Important Safety Information
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 Honda 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.
4 Motorcycle Safety
Important Message to Parents
Your child’s safety 1s very important to Honda.
That's why we urge you to read this message
before you let any young person ride this
motorcycle. Off-road riding can be fun. But, as
with riding a bicycle, bad judgment can result
in injury, and we don’t want that to happen! As
a parent, you can help prevent accidents by
making good decisions about if, when, and
how your youngster rides this motorcycle.
The first decision you'll need to make is
whether your youngster is ready to ride. Riding
readiness varies widely from one person to
another, and age and size are not the only
factors.
PHYSICAL ABILITY is an important
consideration. For example, riders must be big
enough to hold the motorcycle up, get on, and
comfortably sit on the seat with both feet
touching the ground. They should also be able
to easily reach and work the brakes, throttle,
and all other controls.
ATHLETIC ABILITY 1s necessary for riding a
motorcycle. Generally speaking, your
youngster should be good at riding a bicycle
before getting on a motorcycle. Can your
youngster judge speeds and distances while
riding a bicycle and react with proper hand and
foot actions? Anyone who does not have good
coordination, balance, and agility is not ready
to ride this motorcycle.
(cont’d)
Motorcycle Safety 5
Important Message to Parents
MENTAL AND EMOTIONAL MATURITY
are requirements for safe riding. Does your
youngster think through problems and come to
logical solutions? On a bicycle, does your
youngster obey safe riding rules? Be honest!
Young people who take unnecessary risks,
make bad judgments, and don’t obey rules are
not ready to ride this motorcycle.
If you decide that your youngster is ready to
safely operate this motorcycle, make sure both
of you carefully read and understand the
owner’s manual before riding. Also be sure that
your youngster has a helmet and other
appropriate riding equipment and always wears
it when operating the vehicle or sitting on it.
6 Motorcycle Safety
GOOD INSTRUCTION 1s an important part of
hands-on training. The teacher can either be
you or another responsible adult who has
experience with off-road motorcycle riding.
(For help in finding a qualified instructor, talk
with your Honda dealer.) Even if you're not the
main teacher, it’s up to you to ensure your
youngster’s safety. Remember, learning to ride
a motorcycle 1s a gradual, step-by-step process.
It takes time, patience, and practice — many
hours over a period of weeks or months.
Important Message to Parents
SUPERVISION is another important obligation
of parents. Even after youngsters have become
skilled off-road riders, they should always ride
with adult supervision. It helps to regularly
remind young riders of basic safety rules and
precautions. And remember, it’s your
responsibility to see that the motorcycle is
properly maintained and kept in safe operating
condition.
SAFE AND RESPONSIBLE RIDING must be
an on-going commitment —by you and your
youngster. When you both put safety first, you
can enjoy more peace of mind, and your
youngster can enjoy more hours of safe off-
road riding.
For your convenience, this CRF70F comes
with an ignition switch and key. Remove the
key when the motorcycle is parked to help
prevent unauthorized use.
Motorcycle Safety 7
Loading, Accessories & Modifications
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 1t
unsafe. Also, the weight of any accessories Will
reduce the maximum load the motorcycle can
carry.
8 Motorcycle Safety
More specific information on load limits,
accessories, and modifications follows.
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.
A 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.
Loading, Accessories & Modifications
Load Limits
Following are the load limits for your
motorcycle:
Maximum weight capacity
= 132 Ibs (60 kg)
Includes the weight of the rider and any
accessories.
Loading Guidelines
As discussed on page 8, 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:
* 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.
* 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.
* Never exceed the maximum weight limit.
* Check that both tires are inflated properly.
Motorcycle Safety 9
Loading, Accessories & 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 modifications and
accessories.
10 Motorcycle Safety
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
this guideline:
* 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.
Loading, Accessories & Modifications
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 1t unsafe to ride.
We also advise you not to make any
modifications or remove any equipment (such
as the USDA qualified spark arrester or
emission control system components) that
would make the motorcycle illegal in your area.
Motorcycle Safety 11
Safety Labels
This page shows the locations of safety labels on your motorcycle. Some labels warn you of
potential hazards that could cause serious injury. Others provide important safety information. Read
these labels carefully and don’t remove them.
If a label comes off or becomes hard to read, contact your Honda dealer for a replacement.
( TIRE INFORMATION i)
Cold tire pressures : Front 100kPa 1.00kgf/cm? 15psi.
Rear 100kPa 1.00kgf/cm? 15psi.
Maximum weight capacity : 60kg(1321bs)
Tire size : Front 2.50-14 4PR
Rear 3.00-12 4PR
(ee
12 Motorcycle Safety
—
OFF ROAD USE ONLY
THIS VEHICLE IS DESIGNED AND MANUFACTURED
FOR OFF ROAD USE ONLY. IT DOES NOT CONFORM
TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS
AND OPERATION ON PUBLIC STREETS, ROADS, OR
| HIGHWAYS IS ILLEGAL.
For your protection, always wear
your helmet while riding.
Operator only. No passengers.
Read the owner's manual carefully.
When you ride off-road, you need to operate
the throttle, brakes, and other controls without
stopping to look at them. Read this section
carefully before you ride. It describes the
location, function, and operation of all the
basic controls on your motorcycle.
Operating Controls
Operation Component Locations.................... 14
Operating Controls..........................=..eee e. 17
Fuel Valve .....................erirercocein oe DD 17
Choke Lever....................e.erecerroenioe ee DD 18
Ignition SWIitch................e=e=erecrerrornenee De. 19
Engine Stop Switch... 20
Front Brake Le Ve are 20
TTOtE cease eee eee eee R REEL 20
Shift Lever ...................... 0.000 none eones 21
Rear Brake Pedal......................e.eee0rcrieiecena. 21
kickstarter..................enrcccrceeiec ene eee eee 21
Side Stand …….…...…......…......ercrssersscrsrsasarunee 21
Operating Controls 13
Operation Component Locations
front brake lever
throttle grip
engine stop switch
14 Operating Controls
Operation Component Locations
kickstarter
- ignition switch
rear brake pedal
Operating Controls 15
Operation Component Locations
choke lever fuel valve
shift lever
16 Operating Controls
Operating Controls
The three-way fuel valve is used to control the
flow of fuel from the fuel tank to the
carburetor.
ON
Turning the fuel valve ON before attempting to
start the engine allows fuel to flow from the
fuel tank to the carburetor.
OFF
Turning the fuel valve OFF after stopping the
engine prevents the flow of fuel from the fuel
tank to the carburetor.
RES
Turning the fuel valve to RES allows fuel to
flow from the reserve fuel supply to the
carburetor.
(cont’d)
Operating Controls 17
Operating Controls
The reserve fuel supply is:
0.29 US gal (1.1 2)
The tank should be refilled as soon as possible
after switching to reserve, and the fuel valve
should be returned to the ON position after
refueling to avoid running out of fuel with no
reserve.
LEFT SIDE
(1) choke lever
(A) fully ON
(B) fully OFF
18 Operating Controls
The choke lever is used for starting the engine
(page 31). The choke increases the percentage
of fuel in the fuel/air mixture delivered to the
engine.
ON
Used to start a cold engine with air temperature
below 35°C (95°F).
OFF
Used for normal operation, for restarting a
warm engine, or starting a cold engine with air
temperature above 35°C (95°F).
Operating Controls
The ignition switch (1) 1s used to prevent
unauthorized use of the motorcycle.
Before riding, insert the key and turn it to the
right for the ON position.
Key Function Key Removal
Position
OFF The engine cannot be | The key can
operated. be removed.
ON With the engine stop | The key
switch at RUN and the | cannot be
transmission in removed.
neutral, the engine
can be started.
After parking the motorcycle, remove the key.
Operating Controls 19
Operating Controls
The engine stop switch is used to turn the
engine off during normal riding situations. To
operate, turn the switch to the OFF ( 2% )
position. The switch must be in the RUN ( © )
position to start the engine.
The front brake lever is used to slow or stop
your motorcycle. To operate, pull the lever. For
information on braking techniques, see
page 36.
20 Operating Controls
The throttle controls engine rpm (speed). To
Increase engine rpm, rotate the grip toward you.
To reduce engine rpm, rotate the grip away
from you. The throttle will automatically return
to the closed position (engine idle) when you
remove your hand.
Operating Controls
The shift lever is used to select the next higher
or lower gear in the transmission. To operate,
raise the shift lever (after closing the throttle)
to engage the next higher gear or depress the
shift lever to engage the next lower gear. See
Shifting Gears, page 34.
The rear brake pedal 1s used to slow or stop
your motorcycle. To operate, depress the pedal.
For information on braking techniques, see
page 36.
The kickstarter is used to start the engine. To
operate, swing the kickstarter out from its
stored position and depress it through its entire
stroke. See Starting Procedure, page 31.
The side stand is used to support your
motorcycle while parked (page 37). To operate,
use your foot to lower the stand. Before riding,
raise the stand.
Operating Controls 21
22 Operating Controls
Before each ride, you need to make sure you
and your Honda are both ready to ride. To help
get you prepared, this section discusses how to
evaluate your riding readiness, and how to
perform the recommended pre-ride inspection
of your Honda. If you're a parent, be sure you
also read the Important Message to Parents on
page 5.
Before Riding
Are You Ready to Ride ? ......................emmeee.. 24
Protective Apparel .....................es00000eeenen 24
Is Your Motorcycle Ready to Ride ? ............. 26
Pre-ride Inspection ..................... eee... 27
Before Riding 23
Are You Ready to Ride?
Before you ride your motorcycle for the first
time, we strongly recommend that you:
* read this owner’s manual
* make sure you understand all the safety
messages
* know how to operate all the controls
Before each ride, we also suggest that you
make sure you:
* are in good physical and mental condition
* are free of alcohol and drugs
* are wearing an approved motorcycle helmet
(with chin strap tightened securely), eye
protection, and other protective clothing
24 Before Riding
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 1s not possible, wearing the proper
gear can reduce the chance of injury when you
ride. Following are suggestions to help you
choose the proper gear.
Are You Ready to Ride?
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.
Helmets and Eye Protection
Your helmet is your most important piece of
riding gear because it offers the best protection
against head injuries. A helmet should fit your
head comfortably and have a chin strap that can
be tightened securely.
An open-face helmet offers some protection,
but a full-face helmet offers more. Regardless
of the style, look for a DOT (Department of
Transportation) sticker in any helmet you buy
(USA only). 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.
Before Riding 25
Is Your Motorcycle Ready to Ride?
Before each ride, it’s important to inspect your
motorcycle and make sure any problem you
find is corrected. A pre-ride inspection is a
must because off-road riding can be tough on a
motorcycle and you don’t want to have a
breakdown far from help.
A WARNING
Improperly maintaining this motorcycie
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.
26 ¡Before Riding
Note to Parents:
If a youngster will be performing any of the
following pre-ride inspection procedures, it’s
vour responsibility to provide careful
supervision and make sure they are performed
safely.
Is Your Motorcycle Ready to Ride?
Check the following items before you get on
the motorcycle:
Tires
Spokes &
Rims
Leaks
Engine Oil
Use a gauge to check the air
pressure. Adjust if needed. Also
look for signs of damage or
excessive wear (page 92 ).
Make sure the spokes are tight.
Also check the rims for damage
(page 87 ).
Look under the motorcycle for
signs of leaking fluids (fuel,
engine oil).
Check the level and add oil if
needed (page 61).
Fuel
Drive Chain
Cables
Nuts &
Bolts
Spark Plug
& Cap
Check the level and add fuel
(page 55 ) if needed. Also make
sure the fuel fill cap 1s securely
fastened.
Check the condition and slack.
Adjust and lubricate if needed.
Also check the chain slider for
wear and replace if needed
(page 97).
Check the cable housings for
wear. Check the fittings for
looseness. Replace or tighten as
needed.
Use a wrench to make sure all
accessible nuts, bolts, and
fasteners are tight.
Check for looseness (page 75 ).
Before Riding 27
Is Your Motorcycle Ready to Ride?
Check these items after you get on the Remember, be sure to take care of any problem
motorcycle: you find or have your Honda dealer correct it
before you ride.
Throttle Check the freeplay and adjust if
needed. Rotate the throttle to
make sure it moves smoothly
without sticking, and snaps shut
automatically when it is released,
in all steering positions
(page 67).
Brakes Squeeze the front brake lever
and step on the rear brake pedal
to check that the controls
operate normally (page 82).
Adjust freeplay, if necessary.
(pages 82, 84).
28 Before Riding
Basic Operation & Riding
This section gives basic information on how to
begin riding your motorcycle. It includes how
to start and stop your engine, how to use the
throttle and brakes, and what to do when you're
through riding.
For more advanced information —how to make
turns, ride on hills, etc., see the Tips & Practice
Guide for the Off-Highway Motorcyclist
booklet that came with your Honda (USA only).
To protect your new engine and enjoy optimum
performance and service life, refer to Break-in
Guidelines (page 133).
For information about carburetor adjustment
for riding at high altitude, see page 134.
Safe Riding Precautions................ee..ereece... 30
Starting & Stopping the Engine..................... 31
Preparation ….….…..…...…….…rerercrarensererennnesce 31
Starting Procedure... 31
Flooded Engine ….…..…..…..…..…rererereressesenenee 33
How to Stop the Engine... 33
Shifting Gears …….......erecccercrrccrarenenen ns en000e 34
BrAKINE..........…cccrcrerrrorrrenrrna ra ra rarerereee sauna 0es 36
Parking ...............esererecercecenenececocecenerececececarecee. 37
Post-ride Inspection seen 38
Basic Operation € Riding 29
Basic Operation & Riding
Before riding your motorcycle for the first time,
please review the Important Safety
Information beginning on page 2 and the
previous section, titled Before Riding.
