No part of this publication may be reproduced without

No part of this publication may be reproduced without

07/05/15 13:43:58 31KPS650 0001 

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold.

This publication includes the latest production information available before printing.

Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

The vehicle pictured on the front cover may not match your vehicle.

Honda Motor Co., Ltd. 2007

07/05/15 13:44:02 31KPS650 0002 

2008

Honda CRF230F

OWNER’S MANUAL

FOR OFF-ROAD USE ONLY

This vehicle is 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, California, and Environment Canada exhaust emission regulations for off-road motorcycles.

07/05/15 13:44:06 31KPS650 0003 

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 and one of three signal words:

DANGER, WARNING,

or

CAUTION.

These signal words mean:

Safety Messages

07/05/15 13:44:12 31KPS650 0004 

A Few Words About Safety

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.

You CAN be HURT if you don’t follow instructions.

Safety Headings

–– such as Important Safety Reminders or Important Safety Precautions.

Safety Section

–– such as Motorcycle Safety.

Instructions

–– how to use this motorcycle correctly and safely.

This entire book is filled with important safety information –– please read it carefully.

Safety Messages

07/05/15 13:44:22 31KPS650 0005 

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,

.

precautions about loading, accessories, and modifications, and the location of safety labels.

1

Operating Controls ..................................

The location, function, and operation of

.

the throttle, brakes, clutch, and other basic controls.

11

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.

21

Contents

Basic Operation & Riding .......................

.

How to start and stop the engine, shift gears, and brake. Also, riding precautions.

27

Servicing Your Honda .............................

.

Why your motorcycle needs regular maintenance, what you need to know before servicing your Honda, a maintenance schedule, and instructions for specific maintenance items.

39

07/05/15 13:44:33 31KPS650 0006 

Tips ............................................................

How to transport and store your

. 121

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.

131

Technical Information .............................

.

ID numbers, technical specifications, and other technical facts.

145

Consumer Information ...........................

Information on warranties and how to

.

get Honda service manuals.

161

Contents

Table of Contents .....................................

.

Sequential listing of topics in this owner’s manual.

172

Index ..........................................................

.

176

Quick Reference

Handy facts about fuel, engine oil, tire sizes, and air pressures.

Contents

07/05/15 13:44:41 31KPS650 0007 

Introduction

Congratulations on choosing your Honda offroad 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.

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 preride and other periodic checks detailed in this manual.

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 is 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 167 ) thoroughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities.

Introduction

07/05/15 13:44:47 31KPS650 0008 

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!

Introduction

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

07/05/15 13:44:49 31KPS650 0009 

07/05/15 13:44:53 31KPS650 0010 

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 information about the location of safety labels on your motorcycle.

Motorcycle Safety

Important Safety Information ..........................

.2

Loading, Accessories & Modifications

Loading

...........

........................................................

.5

.5

Accessories & Modifications .......................

.7

Safety Labels ....................................................

.9

Motorcycle Safety

1

07/05/15 13:44:59 31KPS650 0011 

Important Safety Information

Your motorcycle can provide many years of service and pleasure

− if you take responsibility for your own safety and understand the challenges you can meet while riding.

There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual. The following are a few that we consider most important.

Always Wear a Helmet

It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an approved motorcycle helmet.

We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear (page 22 ).

Never Carry a Passenger

Your motorcycle is designed for one person only. There are no handholds, footrests, or seat for a second person − so never carry a passenger. A passenger could interfere with your ability to move around to maintain your balance and control of the motorcycle.

Ride Off-Road Only

Your motorcycle is designed and manufactured for off-road use only. The 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.

2

Motorcycle Safety

07/05/15 13:45:04 31KPS650 0012 

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 f or the Of f -Highway Motorcyclist

booklet that came with your motorcycle (USA only).

Important Safety Information

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

07/05/15 13:45:08 31KPS650 0013 

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

07/05/15 13:45:14 31KPS650 0014 

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 it unsafe. Also, the weight of any accessories will reduce the maximum load the motorcycle can carry.

More specific information on load limits, accessories, and modifications follows.

Loading

How much weight you put on your motorcycle, and how you load it, are important to your safety. If you decide to carry cargo, you should be aware of the following information.

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.

Motorcycle Safety

5

07/05/15 13:45:23 31KPS650 0015 

Loading, Accessories & Modifications

Load Limits

Following are the load limits for your motorcycle:

Maximum weight capacity

=

220 lbs (100 kg)

Includes the weight of the rider and any accessories.

Loading Guidelines

As discussed on page 5 , 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 commonsense 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.

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

(page 100 ).

6

Motorcycle Safety

07/05/15 13:45:30 31KPS650 0016 

Loading, Accessories & Modifications

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.

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.

Accessories

We strongly recommend that you use only

Honda Genuine 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.

Motorcycle Safety

7

07/05/15 13:45:34 31KPS650 0017 

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 it 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.

8

Motorcycle Safety

07/05/15 13:45:44 31KPS650 0018 

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.