Even if you have ridden other motorcycles,
take time to become familiar with how this
motorcycle works and handles. Practice in a
safe area until you build up your skills and get
accustomed to your motorcycle’s size and
weight.
For your safety, avoid starting or operating the
engine in an enclosed area such as a garage.
Your motorcycle’s exhaust contains poisonous
carbon monoxide gas which can collect rapidly
in an enclosed area and cause illness or death.
30 Basic Operation & Riding
Your motorcycle is not equipped with lights.
Do not ride at night.
Starting & Stopping the Engine
Always follow the proper starting procedure
described below.
To restart a warm engine, follow the procedure
for High Air Temperature.
Before starting, insert the key and turn the Normal Air Temperature
ignition switch ON. 10° — 35°C (50° — 95°F)
Make sure that the transmission is in neutral
and the engine stop switch is at RUN ( © ). LEFT SIDE
Turn the fuel valve ON.
(1) choke lever (A) fully ÓN
(B) fully OFF
|. Pull the choke lever ( 1) up all the way to
fully ON (A).
(cont d)
Basic Operation & Riding 31
Starting & Stopping the Engine
2. With the throttle slightly open, operate the
kickstarter. Kick from the top of the stroke
through to the bottom with a rapid,
continuous motion.
Allowing the kickstarter to snap back freely
against the pedal stop can damage the engine
case.
3. Warm up the engine by opening and closing
the throttle slightly.
4. About a quarter-minute after the engine
starts, push the choke lever down all the way
to fully OFF (B).
5. If idling 1s unstable, open the throttle slightly.
32 Basic Operation £ Riding
High Air Temperature
35°C (95°F) or above
1. Do not use the choke.
2. Start the engine (see step 2 under Normal
Air Temperature).
Low Air Temperature
10°C (50°F) or below
1. Follow steps 1 — 2 under Normal Air
Temperature.
2. Warm up the engine by opening and closing
the throttle slightly.
3. Continue warming up the engine until it idles
smoothly and responds to the throttle with
the choke lever (1) OFF (B).
Extended use of the choke may impair piston
and cylinder wall lubrication and damage the
engine.
Starting & Stopping the Engine
If the engine fails to start after repeated To stop the engine, shift into neutral, turn the
attempts, it may be flooded with excess fuel. engine stop switch to OFF ( & ).
To clear a flooded engine:
1. Turn the engine stop switch to OFF ( & ).
2. Push the choke lever down all the way to
OFF.
3. Open the throttle fully.
4. Crank the engine several times with the
kickstarter.
. Turn the engine stop switch to RUN ( О).
. Follow the High Air Temperature starting
procedure (page 32).
ON Lh
Basic Operation & Riding 33
Shifting Gears
„©
Your motorcycle has three forward gears.
To start riding, after the engine has been
warmed and the side stand raised:
1. Close the throttle and pull the front brake
lever in.
2. Raise the shift lever from neutral up to first
gear.
34 Basic Operation & Riding
3. Release the front brake. Gradually open the
throttle.
4. When you attain a moderate speed, close the
throttle and raise the shift lever. After
shifting, apply the throttle.
5. To continue shifting up to each higher gear,
repeat step 4.
6. To shift down to a lower gear, close the
throttle and depress the shift lever. After
shifting, apply the throttle.
Remember to close the throttle before shifting.
Improper shifting may damage the engine,
transmission, and drive train.
Shifting Gears
Learning when to shift gears comes with
experience. Upshift to a higher gear or reduce
throttle before engine rpm (speed) gets too high.
Downshift to a lower gear before you feel the
engine laboring (lugging) at low rpm.
Downshifting can help slow your motorcycle,
especially on downhills. However,
downshifting when engine rpm is too high can
cause engine damage.
To prevent transmission damage, do not coast
or tow the motorcycle for long distances with
the engine off.
Basic Operation & Riding 35
Braking
To slow or stop, apply the front brake and rear
brake pedal smoothly, while downshifting to
match your speed. Gradually increase braking
as you feel the brakes slowing your speed. For
support, put your left foot down first, then your
right foot when you are through using the rear
brake.
For maximum braking, close the throttle and
firmly apply the brake lever and pedal controls.
Applying the brakes too hard may cause the
wheels to lock and slide, reducing control of
your motorcycle. If this happens, release the
brake controls, steer straight ahead until you
regain control, then reapply the brakes more
gently.
36 Basic Operation € Riding
Generally, reduce your speed or complete
braking before beginning a turn. Avoid braking
or closing the throttle quickly while turning.
Either action may cause one or both wheels to
slip. Any wheel slip will reduce your control of
your 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 downshifting,
with intermittent use of both brakes.
Parking
Lower the side stand to support your
motorcycle. Turn the ignition switch OFF and
remove the key. If you're through riding for
the day, also turn the fuel valve OFF. Always
choose a level place to park.
Basic Operation & Riding
37
Post-ride Inspection
When you return home after riding, thoroughly
clean your motorcycle and remove any dirt,
mud, brush, rocks or other objects you may
have picked up along the way.
After cleaning, carefully inspect your
motorcycle for leaks or damage.
Be sure to lubricate the drive chain (page 101)
to prevent rusting.
38 Basic Operation & Riding
Servicing Your Honda
Keeping your motorcycle well maintained is
absolutely essential to your safety. It’s also a
good way to protect your investment, get
maximum performance, avoid breakdowns, and
have more fun.
To help keep your motorcycle in good shape,
this section includes a Maintenance Schedule
for required servicing and step-by-step
instructions for specific maintenance tasks.
You'll also find important safety precautions,
information on oils, and tips for keeping your
Honda looking good.
For information about the exhaust emission and
noise emission requirements of the U.S.
Environmental Protection Agency (EPA) and
the California Air Resources Board (CARB),
see page 135.
An optional tool kit may be available. Check
with your Honda dealer’s parts department.
USA only
Maintenance, replacement or repair of the emission
control devices and systems may be performed by
any motorcycle repair establishment or individual
using parts that are “certified” to EPA standards.
Before You Service Your Honda
The Importance of Maintenance..................... 41]
Maintenance Safe Yo... een 43
Important Safety Precautions...................... 43
Maintenance Schedule ................... 2.2... 45
Maintenance Record ................eeeenerccicaenenene. 49
(cont’d)
Servicing Your Honda 39
Servicing Your Honda
Service Preparations
Maintenance Component Locations ...............
Seat Removal ...................... meine EEK
Side Cover Removal .....................eeeee0meeneees
Service Procedures
Fluids & Filters
Engine Oil ccc,
Air Cleaner ..............._eereeccconoreracreneneraroroeoarere—.
Engine
Throttle.......................ececercinnenone nene nren ene.
Clutch System ..........e.e=eene. e... noreverccacocecenneceanee.
Valve Clearance ......................0000cccccecenDeD ee
Engine Idle Speed .................e..e.eeeceneneneninne
Spark Plug rer nens
Spark Arrester sienne
40 Servicing Your Honda
Chassis
Suspension ..............e.e0ececeei e De 79
Brakes...............enccrcccorconenen oca econo eee 82
Wheels .................eeeieenerenerenconoeone enero. 87
Tires & Tubes..................0.r000mmeen ce eee 92
Side Stand .....................e.eeeeereoee nene eee EEK 96
Drive Chain ..................2.erecemorcermereceo ene Dee 97
Appearance Care .......................0000000 104
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
1s 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 is involved in a
crash, be sure your Honda dealer inspects all
major parts, even if you are able to make some
repairs.
A 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 owners manual.
(cont’d)
Servicing Your Honda 41
The Importance of Maintenance
Remember, proper maintenance is the owner's
responsibility. Be sure to inspect your
motorcycle before each ride and follow the
Maintenance Schedule in this section.
42 Servicing Your Honda
Note to Parents:
As a parent, it’s up to you to make sure that
this motorcycle is properly maintained and
kept in safe operating condition. For
youngsters, learning how to take care of a
motorcycle and perform basic maintenance
can be an important part of their riding
experience. However, if you allow a youngster
to perform or assist in any maintenance task,
such as filling the tank with gasoline, you
should provide close supervision to make sure
that it is performed safely.
Maintenance Safety
The maintenance section includes instructions
on how to perform some important
maintenance tasks. 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.
* Make sure the engine 1s off before you begin
any maintenance or repairs.
This will help eliminate several potential
hazards:
Carbon monoxide poisoning from engine
exhaust. Be sure there 1s adequate
ventilation whenever you operate the engine.
Burns from hot motorcycle parts. Let the
engine and exhaust system cool before
touching.
Injury from moving parts. Do not run the
engine unless instructed to do so.
(cont’d)
Servicing Your Honda 43
Maintenance Safety
e 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
gasoline. Use only a non-flammable (high
flash point) solvent such as kerosene — not
gasoline — to clean parts. Keep cigarettes,
sparks, and flames away from all fuel-
related parts.
44 Servicing Your Honda
Maintenance Schedule
To maintain the safety and reliability of your
motorcycle, regular inspection and service 1s
required as shown in the Maintenance Schedule
that follows.
The Maintenance Schedule lists items that can
be performed with basic mechanical skills and
hand tools. Procedures for these items are
provided in this manual.
The Maintenance Schedule also includes items
that involve more extensive procedures and
may require special training, tools, and
equipment. Therefore, we recommend that you
have your Honda dealer perform these tasks
unless you have advanced mechanical skills
and the required tools. Procedures for items in
this schedule are provided in a service manual
available for purchase from your dealer
(page 142).
Because your motorcycle does not have an
odometer, service intervals in the maintenance
schedules are expressed in terms of riding days
as well as miles. To avoid overlooking required
service, we urge you to develop a convenient
way to record the number of days and/or miles
you ride.
If you do not feel capable of performing a
given task or need assistance, remember that
your Honda dealer knows your motorcycle best
and 1s fully equipped to maintain and repair it.
If you decide to do your own maintenance, use
only genuine Honda parts or their equivalents
for repair or replacement to ensure the best
quality and reliability.
(cont’d)
Servicing Your Honda 45
Maintenance Schedule
Perform the pre-ride inspection (page 27 ) at
each scheduled maintenance period.
Each item on the maintenance schedule
requires some mechanical knowledge. Certain
items (particularly those marked * and **) may
require more technical information and tools.
Consult your Honda dealer.
* Should be serviced by your Honda dealer,
unless the owner has the proper tools and
service data and is mechanically qualified.
Refer to the official Honda Service Manual
(page 142).
**In the interest of safety, we recommend
these items be serviced only by your Honda
dealer.
46 Servicing Your Honda
Summary of Maintenance Schedule Notes and
Procedures:
NOTE:
|. Service more frequently when ridden in wet
or dusty conditions.
Maintenance Procedures:
I: inspect and clean, adjust, lubricate, or
replace, 1f necessary
clean
adjust
lubricate
replace
AN
Maintenance Schedule
Whichever Initial Maint. Interval
Frequency Comes First Maint.
= mi 100
[tems km 150
Note Month 1
Fuel Line
Air
V
Oil Filter
“Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified.
Refer to the official Honda Service Manual (page 142 ).
** In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Servicing Your Honda 47
Maintenance Schedule
Whichever Regular Maint. Interval
Frequency Comes
= mi
km
I
Spark Arrester C: every 1,000 mi (1,600 km) or
00 hours
|
*
Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified.
Refer to the official Honda Service Manual (page 142).
** In the interest of safety, we recommend these items be serviced only by your Honda dealer.
48 Servicing Your Honda
Maintenance Record
Keeping an accurate maintenance record will help ensure that your motorcycle 1s properly
maintained. Use the space under Notes to record anything you want to remind yourself about or
mention to your dealer, Of course, if you find any problem while servicing your motorcycle, be sure
it 1s corrected as soon as possible.
Miles Date Performed By: Notes
(km)
600 (1,000)
1,200 (2,000)
1,800 (3,000)
2,400 (4,000)
3,000 (5,000)
3,600 (6,000)
4,200 (7,000)
4,800 (8,000)
5,200 (9,000)
Servicing Your Honda 49
Maintenance Component Locations
front brake lever
throttle grip
50 Servicing Your Honda
Maintenance Component Locations
engine oil filler cap/dipstick
clutch adjuster
spark plug
spark arrester
engine ol rear brake
(under engine) pedal
Servicing Your Honda 51
Maintenance Component Locations
choke lever
air cleaner
ACT
ME
м
AN ER
4 [PIT TEC
Vus
OMA
engine idle speed drive chain
52 Servicing Your Honda
Seat Removal
Refer to Safety Precautions on page 43 .
5 ? aD
(6) 2 A Ae ras
De
Ч a
TN RS
Ё IS > (3)
NA
(1) bolts A (5) slot
(2) bolts B (6) fuel tank bolt
(3) side cover prongs
(7) seat prongs
(4) rubber grommets
Removal |
1. Remove the bolts A ( 1) on each side of the
rear fender.
2. Remove the bolts B (2) under the rear
fender.
3. Pull both side cover prongs (3) out of the
rubber grommets (4).
4. Slide the seat and rear fender back.
Installation
1. Align the slot (5) on the front of the seat
with the bolt (6) on the rear of the fuel tank
— and insert the seat prongs (7) under the
seat into the spaces for them in the frame.
2. Align the side cover prongs with the rubber
grommets. Press the side cover into position.
3. Install the bolts and tighten them.
Servicing Your Honda 53
Side Cover Removal
Refer to Saf ety Precautions on page 43.
LEFT SIDE
(1) bolt
(2) prong
(3) rubber grommet
54 Servicing Your Honda
Removal
|. Remove the bolt ( 1) securing the side cover.