(For USA)

(For Canada)

Motorcycle Safety

9

07/05/15 13:45:46 31KPS650 0019 

10

Motorcycle Safety

07/05/15 13:45:50 31KPS650 0020 

When you ride off-road, you need to operate the throttle, clutch, 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 ...................

.12

Operating Controls .........................................

.15

Fuel Valve ..................................................

.15

Choke Lever ...............................................

.16

Ignition Switch ...........................................

.17

Start Button ................................................

.18

Engine Stop Button ....................................

.18

Front Brake Lever ......................................

.18

Throttle .......................................................

.18

Clutch Lever ...............................................

.19

Shift Lever .................................................

.19

Rear Brake Pedal ........................................

.19

Side Stand ..................................................

.19

Operating Controls

11

07/05/15 13:45:55 31KPS650 0021 

Operation Component Locations

ignition switch clutch lever front brake lever engine stop button

12

Operating Controls

start button throttle grip

07/05/15 13:45:59 31KPS650 0022 

Operation Component Locations

rear brake pedal

Operating Controls

13

07/05/15 13:46:03 31KPS650 0023 

Operation Component Locations

fuel valve choke lever

14

Operating Controls

shift lever

07/05/15 13:46:10 31KPS650 0024 

Fuel Valve

LEFT SIDE

ON OFF RES

The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor.

Operating Controls

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.

Operating Controls

15

07/05/15 13:46:19 31KPS650 0025 

Operating Controls

The reserve fuel supply is:

0.34 US gal (1.3 )

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.

Choke Lever

LEFT SIDE engine (page 29 ). 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).

DETENT

Used to warm a cold engine immediately after starting 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).

(1) choke lever

16

Operating Controls

(1)

(A) fully ON

(B) detent position

(C) fully OFF

07/05/15 13:46:27 31KPS650 0026 

Ignition Switch

unauthorized use of the motorcycle.

Before riding, insert the key and turn it to the

ON position.

Key

Position

OFF

(ON)

Function Key Removal

The engine cannot be operated.

With the transmission in neutral, the engine can be started.

The key can be removed.

The key cannot be removed.

After parking the motorcycle, remove the key.

FRONT

(1)

OFF

Operating Controls

OFF ON

ON

(1) ignition switch

Operating Controls

17

07/05/15 13:46:36 31KPS650 0027 

Operating Controls

Start Button

The start button is used for starting the engine.

Pushing the button in starts the engine. See

Starting Procedure,

page 29 .

When the start button is pushed, the starter motor will crank the engine.

Engine Stop Button

The engine stop button is used to turn the engine off during normal riding situations. To operate, push the button in and hold it in until the engine stops completely.

Front Brake Lever

The front brake lever is used to slow or stop your motorcycle. To operate, pull the lever. For information on braking techniques, see page 35 .

Throttle

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.

18

Operating Controls

07/05/15 13:46:44 31KPS650 0028 

Operating Controls

Clutch Lever

The clutch lever is used to disengage the clutch whenever you shift gears. To operate, pull the clutch lever in all the way before shifting, then slowly release it after shifting.

Shift Lever

The shift lever is used to select the next higher or lower gear in the transmission. To operate, raise the shift lever (after pulling in the clutch lever) to engage the next higher gear or depress the shift lever to engage the next lower gear.

See

Shif ting Gears,

page 33 .

Rear Brake Pedal

The rear brake pedal is used to slow or stop your motorcycle. To operate, depress the pedal.

For information on braking techniques, see page 35 .

Side Stand

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

19

07/05/15 13:46:46 31KPS650 0029 

20

Operating Controls

07/05/15 13:46:54 31KPS650 0030 

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.

Before Riding

Are You Ready to Ride?

Protective Apparel

................................

.....................................

.22

.22

Is Your Motorcycle Ready to Ride?

Pre-ride Inspection

..............

.....................................

.24

.24

Before Riding

21

07/05/15 13:47:02 31KPS650 0031 

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

Protective Apparel

For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved jersey, shirt, or jacket whenever you ride. Although complete protection is not possible, wearing the proper gear can reduce the chance of injury when you ride. Following are suggestions to help you choose the proper gear.

22

Before Riding

07/05/15 13:47:10 31KPS650 0032 

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 on any helmet you buy

Are You Ready to Ride?

(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

23

07/05/15 13:47:18 31KPS650 0033 

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.

Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed.

Always perform a pre-ride inspection before every ride and correct any problems.

Pre-ride Inspection

Check the following items before you get on the motorcycle:

Tires

Spokes &

Rims

Leaks

Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damage or excessive wear (page 101 ).

Make sure the spokes and rim locks are tight. Also check the rims for damage (page 95 ).

Look under the motorcycle for signs of leaking fluids (fuel, engine oil, brake fluid).

24

Before Riding

07/05/15 13:47:27 31KPS650 0034 

Is Your Motorcycle Ready to Ride?

Engine Oil

Fuel

Check the level and add oil if needed (page 65 ).

Check the level and add fuel

(page

60

) if needed. Also make sure the fuel fill cap is securely fastened.

Drive Chain

Check the condition and slack.

Adjust and lubricate if needed.

Also check the chain guide slider and slipper for wear and replace if needed (page

105

).

Cables

Nuts &

Bolts

Spark Plug

& Cap

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 80 ).

Before Riding

25

07/05/15 13:47:36 31KPS650 0035 

Is Your Motorcycle Ready to Ride?

Check these items after you get on the motorcycle:

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 75 ).

Brakes

Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally (pages 87 ,

91 ). Check for proper freeplay

(pages 87 , 91 ). Adjust freeplay, if necessary (pages

87 , 91 ).

Clutch

Lever

Check for smooth operation and adjust if needed (page 76 ).

Remember, be sure to take care of any problem you find or have your Honda dealer correct it before you ride.

26

Before Riding

07/05/15 13:47:42 31KPS650 0036 

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, clutch, 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 f or the Of f -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 153 ).

For information about carburetor adjustment for riding at high altitude, see page 154 .

Safe Riding Precautions .................................

.28

Starting & Stopping the Engine .....................

.29

Preparation .................................................

.29

Starting Procedure ......................................

.29

Flooded Engine ..........................................

.31

How to Stop the Engine .............................

.32

Shifting Gears ................................................

.33

Braking ...........................................................

.35

Parking ...........................................................

Post-ride Inspection .......................................

.37

.38

Basic Operation & Riding

27

07/05/15 13:47:48 31KPS650 0037 

Basic Operation & Riding

Safe Riding Precautions

Before riding your motorcycle for the first time, please review the

Important Saf ety

Inf ormation

beginning on page 2 and the previous section, titled

Bef ore 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.

Your motorcycle is not equipped with lights.

Do not ride at night.

28

Basic Operation & Riding

07/05/15 13:47:57 31KPS650 0038 

Always follow the proper starting procedure described below.

Your motorcycle can be started with the transmission in gear by pulling in the clutch lever before operating the starter.

Preparation

Before starting, insert the key and turn the ignition switch ON.

Make sure that the transmission is in neutral.

Turn the fuel valve ON.

Starting & Stopping the Engine

Starting Procedure

To restart a warm engine, follow the procedure for

High Air Temperature.

Normal Air Temperature

10°

35°C (50°

95°F)

LEFT SIDE

(1) choke lever

1.

(1)

(A) fully ON

(B) detent position

(C) fully OFF

(cont’d)

Basic Operation & Riding

29

07/05/15 13:48:08 31KPS650 0039 

Starting & Stopping the Engine

2.

3.

With the throttle slightly open, press the start button.

Immediately after the engine starts, push the

4.

5.

Warm up the engine by opening and closing the throttle slightly.

About a half-minute after the engine starts, push the choke lever down all the way to

6.

If idling is unstable, open the throttle slightly.

High Air Temperature

35°C (95°F) or above

1.

2.

Do not use the choke.

Start the engine following step

Normal Air Temperature.

2 under

Low Air Temperature

10°C (50°F) or below

1.

2.

Follow steps

Temperature.

1 − 3 under

Normal Air

Warm up the engine by opening and closing

3.

the throttle slightly.

Continue warming up the engine until it will

Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine.

30

Basic Operation & Riding

07/05/15 13:48:16 31KPS650 0040 

Starting & Stopping the Engine

Flooded Engine

If the engine fails to start after repeated attempts, it may be flooded with excess fuel.

To clear a flooded engine:

1.

2.

3.

4.

5.

Push the choke lever down all the way to

OFF.

Open the throttle fully.

While pushing the engine stop button, press the start button for 5 seconds.

Release the engine stop button.

Follow the

High Air Temperature

procedure (page 30 ).

starting

Basic Operation & Riding

31

07/05/15 13:48:20 31KPS650 0041 

Starting & Stopping the Engine

How to Stop the Engine

To stop the engine, shift into neutral, push the engine stop button in, and hold it in until the engine stops.

32

Basic Operation & Riding

07/05/15 13:48:30 31KPS650 0042 

2 3

4

5

6

1

Your motorcycle has six forward gears.

To start riding, after the engine has been warmed and the side stand raised:

1.

2.

Close the throttle and pull the front brake lever in.

Pull the clutch lever all the way in.

Shifting Gears

3.

4.

5.

Depress the shift lever from neutral down to first gear.

Release the front brake. Gradually open the throttle while you slowly release the clutch lever.

If engine rpm (speed) is too low when you release the clutch lever, the engine will stall.

If engine rpm is too high or you release the clutch lever too quickly, your motorcycle may lurch forward.

When you attain a moderate speed, close the throttle, pull the clutch lever in, and raise the shift lever. After shifting, release the clutch lever and apply the throttle.