2. Pull the side cover prong (2) out of the
rubber grommet (3).
Installation
1. Attach the side cover on the rear frame.
2. Align the side cover prong with the rubber
grommet. Press the side cover into position.
3. Install the securing bolt and tighten it.
Use the same procedure to remove and install
the right side cover.
Fuel
Refer to Safety Precautions on page 43.
Type unleaded
Pump Octane 86 (or higher)
Number
Your engine 1s designed to use any gasoline
that has a pump octane number of 86 or higher.
Gasoline pumps at service stations normally
display the pump octane number. For
information on the use of oxygenated fuels, see
page 139.
Use of lower octane gasoline can cause
persistent ‘‘pinging’’ or ‘spark knock’ (a
louder rapping noise) which, if severe, can lead
to engine damage. (Light pinging experienced
while operating under a heavy load, such as
climbing a hill, 1s no cause for concern.)
If pinging or spark knock occurs at a steady
engine speed under normal load, change brands
of gasoline. If pinging or spark knock persists,
consult your Honda dealer.
We recommend that you use unleaded fuel
because it produces fewer engine deposits and
extends the life of exhaust system components.
Never use stale or contaminated gasoline or an
oil/gasoline mixture. Avoid getting dirt, dust,
or water in the fuel tank.
Servicing Your Honda 55
Fuel Tank Capacity, including reserve:
1.45 US gal (5.5 9)
Reserve Capacity:
0.29 US gal (1.1 2)
(1) fuel fill cap
(2) breather tube
(3) front number plate
(4) filler neck
56 Servicing Your Honda
|. To open the fuel fill cap ( 1), pull the
breather tube (2) away from the front
number plate (3). Turn the fuel fill cap
counterclockwise and remove it.
2. Add fuel until the level reaches the bottom
of the filler neck (4). Avoid overfilling the
tank. There should be no fuel in the filler
neck.
AWARNING
Gasoline is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
* Stop the engine and keep heat,
sparks and flame away.
* Handle fuel only outdoors.
* Wipe up spills immediately.
Fuel
3. After refueling, turn the fuel fill cap
clockwise until it is secure.
4. Check that the breather tube is properly
seated in the front number plate.
If you replace the fuel fill cap, use only a
genuine Honda replacement part.
Servicing Your Honda
57
Engine Oil
Refer to Safety Precautions on page 43 .
Using the proper oil, and regularly checking,
adding, and changing oil will help extend your
engine's life. Even the best oil wears out.
Changing oil helps get rid of dirt and deposits
held in the engine. Operating the engine with
old or dirty oil can damage your engine.
Running the engine with insufficient oil can
cause serious damage to the engine and
transmission.
58 Servicing Your Honda
API classification
SG or higher except
oils labeled as
energy conserving
on the circular API
service label
viscosity (weight) SAE 10W-30*
JASO T 903 standard | MA
suggested oil* * Pro Honda GN4 or
HP4 (without
molybdenum
additives) 4-stroke
oil (USA 8: Canada),
or Honda 4-stroke oil
(Canada only), or an
equivalent
motorcycle oil
Engine Oil
* For normal air temperatures. See next page
for additional temperature/viscosity
information.
**Suggested oils are equal in performance to
SJ oils that are not labeled as energy
conserving on the circular API service label.
® Your motorcycle does not need oil additives.
Use the recommended oil.
* 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 OK
* Do not use non-detergent, vegetable, or
castor based racing oils.
Servicing Your Honda 59
Engine Oil
Other viscosities shown in the following chart
may be used when the average temperature in
your riding area 1s within the indicated range.
-30 -20 10 0 10 20 30 40 50°C
! | | I | 1
| |
-20 0 20 40 60 $80 100 120°F
60 Servicing Your Honda
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 1s labeled on the
oil container. For example, the following label
shows the MA classification.
PRODUCT MEETING JASO T 903
COMPANY GUARANTEEING THIS MA PERFORMANCE:
(1) code number of the sales company of the oil
(2) oil classification
Engine Oil
RIGHT SIDE
(1)
>} 7
N N = X eh
y ак
Ud E
АОН в ИСУ
DD ae)
— > | E
(1) oil filler cap/dipstick
(2) upper level mark
(3) lower level mark
|. Park your motorcycle on a firm, level
surface.
2. Clean around the oil filler cap/dipstick (1)
and nearby surfaces.
. Start the engine and let it idle for 3-5
minutes. Stop the engine. Wait 2-3 minutes.
. Immediately unscrew and remove the oil
filler cap/dipstick. Wipe it clean.
. Hold the motorcycle upright.
. Insert the oil filler cap/dipstick until it seats,
but do not screw 1t in.
. Remove the oil filler cap/dipstick and check
the oil level.
* If the oil is at or near the upper level mark
(2), you do not have to add oil.
If the oil is below or near the lower level
mark (3 ), add the recommended oil until
it reaches the upper level mark. (Do not
overfill.)
. Insert the oil filler cap/dipstick and screw it
in tightly.
. Check for oil leaks.
Servicing Your Honda 61
Engine Oil
RIGHT SIDE
(1) oil drain bolt
(2) sealing washer
62 Servicing Your Honda
|. 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.
. Park your motorcycle on a firm, level
surface.
. Remove the oil filler cap/dipstick.
. Place a drain pan under the crankcase.
. Unscrew and remove the oil drain bolt (1).
. After most of the oil is drained, gently tilt
the motorcycle from side to side to drain the
remaining oil.
7. Pour the drained oil into a suitable container
and dispose of it in an approved manner
(page 115).
Improper disposal of drained fluids is harmful
to the environment.
г
ON an Æ Lo
Engine Oil
10.
11.
12.
. Remove the old sealing washer (2) and
install a new sealing washer on the drain bolt.
. Install the oil drain bolt and tighten to the
specified torque:
18 Ibf-ft (24 N-m , 2.5 kgf-m)
Pour the recommended oil into the crankcase,
approximately:
0.6 US qt (0.6 2)
Install the oil filler cap/dipstick securely.
Start the engine. Let it idle 3-5 minutes, then
turn it off.
13. With the motorcycle held upright on level
ground, check the oil level.
If needed, add oil (page 61 ) until it reaches
the upper level mark. (Do not overfill.)
14. Check for oil leaks.
Servicing Your Honda 63
Air Cleaner
Refer to Safety Precautions on page 43.
Proper air cleaner maintenance is very
important for off-road vehicles. A dirty, water-
soaked, worn-out, or defective air cleaner will
allow dirt, dust, mud, and other impurities to
pass into the engine.
Service the air cleaner more frequently if you
ride in unusually wet or dusty areas. Your
Honda dealer can help you determine the
correct service interval for your riding
conditions.
Your motorcycle’s air cleaner has very specific
performance requirements. Use a new genuine
Honda air cleaner specified for your model or
an air cleaner of equal quality.
64 Servicing Your Honda
Using the wrong air cleaner can result in
premature engine damage.
Proper air cleaner maintenance can prevent
premature engine wear or damage, expensive
repairs, low engine power, poor gas mileage,
and spark plug fouling.
Improper or lack of proper air cleaner
maintenance can cause poor performance and
premature engine wear.
Air Cleaner
LEFT SIDE a >
CRE << | N.
/ bE 5- = / J |
— С wi a b y \
Ss 7 Й
У Ah >. 7
/ Zo A ;
SNAP
вы MD y
(1) attaching screws © -
(2) air cleaner housing cover
(3) air cleaner
(4) projection (air cleaner housing cover)
(5) projection (air cleaner housing)
La Y
. Remove the two attaching screws ( 1) and
the air cleaner housing cover (2).
. Remove the air cleaner (3).
. Gently wash the air cleaner in clean, non-
flammable (high flash point) solvent such as
kerosene —not gasoline. After cleaning,
gently squeeze out the remaining solvent.
Avoid twisting or wringing the air cleaner.
This can tear the foam.
. Inspect for tears or cracks in the foam or
seams of the air cleaner. Replace the air
cleaner if it 1s damaged.
. Allow the air cleaner to dry thoroughly
before applying oil. A wet air cleaner will
not fully absorb the oil.
(cont’d)
Servicing Your Honda 65
Air Cleaner
6. Pour clean Pro Honda Foam Filter Oil or an
equivalent (Canada: Honda Foam Filter Oil
or an equivalent) over the entire surface of
the air cleaner. Use both hands to evenly
spread the oil into the air cleaner. Gently
squeeze out any excess oil. (To keep your
hands dry, place the air cleaner in a clean
plastic bag before spreading the oil into the
air cleaner.)
7. Clean the inside of the air cleaner housing.
Install the air cleaner.
8. Install the air cleaner housing cover, aligning
its projection (4) with the projection (5 ) on
the air cleaner housing.
9. Install and tighten the two attaching screws.
66 Servicing Your Honda
Throttle
Refer to Safety Precautions on page 43.
RIGHT SIDE
(1) freeplay
(2)
(2) dust cover (+) increase freeplay
las di nut (—) decrease freeplay
Inspection
Check freeplay (1).
Freeplay: 1/16 —3/16 in (2—4 mm)
If necessary, adjust to the specified range.
Adjustment
1. Pull the rubber dust cover (2) back.
2. Loosen the lock nut (3) on the throttle cable
mechanism.
3. Turn the adjuster (4).
4. Tighten the lock nut. Return the dust cover
to its normal position.
5. After adjustment, check for smooth rotation
of the throttle grip from fully closed to fully
open in all steering positions.
If you can’t get the freeplay within the
specified range, contact your Honda dealer.
Servicing Your Honda 67
Throttle
(1) throttle
(2) throttle cable
I. Check that the throttle assembly is
positioned properly and the securing bolts
are tight.
68 Servicing Your Honda
. Check for smooth rotation of the throttle (1)
from fully open to fully closed in all steering
positions. If there is a problem, see your
Honda dealer.
. Inspect the condition of the throttle cable (2)
from the throttle grip down to the carburetor.
If the cable 1s kinked or chafed, have it
replaced.
. Check the cable for tension or stress in all
steering positions.
. Lubricate the cable with a commercially-
available cable lubricant to prevent
premature rust and corrosion.
Clutch System
Refer to Safety Precautions on page 43.
Inspection
The engine should start easily with the
kickstarter without the clutch slipping. When
shifting gears, the clutch operation should be
smooth and light, especially when shifting into
neutral.
Adjustment
я —— Y
ae
(1) adjuster lock nut (2)
(2) clutch adjuster
1. Loosen the adjuster lock nut (1).
2. Turn the clutch adjuster (2 ) clockwise one
turn; do not turn excessively.
(cont’d)
Servicing Your Honda 69
Clutch System
3. Slowly turn the adjuster counterclockwise
until a slight resistance 1s felt.
4. From this position, turn the adjuster
clockwise 1/8 to 1/4 turn, and tighten the
lock nut.
5. After adjustment, test ride the motorcycle to
be certain the clutch operates properly.
If you can’t get proper adjustment, or the
clutch does not work properly, see your
Honda dealer.
70 Servicing Your Honda
Valve Clearance
Refer to Safety Precautions on page 43.
Excessive valve clearance will cause noise and
eventual engine damage. Little or no clearance
will prevent the valve from closing and cause
valve damage and power loss. Check valve
clearance when the engine is cold at the
intervals specified in the Maintenance Schedule.
The checking or adjusting of the clearance
should be performed while the engine 1s cold.
The clearance will change as engine
temperature rises.
LEFT SIDE (1)
(4) y
7 f
Lex ve (3)
IE
(4) |
) left crankcase cover (2)
) bolts A
)
)
bolt B
(1
(2
(3
(4) adjusting hole caps
1. Remove the left crankcase cover ( 1) by
removing the bolts A (2) and bolt B (3).
2. Remove the adjusting hole caps (4).
(cont’d)
Servicing Your Honda 71
Valve Clearance
LEFT SIDE (5) (6)
(5) T mark
(6) index mark
3. Rotate the generator flywheel
counterclockwise until the T mark (5) on the
flywheel lines up with the index mark (6) on
the crankcase. In this position, the piston
may either be on the compression or exhaust
stroke.
72 Servicing Your Honda
The adjustment must be made when the piston
18 at the top of the compression stroke when
both the intake and exhaust valves are closed.
This condition can be determined by moving
the rocker arms. If they are free, 1t is an
indication that the valves are closed and that the
piston is on the compression stroke. If they are
tight and the valves are open, rotate the
flywheel 360° and realign the T mark to the
index mark.
Valve Clearance
LEFT SIDE
(8)
(7) feeler gauge
(8) adjusting screw
(9) adjusting screw lock nut
4. Check the clearance of both valves by
inserting a feeler gauge (7) between the
adjusting screw (8) and the valve stem.
Clearance should be:
0.002 in (0.05 mm)
5. If it is necessary to make an adjustment,
loosen the adjusting screw lock nut (9) and
turn the adjusting screw (8) so there is a
slight resistance when the feeler gauge (7) is
inserted.
After completing the adjustment, tighten the
adjusting screw lock nut while holding the
adjusting screw to prevent it from turning.
Finally, recheck the clearance to make sure
that the adjustment has not been disturbed.
. Install the left crankcase cover.
. Install and tighten the bolts A, bolt B and
adjusting hole caps.
Servicing Your Honda 73
Engine Idle Speed
Refer to Safety Precautions on page 43. The engine must be at normal operating
temperature for accurate idle speed adjustment.
LEFT SIDE Ten 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.
I. Warm up the engine, shift to neutral and
place the motorcycle on its stand.
2. Connect a tachometer, following the
tachometer manufacturer’s instructions.
3. Adjust idle speed with the throttle stop screw
(1).