(cont’d)

Basic Operation & Riding

33

07/05/15 13:48:37 31KPS650 0043 

Shifting Gears

6.

7.

To continue shifting up to each higher gear, repeat step 5 .

To shift down to a lower gear, close the throttle, pull the clutch lever in, and depress the shift lever. After shifting, release the clutch lever and apply the throttle.

Remember to close the throttle and pull the clutch lever in completely before shifting.

Downshif ting can help slow your motorcycle, especially on downhills. However, downshif ting when engine rpm is too high can cause engine damage.

Improper shif ting may damage the engine, transmission, and drive train.

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.

To prevent transmission damage, do not coast or tow the motorcycle f or long distances with the engine of f .

34

Basic Operation & Riding

07/05/15 13:48:42 31KPS650 0044 

To slow or stop, apply the front brake and rear brake smoothly, while downshifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. To prevent stalling the engine, pull the clutch lever in before coming to a complete stop. 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.

Braking

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.

Basic Operation & Riding

35

07/05/15 13:48:47 31KPS650 0045 

Braking

When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes.

When you brake to a stop, pull the clutch lever in before stopping completely to prevent stalling the engine. For support, put your left foot on the ground first, then your right foot when you’re through braking.

36

Basic Operation & Riding

07/05/15 13:48:50 31KPS650 0046 

Lower the side stand to support your motorcycle. Turn the ignition switch OFF and remove the key. If you’re finished riding for the day, also turn the fuel valve OFF. Always choose a level place to park.

Parking

Basic Operation & Riding

37

07/05/15 13:48:54 31KPS650 0047 

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 to prevent rusting.

110 )

38

Basic Operation & Riding

07/05/15 13:49:02 31KPS650 0048 

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), the

California Air Resources Board (CARB), and

Environment Canada (EC), see page 155 .

For information about replacing fuses, see page

138 .

Servicing Your Honda

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.

Bef ore You Service Your Honda

The Importance of Maintenance ....................

.41

Maintenance Safety ........................................

.43

Important Safety Precautions .....................

.43

Maintenance Schedule

Maintenance Record

...................................

......................................

.45

.49

Competition Inspection ..................................

.50

(cont’d)

Servicing Your Honda

39

07/05/15 13:49:06 31KPS650 0049 

Servicing Your Honda

Service Preparations

Maintenance Component Locations

Tools ...............................................................

.56

Side Cover Removal

..............

.53

......................................

.57

Service Procedures

Fluids & Filters

Fuel .................................................................

.59

Engine Oil

Air Cleaner

......................................................

.62

.....................................................

.68

Crankcase Breather ........................................

.72

Engine

Throttle ...........................................................

.73

Clutch System ................................................

Engine Idle Speed ..........................................

.76

.79

Spark Plug ......................................................

Spark Arrester ................................................

.80

.82

Chassis

Suspension .....................................................

.84

Brakes .............................................................

.87

Wheels ............................................................

.94

Tires & Tubes ...............................................

.100

Side Stand ....................................................

Drive Chain ..................................................

.104

.105

Electrical

Battery ..........................................................

.112

Appearance Care ..........................................

.117

40

Servicing Your Honda

07/05/15 13:49:13 31KPS650 0050 

A well-maintained motorcycle is essential for safe, economical, and trouble-free riding. It will also help reduce air pollution. Careful preride inspections and good maintenance are especially important because your motorcycle is designed to be ridden over rough off-road terrain.

To help you properly care for your motorcycle, this section of the manual provides a

Maintenance Schedule. The service intervals in this schedule are based on average riding conditions.

More frequent service is needed if you subject your motorcycle to severe use (see the

Competition Inspection checklist, page 50 ) or ride in unusually wet or dusty areas.

The Importance of Maintenance

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.

Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed.

Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.

Servicing Your Honda

41

07/05/15 13:49:16 31KPS650 0051 

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

07/05/15 13:49:22 31KPS650 0052 

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.

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 owner’s manual.

Important Safety Precautions

Make sure the engine is off before you begin any maintenance or repairs.

This will help eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you operate the engine.

Burns from hot 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

07/05/15 13:49:27 31KPS650 0053 

Maintenance Safety

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 fuelrelated parts.

Remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new Honda

Genuine Parts or their equivalents for repair and replacement. If you have the tools and skills required for additional maintenance jobs, you can purchase an official Honda

Service Manual (page 164 ).

44

Servicing Your Honda

07/05/15 13:49:33 31KPS650 0054 

To maintain the safety and reliability of your motorcycle, regular inspection and service is 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 164 ).

Maintenance Schedule

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 is fully equipped to maintain and repair it.

If you decide to do your own maintenance, use only Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability.

Servicing Your Honda

45

07/05/15 13:49:42 31KPS650 0055 

Maintenance Schedule

Perform the pre-ride inspection (page 24 ) 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 164 ).

In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Summary of Maintenance Schedule Notes and

Procedures:

NOTES:

1.

Service more frequently when ridden in wet or dusty conditions.

2.

Replace every 2 years. Replacement requires mechanical skill.

C:

A:

L:

R:

Maintenance Procedures:

I: inspect and clean, adjust, lubricate, or replace, if necessary clean adjust lubricate replace

46

Servicing Your Honda

07/05/15 13:49:57 31KPS650 0056 

Maintenance Schedule

Items

Fuel Line

Throttle Operation

Air Cleaner

Crankcase Breather

Spark Plug

Valve Clearance

Engine Oil

Engine Oil Strainer Screen

Engine Oil Centrifugal Filter

Engine Idle Speed

Frequency

Whichever

Comes First

Note

Note 1 mi km

Month

Initial

Maint.

100

150

1

I

R

600

1,000

6

C

I

I

I

R

Regular Maint. Interval

R

C

I

I

C

I

1,200

2,000

12

C

I

I

I

1,800

3,000

18

C

I

I

I

R R

C

I

I

C

I

2,400

4,000

24

C

I

I

I

Refer to page:

73

68

72

80

62

79 I I I

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 164 ).

**

In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Servicing Your Honda

47

07/05/15 13:50:13 31KPS650 0057 

Maintenance Schedule

Items

Drive Chain

Drive Chain Slider

Brake Fluid

Brake Shoes/Pads Wear

Brake System

Clutch System

Side Stand

Suspension

Spark Arrester

Nuts, Bolts, Fasteners

Wheels/Tires

Steering Head Bearings

Frequency

Whichever

Comes First

Note

Note 1 mi km

Month

Note 2

Initial

Maint.

100

150

1

I, L

I

I

Regular Maint. Interval

600

1,000

6

1,200

2,000

12

1,800

3,000

18

2,400

4,000

24

I, L: every 300 mi (500 km) or 3 months

I I I I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

C: every 1,000 mi (1,600 km) or every 100 operating hours

I

I

I

I

I

I

I

I

I

I

I

Refer to page:

105

106

89

90, 92

87

76

104

84

82

94, 100

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 164 ).

**

In the interest of safety, we recommend these items be serviced only by your Honda dealer.

48

Servicing Your Honda

07/05/15 13:50:19 31KPS650 0058 

Maintenance Record

Keeping an accurate maintenance record will help ensure that your motorcycle is 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 is corrected as soon as possible.

Date Performed By: Notes Miles (km) or

Months

600 (1,000) or 6

1,200 (2,000) or 12

1,800 (3,000) or 18

2,400 (4,000) or 24

3,000 (5,000) or 30

3,600 (6,000) or 36

4,200 (7,000) or 42

4,800 (8,000) or 48

5,400 (9,000) or 54

Servicing Your Honda

49

07/05/15 13:50:29 31KPS650 0059 

Competition Inspection

4

5

6

2

3

All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools.

Damage from competition use is not covered by the Distributor’s Limited Warranty on your

Honda.

NOTE:

No

Refer to the Maintenance Schedule (page

Item Inspect For:

46 ) for regular service intervals.

Action

1

Refer to

Page:

24 all pre-ride inspection items engine oil fuel line valve clearance engine idle speed carburetor choke contaminants deterioration, damage, or leakage correct clearance correct idle speed proper operation change replace adjust adjust

62

79

50

Servicing Your Honda

07/05/15 13:50:39 31KPS650 0060 

Competition Inspection

10

11

12

No

7

8

9

Item

clutch discs air cleaner spark plug steering head bearings front suspension rear suspension

Inspect For:

proper operation, see NOTE 1 contamination or tears gap, tightness, proper heat range, hightension terminal security free rotation of handlebar and steering stem nut tightness smooth operation, oil capacity, no oil leaks, good boot condition smooth operation, no oil leaks

Action

replace clean or replace tighten, replace or secure adjust or retighten replace or adjust replace or adjust

Refer to

Page:

68

80

NOTE 1: Competition use may cause more rapid clutch disc wear. Refer to the official Honda Service

Manual, or see your Honda dealer for clutch disassembly and wear inspection.

84

85

Servicing Your Honda

51

07/05/15 13:50:48 31KPS650 0061 

Competition Inspection

No

13

14

15

16

17

18

19

20

Item

swingarm bearings rear suspension linkage bushings brake pads drive chain: max. length/pin sprockets seat control cables engine mounting bolts

Inspect For:

smooth operation wear wear beyond service limit

25.1 in (637 mm) / 41 pins wear and secure installation security smooth operation, kinks and correct routing tightness

Action

replace replace replace replace replace or tighten tighten lubricate or replace tighten

Refer to

Page:

85

85

90

107

108

52

Servicing Your Honda

07/05/15 13:50:53 31KPS650 0062 

Maintenance Component Locations

clutch lever front brake fluid reservoir front brake lever fuel fill cap throttle grip

Servicing Your Honda

53

07/05/15 13:50:57 31KPS650 0063 

Maintenance Component Locations

engine oil filler cap/dipstick air cleaner spark plug spark arrester rear brake pedal

54

Servicing Your Honda

07/05/15 13:51:02 31KPS650 0064 

Maintenance Component Locations

throttle stop screw

(engine idle speed) battery main fuse choke lever crankcase breather tube front brake caliper engine oil drain bolt drive chain

Servicing Your Honda

55

07/05/15 13:51:07 31KPS650 0065 

Tools

Refer to

Saf ety Precautions

on page 43 .