Idle Speed: 1,700 + 100 rom
(1) throttle stop screw (+) increase rpm
(—) decrease rpm
74 Servicing Your Honda
Spark Plug
Refer to Safety Precautions on page 43.
The recommended standard spark plug is
satisfactory for most riding conditions.
However, 1f you plan to ride for extended
periods at high speeds or near maximum power
(high engine rpm) in hot climates, or plan
extended riding in cold climates, a different
plug may be recommended.
Standard CREHSA (NGK) or
U20FSR-U (DENSO)
CR5HSA (NGK) or
U16FSR-U (DENSO)
CR7HSA (NGK) or
U22FSR-U (DENSO)
For cold climate
(below 5°C, 41°F)
For extended high
speed riding
Use only the recommended type of spark plugs
in the recommended heat range.
Using spark plugs with an improper heat range
can cause engine damage.
(а (3)
(1) center electrode
(2) side electrode
(3) spark plug gap
(cont’d)
Servicing Your Honda 75
Spark Plug
> Lobo
76
. Clean any dirt from around the spark plug
base.
. Disconnect the spark plug cap.
. Remove the spark plug with a plug wrench.
. Inspect the spark plug electrodes for wear.
The center electrode ( 1) should have square
edges. The side electrode (2) should not be
eroded. The insulator should not be cracked
or chipped.
. Check the spark plug gap (3), using a wire-
type feeler gauge. If adjustment 1s necessary,
bend the side electrode carefully. The gap
should be:
0.024— 0.028 in (0.60— 0.70 mm)
Make sure the plug washer 1s in good
condition.
If you have to install a new plug, first check
the gap.
. With the plug washer attached, thread the
spark plug in by hand (to prevent cross-
threading).
Servicing Your Honda
7. Tighten the spark plug:
e If the old plug 1s good:
1/8 turn after it seats.
e If installing a new plug, tighten it twice to
prevent loosening:
a) First, tighten the plug:
NGK: 1 turn after it seats.
DENSO: 3/4 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
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.
8. Reinstall the spark plug cap. Take care to
avoid pinching any cables or wires.
Spark Arrester
Refer to Safety Precautions on page 43.
The spark arrester must be serviced every 100
operating hours to maintain its efficiency.
Regular servicing prevents carbon buildup
(which can diminish engine performance) and
also complies with USDA regulations for
regular maintenance to assure proper function.
The spark arrester prevents random sparks
from the combustion process in your engine
from reaching the environment.
RIGHT REAR
(1) bolts
(2) spark arrester
(3) gasket
(4) muffler
1. Allow the engine and muffler to cool.
2. Remove the three bolts ( 1), the spark
arrester ( 2), and the gasket (3) from the
muffler (4).
(cont’d)
Servicing Your Honda 77
Spark Arrester
78
. 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.
Servicing Your Honda
4. Install the spark arrester and the gasket in the
muffler and tighten the three bolts securely.
Suspension
Refer to Safety Precautions on page 43.
Loose, worn, or damaged suspension
components may adversely atfect the handling
and stability of your motorcycle. If any
suspension components appear worn or
damaged, see your Honda dealer for further
inspection. Your dealer is qualified to
determine whether or not replacement parts or
repairs are needed.
(1) mounting bolts
1. Check fork operation. Pull the front brake
lever in, to lock the brake. Then pump up
and down on the fork legs several times. The
suspension should function smoothly. There
should be no oil leakage.
(cont’d)
Servicing Your Honda 79
Suspension
2. Check the security of all handlebar and fork
mounting bolts (1). If any front suspension
components appear worn or damaged, see
your Honda dealer for further inspection.
(1) swingarm bushing
(2) shock absorber attachment points
80 Servicing Your Honda
RIGHT SIDE
— Ve
NE
— © > : ASS
я 7. Rx ==
9 Az
ve A SM
= \ THA NA
(1) swingarm bushing
(2) shock absorber attachment points
1. Place the motorcycle on a maintenance stand.
Push hard against the side of the rear wheel
and feel for any freeplay which indicates
worn swingarm bushings (1).
Suspension
2. Check that the fasteners for the shock
absorber attachment points (2) are secure.
3. Check for oil leaks in the shock absorber. If
any rear suspension components appear
worn or damaged, see your Honda dealer for
further inspection.
Servicing Your Honda 81
Brakes
Refer to Safety Precautions on page 43.
RIGHT SIDE
(1) front brake lever
RIGHT SIDE
(2) rubber dust cover
(3) lock nut
(4) front brake cable adjuster
(+) increase freeplay
(—) decrease freeplay
82 Servicing Your Honda
Inspection
Check freeplay by pulling in slowly on the
front brake lever ( 1) until the brake starts to
engage.
Freeplay: 13/16 —1 3/16 in (20— 30 mm)
If necessary, adjust to the specified range.
Upper Adjustment
1. Pull the rubber dust cover (2) back.
2. Loosen the lock nut (3) and turn the front
brake cable adjuster (4).
3. Tighten the lock nut. Return the dust cover
to its normal position.
4, Apply the brake, release 1t, then spin the
wheel and check that it rotates freely. Repeat
this procedure several times.
Brakes
5. Check the freeplay.
If the cable adjuster is threaded out near its
limit or if the correct freeplay cannot be
obtained using the cable adjuster:
LEFT FRONT
A
Ш
=
(5) cable guide bolt
Lower Adjustment
1. Loosen the lock nut and turn the cable
adjuster all the way in.
2. Tighten the lock nut and return the rubber
dust cover to its normal position.
3. Loosen the front brake cable guide bolt (5).
4. At the lower end of the cable, loosen the
lower lock nut (6). Turn the lower adjusting
nut (7) to obtain the specified freeplay.
Tighten the lower lock nut.
LEFT FRONT (7)
(6) lower lock nut (+) increase freeplay
(7) lower adjusting nut (—) decrease freeplay
(cont’d)
Servicing Your Honda 83
Brakes
5. Tighten the front brake cable guide bolt.
6. Apply the brake, release it, then spin the
wheel and check that it rotates freely. Repeat
this procedure several times.
7. Check the freeplay. If you cannot adjust the
freeplay properly, see your Honda dealer.
(1) rear brake pedal
84 Servicing Your Honda
Inspection
|. Place your motorcycle on its side stand.
2. Check freeplay by slowly depressing the
brake pedal ( 1) until the brake starts to
engage.
Freeplay: 13/16—1 3/16 in (20—30 mm)
If necessary, adjust to the specified range.
Adjustment
RIGHT REAR
(2) adjusting nut (
(3) brake arm pin (
) increase freeplay
) decrease freeplay
| +
Brakes
1. Turn the rear brake adjusting nut (2). Make
sure the cut-out on the adjusting nut is seated
on the brake arm pin (3).
2. Apply the brake, release it, and then spin the
wheel and check that it rotates freely. Repeat
this procedure several times.
3. Check the freeplay. If you can’t adjust the
treeplay properly, see your Honda dealer.
The front and rear brakes are equipped with
external brake wear indicators that let you
check brake wear without disassembly.
Application of the brake control (lever or
pedal) causes the arrow on the brake arm to
move toward a reference mark on the brake
panel.
LEFT FRONT
(4)
(3)
(1) arrow (3) reference mark
(2) brake arm (4) brake panel
(cont’d)
Servicing Your Honda 85
Brakes
RIGHT REAR
(3) reference mark
(4) brake panel
(1) arrow
(2) brake arm
1. Place your motorcycle on its side stand.
2. Apply the brake control (lever or pedal) and
check the movement of the arrow ( 1) on the
brake arm (2). Replace the brake shoes 1f the
arrow aligns with the reference mark (3 ) on
the brake panel (4) upon full application of
the brake. If replacement 1s necessary, see
your Honda dealer.
86 Servicing Your Honda
Other I
* Check that the front lever and rear pedal
assemblies are positioned properly and the
securing bolts are tight.
* Check the front brake cable for kinks or
signs of wear that could cause sticking or
failure.
* Lubricate the front brake cable with a
commercially-available cable lubricant to
prevent premature wear and corrosion.
* Front: Make sure the brake arm, spring, and
fasteners are in good condition.
* Rear: Make sure the brake rod, brake arm,
spring, and fasteners are in good condition.
Wheels
Refer to Safety Precautions on page 43 .
Maintenance of spoke tension and wheel
trueness (roundness) 1s critical to safe
motorcycle operation. During the first 100
miles (150 km), spokes will loosen more
rapidly due to the initial seating of the parts.
Excessively loose spokes may result in
instability at high speeds and the possible loss
of control. Loose spokes may also cause rim or
spoke damage (not covered by warranty). It’s
also important that the rim locks are secure to
prevent tire slippage.
It is not necessary to remove the wheels to
perform the recommended service in the
Maintenance Schedule. However, information
for wheel removal is provided for emergency
situations.
REAR
(1) wheel rim
(2) spoke
1. Inspect the wheel rims ( 1) and spokes (2)
for damage.
2. Tighten any loose spokes.
(cont’d)
Servicing Your Honda 87
Wheels
3. Rotate the wheel slowly to see if it appears
to “wobble.”” If it does, the rim 1s out of
round or not “true.” If the wobble is
noticeable, see your Honda dealer for
Inspection.
(1) cable guide bolt (4) front axle nut
(2) front brake cable (5) lug
(3) brake arm (6) slot
88 Servicing Your Honda
Removal
1. Raise the front wheel off the ground by
placing a maintenance stand or support block
under the engine. Secure the rear of the
motorcycle with tie-down straps.
2. Loosen the cable guide bolt ( 1) on the fork
leg.
3. Disconnect the front brake cable (2 ) from
the brake arm (3).
4. Remove the front axle nut (4) and front axle
shaft.
5. Remove the wheel.
6. Pull the brake assembly out carefully.
Take care to prevent getting grease, oil, or dirt
on the brake shoe surfaces. This can cause poor
brake performance or rapid brake shoe wear
after reassembly.
Wheels
Installation |
|. Reverse the removal procedure. Make sure
the lug (5) on the fork leg is located in the
slot (6) in the brake panel.
2. Torque the front axle nut to:
43 Ibf-ft (59 N-m , 6.0 kgf-m)
3. Check front brake adjustment (page 82).
It a torque wrench was not used to install the
wheel, see your Honda dealer as soon as |
possible to verify proper assembly. Improper
assembly may lead to loss of braking capacity.
Servicing Your Honda 89
Wheels
RIGHT REAR LEFT REAR
(1) adjuster (4) adjusting nut
(2) brake rod (5) rear axle nut
(3) brake arm (6) rear axle shaft
90 Servicing Your Honda
Removal
|.
Raise the rear wheel off the ground by
placing a maintenance stand or support block
under the engine. Secure the front of the
motorcycle with tie-down straps.
. Unscrew the rear brake adjuster ( 1). Press
the rear brake pedal and disconnect the brake
rod (2) from the brake arm (3).
. Loosen the adjusting nut (4) on the chain
adjuster on both sides.
. Unscrew the rear axle nut (5). Pull the rear
axle shaft (6) out. Push the wheel forward
and derail the drive chain from the rear
sprocket. Remove the wheel.
Take care to prevent getting grease, oil, or
dirt on the brake shoe surfaces. This can
cause poor brake performance or rapid brake
shoe wear after reassembly.
Wheels
RIGHT REAR Installation
1. Reverse the removal procedure. Make sure
the lug (7) on the swingarm is located in the
slot (8) in the brake panel ( 9). Check that
the chain adjusters are installed properly.
. Adjust the drive chain (page 99 ).
. Torque the rear axle nut to:
43 Ibf-ft (59 N-m , 6.0 kgf-m)
. Adjust the rear brake (page 84 ).
. Apply the rear brake, release it, then spin the
wheel and check that it rotates freely. Repeat
this procedure several times.
LI bo
Qn Ra
If a torque wrench was not used to install the
wheel, see your Honda dealer as soon as
possible to verify proper assembly. Improper
assembly may lead to loss of braking capacity.
(7) lug
(8) slot
(9) brake panel
Servicing Your Honda 191
Tires & Tubes
Refer to Safety Precautions on page 43. and our recommendations on tire repair and
replacement.
To safely operate your motorcycle, the tires
must be the proper type (off-road) and size, in
good condition with adequate tread, and
correctly inflated.
A WARNING combination of handling, tread life, and riding
comfort. Generally, underinflated tires wear
Using tires that are excessively worn unevenly, adversely affect handling, and are
or improperly inflated can cause a more likely to fail from being overheated.
crash in which you can be seriously Underinflated tires can also cause wheel
hurt or killed. damage in rocky terrain. Overinflated tires
make your motorcycle ride harshly, are more
Follow all instructions in this owner's prone to damage from surface hazards, and
manual regarding tire inflation and wear unevenly.
maintenance.
Make sure the valve stem caps are secure. If
necessary, install a new cap.
The following pages give detailed information
on how and when to check your air pressure,
how to inspect your tires for wear and damage,
92 Servicing Your Honda
Tires & Tubes
Always check air pressure when your tires are
“cold.” If you check air pressure when your
tires are “warm” —evenif your motorcycle
has only been ridden for a few miles — the
readings will be higher. If you let air out of
warm tires to match the recommended cold
pressures, the tires will be underinflated.
The correct “cold” tire pressures are:
Front 15 psi (100 kPa, 1.00 kgf/cm?)
Rear 15 psi (100 kPa, 1.00 kgf/cm?)
If you decide to adjust tire pressures for a
particular riding condition, make changes a
little at a time.
A flat tire or blowout 1s inconvenient and may
even cause an accident. Take time to inspect
your tires and wheels before you ride. For more
information about handling flat tires, see
page 120.