The nipple wrench is delivered with your motorcycle.

You will need to provide your own tools to perform any owner maintenance other than tightening or loosening the spokes (USA only).

(1)

(1) nipple wrench

56

Servicing Your Honda

07/05/15 13:51:16 31KPS650 0066 

Side Cover Removal

Refer to

Saf ety Precautions

on page 43 .

RIGHT SIDE

(4) service the air cleaner.

Right Side Cover Removal

1.

2.

(1)

Right Side Cover Installation

1.

Slide the top of the side cover under the bottom edge of the seat.

2.

3.

Align the side cover prongs with the rubber grommets. Press the side cover into position.

Install the securing screw and tighten it.

(2)

(3)

(1) right side cover

(2) screw

(3) side cover prongs

(4) rubber grommets

Servicing Your Honda

57

07/05/15 13:51:24 31KPS650 0067 

Side Cover Removal

Refer to

Saf ety Precautions

on page 43 .

LEFT SIDE

(1)

(5)

(3)

(4)

(2)

(1) left side cover

(2) screw

(3) bolt A

(4) bolt B

58

Servicing Your Honda

(5) side cover prongs

(6) rubber grommets

(6) service the battery and main fuse and to check the color label.

Left Side Cover Removal

1.

2.

Left Side Cover Installation

1.

2.

3.

Slide the top of the side cover under the bottom edge of the seat.

Align the side cover prongs with the rubber grommets. Press the side cover into position.

Install the securing screw and bolts and tighten them.

07/05/15 13:51:33 31KPS650 0068 

Refer to

Saf ety Precautions

on page 43 .

Fuel Recommendation

Type

Pump Octane

Number premium unleaded

91 (or higher)

Your engine is designed to use any premium gasoline that has a pump octane number of 91 or higher. Gasoline pumps at service stations normally display the pump octane number. For information on the use of oxygenated fuels, see page 159 .

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, is no cause for concern.)

Fuel

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

59

07/05/15 13:51:42 31KPS650 0069 

Fuel

Refueling Procedure

Fuel Tank Capacity, including reserve:

1.85 US gal (7.0 )

Reserve Capacity:

0.34 US gal (1.3 )

(3)

(4)

1.

2.

and remove it.

Add fuel until the level reaches the bottom tank. There should be no fuel in the filler neck.

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.

(2)

(1) fuel fill cap

(2) breather tube

60

Servicing Your Honda

(1)

(3) steering stem nut

(4) filler neck

07/05/15 13:51:47 31KPS650 0070 

3.

4.

After refueling, turn the fuel fill cap clockwise until it is secure.

Insert the breather tube in the steering stem nut.

If you replace the fuel fill cap, use only a

Honda Genuine replacement part.

Fuel

Servicing Your Honda

61

07/05/15 13:51:56 31KPS650 0071 

Engine Oil

Refer to

Saf ety 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.

Oil Recommendation

API classification viscosity (weight)

JASO T 903 standard suggested oil

**

SG or higher except oils labeled as energy conserving on the circular API service label

SAE 10W-30

MA

Pro Honda GN4 4stroke oil (USA &

Canada), or Honda

4-stroke oil (Canada only), or an equivalent motorcycle oil

62

Servicing Your Honda

07/05/15 13:52:05 31KPS650 0072 

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.

Engine Oil

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.

(cont’d)

Servicing Your Honda

63

07/05/15 13:52:12 31KPS650 0073 

Engine Oil

Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range.

JASO T 903 standard

The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines.

There are two classes: MA and MB.

Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification.

(1)

(2)

(1) code number of the sales company of the oil

(2) oil classification

64

Servicing Your Honda

07/05/15 13:52:23 31KPS650 0074 

Checking & Adding Oil

RIGHT SIDE

(1)

(1) oil filler cap/dipstick

(2) upper level mark

(3) lower level mark

1.

Park your motorcycle on a firm, level surface.

2.

and nearby surfaces.

(2)

(3)

Engine Oil

3.

4.

5.

6.

7.

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 it in.

Remove the oil filler cap/dipstick and check the oil level.

If the oil is at or near the upper level mark

If the oil is below or near the lower level

8.

9.

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

65

07/05/15 13:52:33 31KPS650 0075 

Engine Oil

Changing Engine Oil

UNDER

1.

2.

3.

4.

5.

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 its side stand on a firm, level surface.

Remove the oil filler cap/dipstick.

Place a drain pan under the crankcase.

6.