(1) tire tread depth
(2) spoke nut
(cont’d)
Servicing Your Honda 93
Tires & Tubes
* Inspect carefully for bumps or bulges in the
side of the tire or the tread. Replace any tire
that has a bump or bulge.
* Look closely for cuts, slits, or cracks in the
tires. Replace a tire if you can see fabric or
cord.
* Check for rocks or other objects embedded
in the tire or tread. Remove any objects.
* Measure tread depth ( 1). Replace the tire
before depth at the center reaches 0.12 in (3
mm), or any time you notice a reduction in
traction.
* Check the position of both valve stems. A
tilted valve stem indicates the tube is
slipping inside the tire or the tire is slipping
on the rim. See your Honda dealer.
94 Servicing Your Honda
If a tube is punctured or damaged, you should
replace it as soon as possible. A repaired tube
may not have the same reliability as a new one,
and it may fail while you are riding. For
information on making a temporary repair, see
page 120.
Use a replacement tube equivalent to the
original.
We recommend that tubes be replaced by your
Honda dealer. Replacing a tube requires
removing and reinstalling the wheel. Any time
a tube is replaced, carefully inspect the tire as
described on page 93 .
Tires & Tubes
The tires that came on your motorcycle were
designed to provide a good combination of
handling, braking, durability, and comfort
across a broad range of riding conditions.
A WARNING
Installing improper tires 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 tires
recommended in this owner's manual.
Front 2.50-14 4PR
Rear 3.00-12 4PR
Type bias-ply, tube
e Use a replacement tire equivalent to the
original.
e Replace the tube any time you replace a tire.
The old tube will probably be stretched and,
if installed in a new tire, could fail.
o Have the wheel balanced after a new tire 18
installed.
* We recommend that tires be replaced by
your Honda dealer.
Servicing Your Honda 195
Side Stand
Refer to Safety Precautions on page 43.
LEFT SIDE
(1) side stand spring
96 Servicing Your Honda
I. Check the side stand spring ( 1) for damage
and loss of tension.
2. Check the side stand assembly for freedom
of movement.
If the side stand is stiff or squeaky, clean the
pivot area and lubricate the pivot bolt with
clean engine oil.
Drive Chain
Refer to Safety Precautions on page 43.
The service life of the chain depends on proper
lubrication and adjustment. Poor maintenance
can cause premature wear or damage to the
drive chain or sprockets.
Under severe usage, or when the motorcycle 1s
ridden in unusually dusty or muddy areas, more
frequent maintenance will be necessary.
Before servicing your drive chain, turn the
engine OFF, lower the side stand, and check
that your transmission 1s in neutral.
It is not necessary to remove or replace the
drive chain to perform the recommended
service in the Maintenance Schedule.
> GE 90 9
> COTO O
(1) drive chain
1. Check slack in the lower drive chain (1) run
midway between the sprockets. Drive chain
slack should allow the following vertical
movement by hand:
3/8—13/16 in (10—20 mm)
(cont’d)
Servicing Your Honda 97
Drive Chain
2. Check drive chain slack at several points
along the chain. The slack should remain
constant. If it isn’t, some links may be
kinked and binding. Lubricating the chain
will often eliminate binding and kinking.
Excessive chain slack may allow the drive
chain to damage the engine cases.
3. Inspect the drive chain for:
e damaged rollers
* loose pins
* dry or rusted links
* kinked or binding links
e excessive wear
Replace the drive chain (page 102) if it has
damaged rollers, loose pins, or kinks that
cannot be freed. Lubricate the drive chain
(page 101 ) if it appears dry or shows signs
of rust. Lubricate any kinked or binding
98 Servicing Your Honda
links and work them free. Adjust chain slack
if needed.
4, Check the chain slider (2 ) for wear. If the
ridge (3 ) in the center of the slider is worn,
have your Honda dealer replace the chain
slider.
LEFT SIDE
>— OI
ao
e NS ese.
(2) chain slider (3) ridge
5. Replace the drive chain if chain slack 1s
excessive when the rear axle 1s moved to the
farthest limit of adjustment. Excessive slack
indicates the chain is worn beyond its service
limit.
To check the chain’s service limit, remove
the drive chain (page 102 ). Then measure
the distance between a span of 85 pins,
from pin center to pin center. H the distance
exceeds the service limit, the drive chain 1s
worn out and should be replaced.
Drive Chain
Measure a span of 85 pins
New Chain: 42.5 in (1,080 mm)
Service Limit: 43.3 in (1,101 mm)
(cont’d)
Servicing Your Honda 99
Drive Chain
6. Inspect the front and rear sprocket teeth for
excessive wear or damage. If necessary, have
your Honda dealer replace a worn sprocket.
Damaged Sprocket Worn Sprocket
Teeth Teeth
REPLACE REPLACE
Normal Sprocket Teeth
GOOD
Use of a new chain with worn sprockets will
cause rapid chain wear.
100 Servicing Your Honda
(1) rear axle nut
(2) adjusting nut (3)
(3) adjuster index mark
(4) graduated scale
1. Loosen the rear axle nut (1).
2. Turn the adjusting nuts (2) on the right and
left chain adjusters an equal number of turns
to increase or decrease chain slack.
Drive Chain
3. Align the chain adjuster index marks (3)
with the graduated scales (4 ) on both sides
of the swingarm.
4. Torque the rear axle nut to:
43 Ibf-ft (59 N-m , 6.0 kgf-m)
If a torque wrench 1s not used for this
installation, see your Honda dealer as soon as
possible to verif y proper assembly.
5. Recheck drive chain slack.
6. Check rear brake pedal freeplay and adjust
as necessary (page 84). Freeplay 1s affected
when repositioning the rear wheel to adjust
drive chain slack.
Lubricate every 300 miles (500 km) or sooner
if chain appears dry.
Turn the rear wheel by hand. Saturate each
chain link joint so that the lubricant penetrates
between the link plates, pins, bushings, and
rollers.
Servicing Your Honda 101
Drive Chain
Fa When the drive chain becomes extremely dirty,
t it should be removed and cleaned prior to
o lubrication.
|. Remove the master link retaining clip (1)
With pliers. Do not bend or twist the clip.
— Remove the master link. Remove the drive
\ chain.
2. Clean the drive chain with a non-flammable
>< PS \ SR (1) (high flash point) solvent such as kerosene —
Su O VS . — .
Q/ N not gasoline — and allow it to dry.
3 6) VA À 3. Inspect the drive chain for possible wear or
e, | DD damage. Replace the drive chain if it has
So SON damaged rollers, loose fitting links, or
ESS ЕС NE CITAS,
% A № otherwise appears unserviceable.
(1) master link retaining clip
102 Servicing Your Honda
Drive Chain
4.
OX Lh
Inspect the sprocket teeth for wear or
damage. We recommend replacing the
sprocket whenever a new chain 15 installed.
. Lubricate the drive chain.
. Pass the chain over the sprockets and join the
ends of the chain with the master link. For
ease of assembly, hold the chain ends against
adjacent rear sprocket teeth while inserting
the master link. Install the master link
retaining clip so that the closed end of the
retaining clip will face the direction of
forward wheel rotation.
* The master link 1s the most critical element
of drive chain security. Master links are
reusable, as long as they remain in excellent
condition. We recommend installing a new
master link retaining clip when the drive
chain 1s reassembled.
* You may find it easier to install a new chain
by connecting it to the old chain with a
master link and pulling the old chain to
position the new chain on the sprockets.
Servicing Your Honda 103
Appearance Care
Refer to Safety Precautions on page 43.
Frequent cleaning and polishing will keep your
Honda looking newer longer. Frequent
cleaning also identifies you as an owner who
values your motorcycle. A clean motorcycle is
also easier to inspect and service.
While you're cleaning, be sure to look for
damage, wear, and gasoline or oil leaks.
104 Servicing Your Honda
* To clean your motorcycle, you may use:
— Water
—a mild, neutral detergent and water
—a mild spray and wipe cleaner/polisher
—a mild spray and rinse cleaner/degreaser
and water
* Avoid products that 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.
Appearance Care
* We recommend the use of a garden hose to
wash your motorcycle. High pressure
washers (like those at coin-operated car
washes) can damage certain parts of your
motorcycle. If you use a high pressure
washer, avoid spraying the following areas:
wheel hubs
muffler outlet
area under seat
engine stop switch
under fuel tank
drive chain
carburetor
High pressure water (or air) can damage
certain parts of your motorcycle.
. Rinse your motorcycle thoroughly with cool
water to remove loose dirt.
. Fill a bucket with cool water. Mix in a mild,
neutral detergent, such as dish washing
liquid or a product made especially for
washing motorcycles or automobiles.
3. Wash your motorcycle with a sponge or a
soft towel. As you wash, check for heavy
grime. If necessary, use a mild cleaner/
degreaser to remove the grime.
. After washing, rinse your motorcycle
thoroughly with plenty of clean water to
remove any residue.
. Dry your motorcycle with a chamois or a
soft towel.
(cont’d)
Servicing Your Honda 105
Appearance Care
. Lubricate the drive chain to prevent rusting.
. Start the engine and let it idle for several
minutes. The engine heat will help dry moist
areas.
8. As a precaution, ride at a slow speed and
apply the brakes several times. This will help
dry the brakes and restore normal braking
performance.
~J ON
106 Servicing Your Honda
Here’s helpful advice on how to prepare for an
off-road adventure, how to transport and store
your Honda, and how to be an environmentally
responsible motorcycle owner.
Preparing for a Ride...
Transporting Your Honda...........................
Storing Your Honda...
You & the Environment...
Tips
107
Preparing for a Ride
A safe and enjoyable ride begins with good
planning and preparation. Always ride with at
least one other person in case you have trouble,
and let someone know where you're going and
when you expect to return.
Before riding in an unfamiliar area, find out in
advance if you need special permits, get maps
so you can study the terrain, and talk to other
riders who know the area. The Forest Service
and the Bureau of Land Management (USA
only), the Ministry of Natural Resources
(Canada only), riding clubs, and off-road
magazines are good sources of information.
108 Tips
Along with your motorcycle and riding gear,
you should take along some tools and supplies
in case you have a problem. For some of the
difficulties you might encounter, see Taking
Care of the Unexpected, which begins on page
117.
We recommend that you always take water,
food, a first aid kit, and your owner’s manual.
Other items you should consider loading on
your truck or trailer include:
e a tool kit
e tire repair supplies and tools, tubes, and tires
e extra parts, such as a drive chain and master
links, control levers, cables, and spark plugs
e wire, duct tape, and rope
e extra gasoline
Preparing for a Ride
For safety, all refueling should be done at a gas
station on the way to the riding area or at your
base camp.
What you take with you during a ride depends
on the kind of terrain, how long you expect to
ride, how far you might go from your base
camp or help, and how experienced you or your
companions are in making repairs.
If you decide to take some tools, spare parts, or
other supplies on the trail, be sure you can
carry them safely and know how to use them.
Also, be sure to follow the loading guidelines
and weight limit (page 9 ).
Tips 109
Transporting Your Honda
If you use a truck or motorcycle trailer to
transport your Honda, we recommend that you
follow these guidelines:
* Use a loading ramp.
* Make sure the fuel valve 1s off.
e Secure the motorcycle in an upright position,
using motorcycle tie-down straps. Avoid
using rope, which can loosen and allow the
motorcycle to fall over.
110 Tips
To secure your motorcycle, brace the front
wheel against the front of the truck bed or
trailer rail. Attach the lower ends of two straps
to the tie-down hooks on your vehicle. Attach
the upper ends of the straps to the handlebar
(one on the right side, the other on the left),
close to the fork.
Transporting Your Honda
Check that the tie-down straps do not contact
any control cables or electrical wiring.
Tighten both straps until the front suspension is
compressed about half-way. Too much
pressure is unnecessary and could damage the
fork seals.
Use another tie-down strap to keep the rear of
the motorcycle from moving.
We recommend that you do not transport your
motorcycle on its side. This can damage the
motorcycle, and leaking gasoline could be a
hazard.
Tips 111
Storing Your Honda
If you won't be riding for an extended period,
such as during the winter, thoroughly inspect
your motorcycle and correct any problem
betore storing it. That way, needed repairs
won't be forgotten and it will be easier to get
your motorcycle running again.
112 Tips
For more information about storage, refer to
the Honda Motorcycle Winter Storage Guide,
available from your Honda dealer (USA only).
We suggest you perform the following
procedures to keep your motorcycle in top
condition. These storage procedures will reduce
the deterioration that can occur during storage.
Storing Your Honda
4. Drain the carburetor into an approved
gasoline container and dispose of it in an
or - a“ Ш approved manner (page 115 ). If storage will
1. Change the engine oil (page 62). last longer than one month, carburetor
2. Fill the fuel tank. Make sure the fuel fill cap draining is important, {0 assure proper
1s properly installed. performance after storage.
3. Check that the fuel valve is OFF.
A WARNING
Gasoline is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
* Stop the engine and keep heat,
sparks and flame away.
* Handle fuel only outdoors.
* Wipe up spills immediately.
(cont’d)
Tips 113
Storing Your Honda
. Wash and dry your motorcycle.
. Lubricate the drive chain.
. Inflate the tires to their recommended
pressures (page 92 ).
8. Store your motorcycle in an unheated area,
free of dampness, away from sunlight, with
a minimum of daily temperature variation.
9. Cover your motorcycle with a porous
material. Avoid using plastic or similar non-
breathing, coated materials that restrict air
flow and allow heat and moisture to
accumulate.
~] ON Lh
114 Tips
Removal
—
nn =
. Uncover and clean your motorcycle.
. If your motorcycle has been stored for more
than four months — change the engine oil
(page 62).
. If your motorcycle has been stored for more
than two months —drain and replace the fuel.
. Lubricate the drive chain.
. Perform a pre-ride inspection (page 27),
then test-ride your motorcycle at low speeds.
You & the Environment
Owning and riding a motorcycle can be
enjoyable, but you must do your part to protect
nature. When you show respect for the land,
wildlife, and other people, you also help
preserve the sport of off-road riding.
Following are tips on how you can be an
environmentally-responsible motorcycle owner.
* Tread Lightly. Stay on existing roads and
trails, avoid surfaces that are easily damaged,
and ride only in areas approved for off-road
vehicles.
* Keep the Noise Down. Loud motorcycles
can be offensive. Ride as quietly as possible,
don’t remove your spark arrester, and don’t
modify the muffler or any other part of your
air intake and exhaust systems. Such
modifications not only increase noise, they
also reduce engine performance and may be
illegal.
e Choose Sensible Cleaners. Use a
biodegradable detergent when you wash
your motorcycle. Avoid aerosol spray
cleaners that contain chlorofluorocarbons
(CFCs) which damage the atmosphere’ s
protective ozone layer. Don’t throw cleaning
solvents away; see the following guidelines
for proper disposal.
(cont’d)
Tips 115
You & the Environment
* Recycle Wastes. It's illegal and thoughtless
to put used engine oil in the trash, down a
drain, or on the ground. Used oil, gasoline,
and cleaning solvents contain poisons that
can hurt refuse workers and contaminate our
drinking water, lakes, rivers, and oceans.
Before changing your oil, make sure you
have the proper containers. Put oil and other
toxic wastes in separate sealed containers
and take them to a recycling center. Call
your local or state office of public works or
environmental services to find a recycling
center in your area and get instructions on
how to dispose of non-recyclable wastes.
116 Tips
Taking Care of the Unexpected
With all the challenges you can encounter off- General Guidelines... 118
road, there’s a chance that sometime something If Your Engine Quits or Won't Start............ 119
may go wrong. This section gives practical If You Have a Flat Tiere 120
advice to help you deal with a wide range of If You Crash............ ere e 121
problems. Take time to read this section before If You Lose Your Key... 122
you ride. Also review the tips in Preparing for If a Component Fails …………..…...….…rrseerese 123
a Ride (page 108).
Taking Care of the Unexpected 117
Taking Care of the Unexpected
If something goes wrong during a ride, the first
thing to do is stop as soon as you safely can.
Do not continue riding if you have a flat tire, or
you hear an unusual noise, or your motorcycle
just doesn’t feel right. If you continue riding,
you could cause more damage and endanger
your own safety.
After a stop, take time to assess the situation.
Carefully inspect your motorcycle to identify
the problem, then consider your options before
you decide what to do.
118 Taking Care of the Unexpected
If a problem is relatively minor and you have
the tools, supplies, and skills to make a
permanent repair, you may be able to fix it on
the trail and continue riding. Or, you may be
able to make a temporary repair that allows you
to slowly ride back to your base where you can
make a permanent repair or get help.
When a problem is more serious — or you don’t
have the tools, supplies, experience, or time to
deal with it— you need to choose the safest way
to get yourself and your motorcycle back to
base. For example, if you are close enough,
you (or you and another person) might be able
to push it back.
Whatever the problem, the most important rules
are:
Always put personal safety first.
Taking Care of the Unexpected
* It the problem is relatively minor and you
have the tools, supplies, and skills to make a
temporary repair, be sure to have permanent
repairs made as soon as possible.
* Do not continue riding if you are hurt or
your motorcycle is not in safe riding
condition.
Additional recommendations for specific
problems follow.
If the engine wasn’t making any unusual noises
before it quit running, and it feels normal when
you operate the kickstarter, you can probably
rule out a major mechanical problem.
The next area to check is the fuel system:
* Make sure there is enough gas in the tank
and the fuel valve is at the ON or RESERVE
position.
* Check the fuel fill cap vent tube to see if it is
pinched or obstructed.
* Turn the fuel valve OFF, disconnect the fuel
line that goes from the fuel valve to the
carburetor, then momentarily turn the fuel
valve ON. If fuel does not flow out, there is
an obstruction in the fuel tank or the fuel
valve,
(cont’d)
Taking Care of the Unexpected 119
Taking Care of the Unexpected
If the fuel system appears to be okay, check the
ignition system (this requires a spark plug
wrench):
How you handle a flat tire on the trail depends
e Check that the spark plug cap isn’t loose or on how serious the tube or tire damage is, and
disconnected. what tools and supplies you have with you.
Disconnect the spark plug cap and remove
the spark plug. Connect the spark plug cap to If you have a slow leak or a minor puncture,
the spark plug and ground the threaded there are two ways to try making a temporary
portion of the spark plug on the cylinder repair:
head.
* Operate the kickstarter while you watch the * Use an aerosol tire sealer to seal the puncture
spark plug. If it sparks, the ignition system is and inflate the tube. (This can be done
probably working. If there is no spark, install without removing the tire or wheel.)
a new spark plug, if you have one with you. * Use a tube patch kit to repair the puncture.
If there is still no spark, there is a problem in (This requires removing the tire.)
the ignition system.
If you cannot identify or correct the problem,
you will have to push your motorcycle back to
your base or get some help.
120 Taking Care of the Unexpected
Taking Care of the Unexpected
If the leak 1s more serious, or a temporary
repair doesn’t hold, the tube must be replaced.
The tire will also need to be replaced if it is
damaged (page 95 ). Replacing a tube or tire
involves removing and re-installing the wheel
(pages 88 , 90).
If you are unable to repair a flat tire on the trail,
you will need to push the motorcycle back to
your base or send for help. We strongly
recommend that you do not try to ride with a
flat tire. The motorcycle will be hard to handle,
and if the tire comes off the rim, it may lock up
the wheel and cause you to crash.
Personal safety 1s your first priority after an
accident. If you or anyone else has been injured,
take time to assess the severity of the injuries
and whether it 1s safe to continue riding. If you
cannot ride safely, send someone for help. Do
not ride if you will risk further injury.
If you decide you are capable of riding safely,
carefully inspect your motorcycle for damage
and determine if it is safe to ride. Check the
tightness of critical nuts and bolts securing
such parts as the handlebar, control levers,
brakes, and wheels.
(cont’d)
Taking Care of the Unexpected 121
Taking Care of the Unexpected
If there is minor damage, or you are unsure
about possible damage but decide to try riding
the motorcycle back to your base, ride slowly
and cautiously.
Sometimes, crash damage is hidden or not
immediately apparent. When you get home,
thoroughly check your motorcycle and correct
any problems you find. Also, be sure to have
your Honda dealer check the frame and
suspension after any serious crash.
122 Taking Care of the Unexpected
Be sure to record your key number in the Quick
Reference section at the rear of the manual.
You'll need this number to have a duplicate
key made.
If you lose your key and aren't carrying a
duplicate, either get your spare or have one
made. If you don’t know your key number, call
the dealer you purchased your Honda from.
They may have 1t listed in their records. If they
don’t, transport your motorcycle to them or the
nearest Honda dealer. The dealer will probably
have to remove the ignition switch assembly to
find the key number so they can make a key for
you.
Taking Care of the Unexpected
The drive chain, master link, brake lever or
pedal, control cables, and other components
can be damaged as you ride in dense brush or
over rocky terrain. Making a trailside repair
depends on how serious the damage is and
what tools and supplies you have with you.
* If the drive chain comes off because the
master link clip gets knocked off, you may
be able to put the chain back on with a new
master link. However, if the chain breaks or
does other damage when it comes off, you
may not be able to make a trailside repair.
* [f any component of the front brake system
1s damaged, you may be able to ride
carefully back to your base using the rear
brake for slowing or stopping.
* [If you damage a throttle cable or other
critical component, your motorcycle may be
unsafe to ride. Carefully assess the damage
and make any repairs that you can. But if
there 1s any doubt, it’s best to be
conservative and safe.
Taking Care of the Unexpected 123
124 Taking Care of the Unexpected
This section contains dimensions, capacities,
and other technical data, plus information on
government requirements and how to break-in
your motorcycle.
Technical Information
Vehicle Identification es 126
Specifications..….…....….…..….….…..……errerenescanesenne 128
Break-in Guidelines ….…..…..…..…..…………ererenencre 133
High Altitude Carburetor Adjustment .......... 134
Emission Control Systems... 135
Oxygenated Fuels... 139
Technical Information 125
Vehicle Identification
The VIN and engine serial numbers are
required when you register your motorcycle.
They may also be required when ordering
replacement parts. You may record these
numbers in the Quick Reference section at the
rear of the manual.
The VIN (1) is stamped on the left side of the
steering head.
The engine number (2) is stamped on the left
side of the engine.
126 Technical Information
LEFT SIDE
(1) VIN
LEFT SIDE
(2) engine number
Vehicle Identification
The color label ( 1) is attached to the frame
behind the left side cover (page 54).
The color code is helpful when ordering
replacement parts. You may record the color
and code in the Quick Reference section at the
rear of the manual.
LEFT SIDE
(1)
NE
EN
’ _
(1) color label
Technical Information 127
Specifications
Fuel & Lubricants
Fuel tank capacity
1.45 US gal (5.5 9)
including reserve
Fuel tank reserve
0.29 US gal (1.1 2)
Dimensions
Overall length 61.8 in (1,569 mm)
Overall width 27.3 in (694 mm)
Overall height 34.8 in (885 mm)
Wheelbase 41.9 in (1,063 mm)
128 Technical Information
Fuel unleaded gasoline,
recommendation pump octane
number of 86 or
higher
Air cleaner oil Pro Honda (USA
only) or Honda
(Canada only) Foam
Filter Oil or an
equivalent
Engine oil capacity
after draining:
0.6 US at (0.6 2)
after disassembly:
0.8 US qt (0.8 2)
Specifications
Fuel & Lubricants
Fuel & Lubricants (cont'd)
Engine oll
recommendation
API Service
Classification SG or
higher except oils
labeled as energy
conserving on the
circular API service
label, SAE 10W-30,
JASO T 903 standard
MA,
Pro Honda GN4 or HP
4 (without
molybdenum
additives) 4-stroke oil
(USA & Canada) or
Honda 4-stroke oil
(Canada only), or an
equivalent motorcycle
oil
Drive chain Pro Honda Chain
lubricant Lube or an
equivalent, or SAE
80 or 90 gear oil
Capacities
Passenger operator only;
capacity no passenger
Maximum weight 132 165 (60 Ка)
capacity
Cargo capacity none
Engine Specifications
Displacement
4.38 cu-in (71.8 cm?)
Bore & stroke
1.85 X 1.63 in
(47.0 X 41.4 mm)
Compression ratio
9.0: 1
Technical Information 129
Specifications
Engine Specifications
Power Transmission
Primary reduction 3.722
Gear ratio, 1st 3.272
2nd 1.666
3rd 1.190
Final reduction 2.400
Final drive chain
Valve clearance Intake: 0.002 in
(cold) (0.05 mm)
Exhaust: 0.002 in
(0.05 mm)
Spark plug CR6HSA (NGK) or
(standard) U20FSR-U (DENSO)
Spark plug CR5HSA (NGK) or
(cold climate; U16FSR-U (DENSO)
below 5°C, 41°F)
Spark plug CR7HSA (NGK) or
(extended high U22FSR-U (DENSO)
speed riding)
Spark plug gap 0.024 — 0.028 in
(0.60 — 0.70 пт)
| Idle speed 1,700 + 100 rpm
130 Technical Information
Specifications
Power Transmission
Drive chain
freeplay
3/8— 13/16 in
(10—20 mm)
New chain length
42.5 in (1,080 mm)
distance between a
span of 85 pins
Used chain service
limit length
43.3 in (1,101 mm)
distance between a
span of 85 pins
Chassis & Suspension
Caster 26°12’
Trail 2.42 in (61.5 mm)
Tire size, front 2.50-14 APR
Tire size, rear 3.00-12 4PR
Tire type bias-ply, tube
Tire pressure, front 15 psi
(cold) (100 kPa , 1.00 kgf/cm?)
Tire pressure, rear 15 psi
(cold) (100 kPa, 1.00 kgf/cm?)
Suspension, front 3.9in (100 mm)
cushion stroke
3.5 in (90 mm)
axle travel
| Suspension, rear 3.5 in (88 mm)
axle travel
Technical Information 131
Specifications
Torque Specifications
Engine oil drain bolt 18lbf-ft
(24 №т ‚ 2.5 kgf-m)
Rear wheel axle 1 43 1bf-ft
(59 N-m, 6.0 kgf-m)
Front wheel axle 43 |bf-ft
(59 N-m , 6.0 kgf-m)
132 Technical Information
Break-in Guidelines
Help assure your motorcycle’s future reliability
and performance by paying extra attention to
how you ride during the first operating day or
15 miles (25 km).
During this period, avoid full-throttle starts and
rapid acceleration.
Technical Information 133
High Altitude Carburetor Adjustment
At high altitude, the standard carburetor air-
fuel mixture will be too rich. Performance will
decrease, and fuel consumption will increase. A
very rich mixture will also foul the spark plug
and cause hard starting. Operation at an altitude
that differs from that at which this engine was
certified, for extended periods of time, may
Increase emissions.
High altitude performance can be improved by
specific modifications to the carburetor. If you
always operate your engine at altitudes above
6,500 feet (2,000 meters), have your servicing
dealer perform this carburetor modification.
This engine, when operated at high altitude
with the carburetor modifications for high
altitude use, will meet each emission standard
throughout its useful life.
134 Technical Information
Even with carburetor modification, engine
horsepower will decrease about 3.5% for each
1,000-foot (300-meter) increase in altitude. The
effect of altitude on horsepower will be greater
than this if no carburetor modification is made.