Pour the drained oil into a suitable container and dispose of it in an approved manner

(page 129 ).

Improper disposal of drained f luids is harmf ul to the environment.

(1) oil drain bolt

(2) O-ring

(4) (3) (2) (1)

(3) spring

(4) oil strainer screen

66

Servicing Your Honda

07/05/15 13:52:44 31KPS650 0076 

Engine Oil

7.

8.

Clean the oil strainer screen.

Check that the oil strainer screen, sealing rubber, and drain bolt O-ring are in good condition.

9.

Install the O-ring to the oil drain bolt.

10.

Install the oil strainer screen, spring, and drain bolt.

11.

Tighten the oil drain bolt to the specified torque:

11 lbf·ft (15 N·m , 1.5 kgf·m)

12.

Pour the recommended oil into the crankcase, approximately:

1.1 US qt (1.0 )

13.

Install the oil filler cap/dipstick securely.

14.

Start the engine and let it idle for 3-5 minutes. Stop the engine. Wait 2-3 minutes.

15.

With the motorcycle held upright on level ground, check the oil level.

If needed, add oil (page 65 ) until it reaches the upper level mark. (Do not overfill.)

16.

Check for oil leaks.

Servicing Your Honda

67

07/05/15 13:52:51 31KPS650 0077 

Air Cleaner

Refer to

Saf ety Precautions

on page 43 .

Proper air cleaner maintenance is very important for off-road vehicles. A dirty, watersoaked, 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 Honda

Genuine air cleaner specified for your model or an air cleaner of equal quality.

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 perf ormance and premature engine wear.

68

Servicing Your Honda

07/05/15 13:53:00 31KPS650 0078 

Cleaning

RIGHT SIDE

(1)

(2)

Air Cleaner

1.

2.

Remove the right side cover (page 57 ).

3.

bending the set spring and set spring holder

4.

(1) screws

(2) air cleaner housing cover

(1)

(5)

(3) set spring

(4) set spring holder

(5) air cleaner

(3) (4) (cont’d)

Servicing Your Honda

69

07/05/15 13:53:07 31KPS650 0079 

Air Cleaner

(5)

(8)

(8)

(6)

(5) air cleaner

(6) air cleaner holder

(7) tabs

(8) air cleaner holes

(7)

5.

6.

7.

8.

Gently wash the air cleaner in clean, nonflammable (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 is damaged.

Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil.

70

Servicing Your Honda

07/05/15 13:53:17 31KPS650 0080 

9.

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.)

10.

Assemble the air cleaner and holder.

11.

Clean the inside of the air cleaner housing.

12.

Apply a thin coat of grease to the sealing surface of the air cleaner.

13.

Install the air cleaner assembly by inserting

Air Cleaner

14.

Install the air cleaner housing cover and screws.

15.

Install the right side cover (page 57 ).

RIGHT SIDE

(7)

(9)

(10)

(7)

( 10 ).

Hook the set spring.

Check that the air cleaner is properly seated.

(7) tabs (9) upper hole

(10) lower hole

Servicing Your Honda

71

07/05/15 13:53:23 31KPS650 0081 

Crankcase Breather

Refer to

Saf ety Precautions

on page 43 .

Service more frequently if your motorcycle is ridden in the rain or often at full throttle.

LEFT SIDE

Drain the deposits by pinching the crankcase

(1)

(1) crankcase breather tube

72

Servicing Your Honda

07/05/15 13:53:34 31KPS650 0082 

Refer to

Saf ety Precautions

on page 43 .

Throttle Freeplay

RIGHT SIDE

(1)

Throttle

Upper Adjustment

Minor adjustments are generally made with the upper adjuster.

RIGHT SIDE

(2)

(3)

(1) freeplay

Inspection

Freeplay:

1/16 − 1/4 in (2 − 6 mm)

If necessary, adjust to the specified range.

(1)

(1) rubber dust cover

(2) upper lock nut

(3) upper adjuster

1.

2.

3.

cable mechanism.

(cont’d)

Servicing Your Honda

73

07/05/15 13:53:43 31KPS650 0083 

Throttle

4.

5.

Tighten the lock nut. Return the dust cover to its normal position.

After adjustment, check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions.

Lower Adjustment

The lower adjuster is used for major freeplay adjustment, such as after replacing the throttle cables or removing the carburetor. It is also used if you can not get the proper adjustment with the upper adjuster.

LEFT SIDE

(5)

(4)

(4) lower lock nut

(5) lower adjuster

1.

2.

3.

Tighten the lock nut.

If you can’t get the freeplay within the specified range, contact your Honda dealer.

74

Servicing Your Honda

07/05/15 13:53:51 31KPS650 0084 

Throttle Inspection

(2)

(1)

(2)

(1) throttle

(2) throttle cables

1.

Check that the throttle assembly is positioned properly and the securing bolts are tight.

2.

from fully open to fully closed in all steering positions. If there is a problem, see your

Honda dealer.

Throttle

3.