When the carburetor has been modified for
high altitude operation, the air-fuel mixture
will be too lean for low altitude use. Operation
at altitudes below 5,000 feet (1,500 meters)
with a modified carburetor may cause the
engine to overheat and result in serious engine
damage. For use at low altitudes, have your
servicing dealer return the carburetor to
original factory specifications.
Emission Control Systems
Exhaust Emission Requirements (USA only)
The U.S. Environmental Protection Agency
(EPA) and the California Air Resources Board
(CARB) require that your motorcycle comply
with applicable exhaust emission standards
during its useful life, when operated and
maintained according to the instructions
provided.
The Vehicle Emission Control Information
Label ( 1) 1s attached to the inside of the left
fuel tank shroud.
(1) vehicle emission control
information label
Noise Emission Requirements
The EPA also requires that motorcycles built
after January 1, 1983 comply with applicable
noise emission standards for one year or
1,865 miles (3,000 km) after the time of sale to
the ultimate purchaser, when operated and
maintained according to the instructions
. provided. (USA only)
Technical Information 135
Emission Control Systems
Source of Emissions
The combustion process produces carbon
monoxide (CO), oxides of nitrogen (NOx), and
hydrocarbons (HC). Control of hydrocarbons
and oxides of nitrogen is very important
because, under certain conditions, they react to
form photochemical smog when subjected to
sunlight. Carbon monoxide does not react in
the same way, but it 1s toxic.
Honda Motor Co., Ltd. utilizes various systems
to reduce carbon monoxide, oxides of nitrogen
and hydrocarbons.
136 Technical Information
Exhaust Emission Control System
The exhaust emission control system is
composed of appropriate carburetor settings.
No adjustments should be made except for an
idle speed adjustment with the throttle stop
screw or carburetor adjustment for high altitude
operation. The exhaust emission control system
IS separate from the crankcase emission control
system.
Crankcase Emission Control System
The engine is equipped with a closed crankcase
system to prevent discharging crankcase
emissions into the atmosphere.
Blow-by gas is returned to the combustion
chamber through the air cleaner and the
carburetor.
Emission Control Systems
Noise Emission Control System
TAMPERING WITH THE NOISE CONTROL
SYSTEM IS PROHIBITED: U. S. federal law
prohibits, or Canadian provincial laws may
prohibit the following acts or the causing
thereof: (1) The removal or rendering
inoperative by any person, other than for
purposes of maintenance, repair or replacement,
of any device or element of design
incorporated into any new vehicle for the
purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it 1s
in use; or (2) the use of the vehicle after such
device or element of design has been removed
or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO
CONSTITUTE TAMPERING ARE THE
ACTS LISTED BELOW:
|. Removal of, or puncturing the muftler,
baffles, header pipes, or any other
component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the
intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle,
or parts of the exhaust or intake system, with
parts other than those specified by the
manufacturer.
Technical Information 137
Emission Control Systems
Problems that May Affect Motorcycle
Emissions
If you are aware of any of the following
symptoms, have the vehicle inspected and
repaired by your Honda Motorcycle Dealer:
I. Hard starting or stalling after starting
2. Rough idle
3. Mistiring or backfiring during acceleration
4. After-burning (backfiring)
5. Poor performance (driveability) and poor
fuel economy
Federal regulations prohibit removing or
disabling a device or element of design that
may affect your engine’s emission
performance unless your motorcycle will be
used exclusively in competition. If you modify
your engine for use in sanctioned competition
events, you must deface or destroy the
emission control information label.
138 Technical Information
Oxygenated Fuels
Some conventional gasolines are being blended
with alcohol or an ether compound. These
gasolines are collectively referred to as
oxygenated fuels. To meet clean air standards,
some areas of the United States and Canada use
oxygenated fuels to help reduce emissions.
If you use an oxygenated fuel, be sure it is
unleaded and meets the minimum octane rating
requirement.
Before using an oxygenated fuel, try to
confirm the fuel’s contents. Some states/
provinces require this information to be posted
on the pump.
The following are the EPA-approved
percentages of oxygenates:
ETHANOL (ethyl or grain alcohol) 10% by
Volume
You may use gasoline containing up to 10%
ethanol by volume. Gasoline containing ethanol
may be marketed under the name ““Gasohol”.
MTBE (Methyl Tertiary Butyl Ether) 15% by
Volume
You may use gasoline containing up to 15%
MTBE by volume.
METHANOL (methyl or wood alcohol) 5% by
Volume
You may use gasoline containing methanol
containing up to 5% methanol by volume as
long as it contains cosolvents and corrosion
inhibitors to protect the fuel system. Gasoline
containing more than 5% methanol by volume
may cause starting and/or performance
problems. It may also damage metal, rubber,
and plastic parts of your fuel system.
(cont’d)
Technical Information 139
Oxygenated Fuels
If you notice any undesirable operating
symptoms, try another service station or switch
to another brand of gasoline.
Fuel system damage or performance problems
resulting from the use of an oxygenated fuel
containing more than the percentages of
oxygenates mentioned above are not covered
under warranty.
Oxygenated fuels can damage paint and plastic.
Be careful not to spill fuel when filling the fuel
tank. Wipe up any spills immediately.
140 Technical Information
Oxygenated fuels can damage paint and
plastic. Damage caused by spilled fuel is not
covered under warranty.
Consumer Information
This section contains information on your Authorized Manuals......................ee.ee...e e... 142
warranty and how to get an official Honda Warranty Coverage ................e....100000000m0e 145
service manual. Warranty ServiCe................ 2... meesenenence eee 146
Contacting Honda .........................esee0eecene 147
The Honda Riders Club (USA only)........... 148
Your Honda Dealer.…….….…..…...……crresssssrencess 150
Consumer Information 141
Authorized Manuals
The Service Manual used by your authorized Honda dealer is available from Helm, Inc. (USA only,
Canada: See your Honda dealer to order authorized manuals.)
Also available but not necessary to service your model is the Honda Common Service Manual
which explains theory of operation and basic service information for various systems common to all
Honda motorcycles, motor scooters and ATVs.
These Honda manuals are written for the professional technician, but most mechanically-capable
owners should find them easy to use if they have the proper tools and observe proper safety
standards. Special Honda tools are necessary for some procedures.
Publication Item No. Description Price Each”
61GCF53 2007 CRF70F Service Manual $38.00
61CM002 Common Service Manual | $48.00
31GCF700 2007 CRF70F Owner's Manual $16.00
*Prices are subject to change without notice and without incurring obligation.
142 Consumer Information
Order On-Line: www.helminc.com
Order Toll Free: 1-888-CYCLE93 (1-888-292-5393)
(NOTE: For Credit Card Orders Only)
Monday — Friday 8:00 AM — 6:00 PM EST
OR
By completing this form you can order the materials desired. You can pay by check or money order,
or charge to your credit card. Mail to Helm, Inc. at the address shown on the back of this order form
(USA only).
Canada: See your Honda dealer to order authorized manuals.
Publication Item Description Qty. Price Total
Item No. Each* Price
| |
*Prices are subject to change without notice and without incurring Sub Total
obligation. Purchaser’s Sales Tax
Mich. Add 6 %
Orders are mailed within 10 days. Please allow adequate time for Calif. Add 8.25 %
delivery. Handling Charge $5.00 |
Grand Total
Consumer Information 143
NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person to
whose attention the shipment should be sent.
Customer Name Attention
Street Address - No P. O. Box Number Apartment Number
City State Zip Code
Daytime Telephone Number ( )
Г Check or money order enclosed payable to Helm Inc. Check here if your billing address is different
U.S. funds only. Do not send cash. from the shipping address shown above.
| | MasterCard Account Number Expiration: Mo. Yr.
7 visa EEE EEE =
| | Discover
—-ZME<>T
Customer Signature Date
These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery. On
returns, a restocking fee may be applied against the original order.
HELM P.O. BOX 07280, DETROIT, MICHIGAN 48207
144 Consumer Information
Warranty Coverage
Your new Honda is covered by these
warranties:
* Motorcycle Limited Warranty
* Exhaust Emission Warranty (USA only)
e Noise Control Warranty (USA only)
There are responsibilities, restrictions, and
exclusions which apply to these warranties.
Please read the Honda Motorcycle Warranties
Booklet given to you by your Honda dealer at
the time of purchase. Be sure to keep your
Honda owner's card (USA only) with your
Warranties Booklet.
It is important to realize that your warranty for
your Honda applies to defects in material or
factory workmanship. Your warranty coverage
does not apply to normal wear or deterioration
associated with using the motorcycle.
Your warranty coverage will not be voided if
you choose to perform your own maintenance.
However, you should have the proper tools and
service information and be mechanically
qualified. Failures that occur due directly to
improper maintenance or lack of maintenance
are not covered.
Almost all of your warranty coverage can be
extended through the Honda Protection Plan
(USA only). For more information, see your
Honda dealer.
Consumer Information 145
Warranty Service
Please remember that recommended
maintenance interval servicing is not included
in your warranty coverage. Additionally, your
warranty does not apply to the normal wear of
items (such as brakes, tires, etc.).
If you believe you have a problem with your
Honda, call the service department of your
Honda dealer. Make an appointment for an
Inspection and diagnosis. Remember, as the
owner of the motorcycle, you will be asked to
authorize that inspection. Your dealer will give
you the results of the inspection. If the problem
1s covered under warranty, your dealer will
perform the warranty repairs for you.
If you have questions about warranty coverage
or the nature of the repair, it is best to talk to
the service manager of your Honda dealer.
146 Consumer Information
Sometimes, in spite of the best intentions of all
concerned, a misunderstanding may occur. If |
you aren't satisfied with your dealer’s handling
of the situation, we suggest you discuss your
problem with the appropriate member of the
dealership’s management team. If the problem
has already been reviewed with the Service
Manager, Parts Manager, Sales Manager, etc.,
contact the Owner of the dealership or his
designated representative.
Contacting Honda
Your owner’s manual was written to cover
most of the questions you might ask about your
Honda. Any questions not answered in the
owner’s manual can be answered by your
Honda dealer. If he doesn’t have the answer
right away, he will get it for you.
If you have a difference of opinion with your
dealer, please remember that each dealership 1s
independently owned and operated. That's why
it’s important to work to resolve any
differences at the dealership level.
If you wish to comment on your experiences
with your Honda or with your dealer, please
send your comments to the following address
(USA only):
Motorcycle Division, American Honda Motor
Co., Inc., P.O. Box 2220, Torrance, CA 90509-
2220, mailstop: 100-4C-7B, telephone: (866)
784-1870.
Canada: Refer to the warranty booklet that was
supplied with your vehicle.
Please include the following information in
your letter:
e name, address, and telephone number
e product model, year, and VIN
e date of purchase
e dealer name and address
We will likely ask your Honda dealer to
respond, or possibly acknowledge your
comments directly.
Consumer Information 147
The Honda Rider’s Club (USA only)
One of the best ways to get the most enjoyment
from owning and nding your Honda 1s through
the Honda Rider’s Club of America. Your
purchase of a new motorcycle, scooter, ATV or
PWC from a participating U.S. Honda dealer
entitles you to a complimentary one-year
membership in the Club. There are hundreds of
HRCA Chapter-sponsoring dealers across the
USA with events and activities almost every
weekend. Membership benefits include:
e 24-hour, toll-free roadside assistance for
your new Honda (includes roadside
assistance for your transport vehicle [up to
one ton] as long as your Honda is aboard or
in tow). For street-legal motorcycles and
scooters only.
* An exclusive HRCA website complete with
access to the official Honda Common
Service Manual, contests, insider
information and more.
148 Consumer Information
* Reimbursement (up to $75) for successful
completion of a Motorcycle Safety
Foundation training course. Separate,
complimentary training from the Specialty
Vehicle Institute of America for purchasers
of new ATVs.
* One full year of Honda Red Rider magazine
(s1X issues).
* Discounts from HRCA partners for
experienced rider courses.
* Discounted vehicle insurance from the
HRCA's insurance partner.
* Racing contingency programs and assistance
at selected dual-sport, off-road and
motocross events for off-road motorcycles
and selected ATVs.
The Honda Rider’s Club (USA only)
If you purchased an of f -road motorcycle, ATV
or PWC, your benefits do not include roadside
assistance or trip interruption protection.
Contact your Honda dealer for more
information or call:
1-800-847-4722 or log on to
www. hrca.honda.com.
Consumer Information 149
Your Honda Dealer
Once you purchase your new Honda, get
familiar with the organization of your Honda
dealer so you can utilize the full range of
services available.
The service department is there to perform
regular maintenance and unexpected repairs. It
has the latest available service information
from Honda. The service department will also
handle warranty inspections and repairs.
The parts department offers Genuine Honda
parts, Pro Honda products, Hondaline
accessories (USA only), and Honda accessories
and products (Canada only). The same quality
that went into your Honda can be found in
Genuine Honda replacement parts. You'll also
find comparable quality in the accessories and
products available from the parts department.
150 Consumer Information
The sales department offers the Honda
Protection Plan to extend almost all of your
Warranty coverage (USA only).
Your dealer can inform you about competition
and other riding events in your area. You'll also
find that your dealer is a source of information
(USA only) about American Honda's Rider
Education Centers and the Honda Rider’s Club
of America.
We're sure you'll be as pleased with the service
your Honda dealer continues to provide after
the sale as you are with the quality and
dependability of your Honda.
Consumer Information 151
Table of Contents
The following presents the contents of each
section of your owner's manual.
MOTORCYCLE SAFETY ...1
Important Safety Information........................... 2
Important Message to Parents........................... 5
Loading, Accessories & Modifications ............ 8
Loading ...............eceeieecce ene ene ER EEE ERE REKEN 8
Accessories dz Modifications...................... 10
Safety Label Sa... 12
OPERATING CONTROLS 13
Operation Component Locations................... 14
Operating COntrolS.….….….….….…crerrssserreseseerennns 17
Fuel Valve .................. mee 17
Choke Lever.…..........…......……rrersrissssenrrrracnues 18
Ignition Switch... 19
Engine Stop SWitch.…..…...…….…erecircrassenenene 20
Front Brake Lever..................emmeenen e 20
Throttle....................ererieim e TREE EEE 20
152 Table of Contents
Shift Lever ..................emenicece eee _ 21
Rear Brake Pedal...................eeeeeeeeerereneecon.s 21
KiCKkStarter....................eeecerererenerncicce eee 21
Side Stand... RER K RK R EEK 21
BEFORE RIDING 23
Are You Ready to Ride ? ss 24
Protective Apparel …….……...….……reerereesssessuens 24
Is Your Motorcycle Ready to Ride ? ............. 26
Pre-ride Inspection ..................... e... 27
Table of Contents
BASIC OPERATION & RIDING............... 29
Safe Riding Precautions................. e... 30
Starting & Stopping the Engine..................... 31
Preparation .................e.e.eenererererererere enero. 31
Starting Procedure... 31
Flooded Engine .................e..mreececerrenee e. 33
How to Stop the Engine... 33
Shifting Gears ..............e...m.e.0emenene 34
Braking.....................eeeceeececec e ore. 36
Parking ......................eeeeereericecer eee recrea. 37
Post-ride Inspection .......................... mn... 38
SERVICING YOUR HONDA 39
Before You Service Your Honda
The Importance of Maintenance..................... 41
Maintenance Safety... 43
Important Safety Precautions...................... 43
Maintenance Schedule ...................e.enee.eerereeos 45
Maintenance Record ................ee.mrmerene eee. 49
(cont d)
Table of Contents 153
Table of Contents
SERVICING YOUR HONDA (cont’d)
Service Preparations
Maintenance Component Locations ...............
Seat Removal .................. meme e
Side Cover Removal .......................e...00m......
Service Procedures
Fluids & Filters
Engine Oil ….....…..….……csssessscsenssaseneararerasa serve
Air Cleaner .…….….…..….….….rrercrererenen caca sen nenanes
Engine
Throttle.....................e.erereececeecececacane re ae EEE EEG
Clutch System ..................e.e.e0emmeniericc ce nen
Valve Clearance ....................0000000000D
Engine Idle Speed ...................e...e.e.0iine...
Spark Plug......................eieee.eneecren e e eee
Spark ATrester .................ereececeerccrcianereree ene.
154 Table of Contents
Chassis
Suspension ..............e.e.eerererececeeeee eee. 79
Brakes...............ecerercocerecccarcececcecacrereenenerecoreeee 82
Wheels....................mericenneneeoeceronene earn nacen 87
Tires € TU Sasse een EEK EEK 92
Side Stand ..…...…......…....……erererrerersrananesaances 96
Drive Chain ..…….......….....errerrcereneenencrecerenreee 97
Appearance Care ….….….…..….....………eececrenmererenss 104
TIPS 107
Preparing for a Ride... ee 108
Transporting Your Honda............................. 110
Storing Your Honda..................e2e=esereevererores 112
You ¿ the Environment................—. eee... 115
Table of Contents
TAKING CARE OF THE
UNEXPECTED. 0.117
General Guide Seesen ee 118
If Your Engine Quits or Won't Start............ 119
If You Have a Flat Tire... 120
If You Crash.…….….…....reeeccccrecesaransenenrseceese 121
If You Lose Your Key ..................... meme 122
If a Component Fails ............................. e... 123
TECHNICAL INFORMATION. .......... 125
Vehicle Identification 126
SPECITICAtIONS..….........….…….rrereserencen carre seen re0e 128
Break-in Guidelines ressens 133
High Altitude Carburetor Adjustment.......... 134
Emission Control Systems... 135
Oxygenated Fuels..…....…...…..…......…….……eneescees 139
CONSUMER INFORMATION -............... 141
Authorized Manuals...............e...... 2... e... 142
Warranty Coverage .......................e...e.eaiennos 145
Warranty ServiCe..................e...emmenenence nene 146
Contacting Honda .....................eeseecrierer 147
The Honda Riders Club (USA only)........... 148
Your Honda Dealer................e......0. 00... 150
TABLE OF CONTENTS ..152
INDEX 156
QUICK REFERENCE
Table of Contents 155
Index
A
ACCESSOFES..........e..erererooccocececeerenereooocecerenerennena 10
10 econ e errores 64
air pressure, tires ....................eecerencevevenerrnenences 92
altering your motorcycle ...................... ==... 11
arrester, sparK …..….…......….….…..….…eeercrcrrrerssarercecene 77
authorized manuals ...................e.eseemerececeroeeos 142
B
brakes,
cable inspection/lubrication .................——... 86
lever, front..................ee.eernorrDenreecen eee 20
pedal, Tea are ieee, 21
ShOE Weder REKEN RER eee 85
DTAKING eee eee. 36
break-in guidelines... 133
156 Index
C
capacity, fuel... 56
carburetor,
high altitude adjustment............................ 134
Idle speed..........................0ri00 ee ee 74
choke lever ......................eceneroone nera reo ee ererenees 18
cleaner, af .................eevecrccerrne eee e e e e eee. 64
cleaning, appearance care ..................c......... 104
clearance, valve ..................200er0rme RER eee 71
clutch system, adjustment 69
color label....................e.e... e. 000000 Den reee. 127
consumer information ..........................eveeeeee. 141
controls, operating....................ereeemeree 13
customer ServiCe...................eerneirirr eee e. 147
Index
D F
drive chaif................e.eeeccerer ocre e e DD 97 filter, alf....................... EEE EEE e en ce eee. 64
TE 120
E flooded engine, StartiN£ esse 33
FOTK coerce eee eran 79
front brake,
education, rider ...................eeeeemmercecieneeeenos 3, 149 1 (7 e reer eee eres seer ee eaa anne 20
emission control systems ….……….….….….…..….e 135 lever freeplay ......................erececcicier eee 82
engine number....................e.ereereeciice EEE 126 front Suspension ..............e.ee0reicicarnero e 79
engine, front wheel removal ...........................m..e.non.. 88
flooded ........................e..eroanonen aro reee. 33 fuel,
1dle speed.....................e..imeiien nene ere 74 recommendation.…...…..…..….…..…..….…………ereseerernenss 55
PINging ...............receaerericree ner reee one ee rneee. 55 oxygenated...................e.emmieiic ren REN 139
StartiNg..................eeeeeeccccererenrencecooteneene reee 31 tank CApaCItY ….…........…ercrererssnneneeseranann sers 56
stop SWItch.................==..íeeeeeeieer DA 20 Valve ...........eeeneecemecenceeoe rene reee reee es 17
StOPpINg................erereerceccec cer es 33 |
Won't start ..............e=ererececccececroeerareneene rene. 119
environment, protecting ......................——.—...... 115
Index 157
Index
G
gap, spark plug ..........................ee2eer 76
gasohol ................eeeerirenereeee e eee eee 139
gasoline ...............e........00erecenerenee econo neneea ee. 55
gears, ShIfting........... e ee. —.—....eienecenececcceene nene. 34
H
high altitude carburetor adjustment .............. 134
Honda, contacting .............e.e.ee.e.eeeeererereeeenee 147
Honda service manual... 142
I
idle speed, engine...................... eee 74
Inspection,
POSt-ride ....................enerececeoce eee e 38
Pre-ride ...............eeerererecnone een eee. 27
158 Index
K
Key, JOSE. uniter, 122
KICK SAITO eee o eee. 21
L
lever,
front brakKe...................e.svereeerieremec A 20
SHifE..............eermececeeeocenenone neon erroneo. 21
limit, weight o.oo, 9
10ading ....vvveiiiiii ren erR Re reee 8
Index
M
maintenance,
component locations see 50
Гесог@ TO 49
safety ..................emenericecee serena recen ere ener. 43
schedule.…….…........…....…rrrercrrrararsseeneaseecrences 45
manual, SErvICE..….......….…......…….ereresssereresscress 142
MOCIfICATIONS ...............erasreccercrrranarsrra encre 11
О
Oil, ENZINE.................ereererecrrenecer eee eee. 58
operating CONtrolS....................imiernn A 13
operation component locations ....................... 14
OVEI-IEVVINE ...........e.eeerrnereanococoneeetonarac era cacee. 35
oxygenated fuels...................e...eremeeeener ee. 139
P
parking ...............e.erereeeenicecenenennee nene neneen ere eee 37
pedal, rear brake ......................eeeierecieni 21
pinging, engine.....................emeereierrcen e 55
plug, Sparkassen ernten EEE EEE PT 75
post-ride inspection ....................em EEE EEE 38
pre-ride iInspection......................eeememee 27
R
reserve capacity, fuel tank 56
rider training..............e.e.e..eeeerernecoreererevenenes 3, 149
riding,
basic operation ..................eeereremre 29
before ..............e.erececne caian nee nene 23
ClOthing.................e.e..eeereececrnccecere ree rananre ne 24
precautions .............ee....emeeeeeee 30
SAÎELY TEEN 2
Index 159
Index
S
schedule, maintenance ..................e.eccerierriceno. 45
service,
CUStOMEer ...................rceomereereenenenerecra recae. 147
manuals ......................erererercccreciocerorer een. 142
WAalTanty ................-....ereeeeeoneriioceo eee. 146
Shifting gears.............——.....eeeeeeeere ees 34
shoe, brake .................e.e.erdcericcricerrorer eee 85
side cover, removal ...................eeesirnecerereceecee 54
side Stande eK RETRO 21, 96
spark arrester ……………………….….....….…erernenenenessssues 77
spark knock ................. e... ese eneenene e nene 55
spark plug.....................emeeereee ene eee 75
specifications ..................erecenen EEE EEE EEE 128
stand, SIde................e..erenererererccarecareorerenene. 21,96
starting, ENgiNE..............—————.....eemenenenece eee 31
stop switch, engine ..............———-——wemereeceeenneroenes 20
StOPPpINE ENGINE …................rcrccccorerensecrcncues 33
Storage ..............ereeeooerrenerorotere nene e eee 112
160 Index
suspension,
ÍrONt............eienenenecooneneennene rc oo oe reen o nereene. 79
A rerececareeeeceees 80
T
throttle
freeplay .....................0000emme DAA 67
Operation...............—....emmiereiecer nee rene 20
tires,
alr Pressure ...............e.ememerereeenenearo re rene rar 92
Flat cee, 120
TEPlACING cree e A 95
(OWIDSerreererere nern RER EEE EEE E EEE RERRRR KK EEE EEEE LE REEEEEN 35
training, Tide RER EEE 3, 149
transporting ....................e.e..... 0er ene 110
troubleshooting, starting ===... 119
Index
U
unexpected problems ass 117
V
VALVE, TUEL. cee eK 17
vehicle identification no. (VIN).................... 126
W
warranty,
COVEragE ...............0r0e0eionenencoe ooo r acer rene 145
extended ..................ee000e0 EEE 145
SEIVICE ....nrnerereenrorececasnerseacacearaceneneneneere nenes 146
washing your motorcycle.................— eee... 10S
weight IM essen ernennen EEK rene. 9
WHEEIS. oie 87
Index 161
Quick Reference
The following is a brief, but important
collection of information you need to know
about your Honda. You’ll also find space to
record important notes.
Your Honda engine can be the most expensive
component to repair. Proper maintenance,
especially the use of the recommended fluids
and filters, prevents premature wear and
damage.
Frequent causes of costly engine repairs are:
* Engine oil: insufficient quantity, improper
oil.
* Air cleaner: dirty, cleaned but not oiled,
leaking because of improper installation
(poor seal).
Quick Reference
Frequent causes of costly chassis repair are:
* Chain: A loosely adjusted chain or a chain
stretched because of lack of lubrication may
come off and damage an engine case or
wheel hub.
* Spokes: Loose spoke may break and damage
the wheel hub or rim.
Record important information on the following
page:
Record important information here:
VIN
No.
No.
Color Label
Owner's:
Name
Address
/State
Phone
Dealer's:
Name
Address
City/State
Phone
Service M
Quick Reference
Quick Reference
Quick Reference
Initial Maintenance
about 100 miles (150 km) or 1 month.
Regular
Maintenance
about every 600 miles (1,000 km) or 6 months.
Pre-ride Inspection
Check the following items each time before you ride (page 27 ): tires, spokes & rims,
leaks, engine oil, fuel, drive chain, cables. nuts & bolts, spark plug & cap, throttle, and
brakes.
Fuel/Capacity unleaded gasoline, pump octane number of 86 or higher
tank: 1.45 US gal (5.5 2)
reserve: 0.29 US gal (1.1 2)
Engine Oil API Service Classification SG or higher except oils labeled as energy conserving on the
circular API service label, SAE 10W-30, JASO T 903 standard MA,
Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent
Maximum Weight 132 Ibs (60 kg)
Capacity rider only (no passenger or cargo) and any accessories
Tires Front: 2.50-14 4PR Rear: 3.00-12 4PR
Type: bias-ply, tube
Tire Pressure (cold)
Front: 15 psi (100 kPa, 1.00 kgf/cm?)
Rear: 15 psi (100 kPa, 1.00 kgf/cm?)
Spark Plug
CR6HSA (NGK) or U20FSR-U (DENSO)
Quick Reference
HONDA
The Power of Dreams
31GCF700 E OCHO 2000.2006.03.
00X31-GCF-7000 PRINTED IN JAPAN