Inspect the condition of the throttle cables

4.

5.

carburetor. If the cable is kinked or chafed, have it replaced.

Check the cables for tension or stress in all steering positions.

Lubricate the cables with a commerciallyavailable cable lubricant to prevent premature rust and corrosion.

Servicing Your Honda

75

07/05/15 13:54:03 31KPS650 0085 

Clutch System

Refer to

Saf ety Precautions

on page 43 .

Clutch Freeplay

LEFT SIDE

(1)

(1) clutch lever

Inspection

Check freeplay.

Freeplay: 3/8 − 13/16 in (10 − 20 mm)

If necessary, adjust to the specified range.

Improper freeplay adjustment can cause premature clutch wear.

76

Servicing Your Honda

Upper Adjustment

Minor adjustments are generally made with the upper clutch cable adjuster.

Upper clutch assembly adjuster:

LEFT SIDE

(4)

( ( ) )

(3)

( ( ) )

(2)

(2) rubber dust cover

(3) upper lock nut

(4) upper clutch cable adjuster

( + ) increase freeplay

( − ) decrease freeplay

1.

2.

3.

obtain the specified freeplay.

07/05/15 13:54:14 31KPS650 0086 

4.

5.

Tighten the lock nut and check the freeplay again.

Return the dust cover to its normal position.

Lower Adjustment

The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out near its limit

− or the correct freeplay cannot be obtained.

RIGHT SIDE

(6)

( ( ) )

( ( ) )

(5)

Clutch System

1.

2.

(to provide maximum freeplay).

Tighten the upper lock nut and pull the dust

3.

4.

5.

cable.

Turn the lower adjusting nut to obtain the specified freeplay.

Hold the lower adjusting nut and tighten the lower lock nut. Check the adjustment.

(5) lower adjusting nut

(6) lower lock nut

( + ) increase freeplay

( − ) decrease freeplay

(cont’d)

Servicing Your Honda

77

07/05/15 13:54:20 31KPS650 0087 

Clutch System

6.

Start the engine, pull the clutch lever in, and shift into gear. Make sure the engine does not stall and the motorcycle does not creep.

Gradually release the clutch lever and open the throttle. Your motorcycle should move smoothly and accelerate gradually.

If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the official Honda Service Manual (page 164 ).

Other Inspections & Lubrication

Check that the clutch lever assembly is positioned properly and the securing bolts are tight.

Check the clutch cable for kinks or signs of wear. If necessary, have it replaced.

Lubricate the clutch cable with a commercially-available cable lubricant to prevent premature wear and corrosion.

78

Servicing Your Honda

07/05/15 13:54:29 31KPS650 0088 

Refer to

Saf ety Precautions

on page 43 .

Engine Idle Speed

LEFT SIDE

( ( ) )

(1)

( ( ) )

(1) throttle stop screw ( + ) increase rpm

( − ) decrease rpm

Engine Idle Speed

The engine must be at normal operating temperature for accurate idle speed adjustment.

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.

1.

2.

3.

Warm up the engine, shift to neutral and place the motorcycle on its stand.

Connect a tachometer, following the tachometer manufacturer’s instructions.

Adjust idle speed with the throttle stop screw

Idle Speed: 1,400 ± 100 rpm

Servicing Your Honda

79

07/05/15 13:54:40 31KPS650 0089 

Spark Plug

Refer to

Saf ety Precautions

on page 43 .

Spark Plug Recommendation

The recommended standard spark plug is satisfactory for most riding conditions.

However, if 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

For cold climate

(below 5°C, 41°F)

DPR8EA-9 (NGK) or

X24EPR-U9 (DENSO)

DPR7EA-9 (NGK) or

X22EPR-U9 (DENSO)

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.

(2)

(3)

(1)

(1) center electrode

(2) side electrode

(3) spark plug gap

1.

Clean any dirt from around the spark plug base.

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Servicing Your Honda

07/05/15 13:54:52 31KPS650 0090 

2.

3.

4.

Disconnect the spark plug cap.

Using a spark plug wrench, remove the spark plug.

Inspect the spark plug electrodes for wear.

eroded. The insulator should not be cracked or chipped.

5.

6.

type feeler gauge. If adjustment is necessary, bend the side electrode carefully. The gap should be:

0.031

− 0.035 in (0.80

− 0.90 mm)

Make sure the plug washer is 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 crossthreading).

Spark Plug

7.

Tighten the spark plug:

If the old plug is good: a.

1/8 turn after it seats.

If installing a new plug, tighten it twice to prevent loosening:

First, tighten the plug: b.

c.

NGK:

DENSO:

3/4

1/2 turn after it seats.

turn after it seats.

Then loosen the plug.

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.

Servicing Your Honda

81

07/05/15 13:55:04 31KPS650 0091 

Spark Arrester

Refer to

Saf ety 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

(2)

(1)

(3)

(4)

(1) spark arrester

(2) bolts

(3) gasket

(4) muffler

1.

2.

Allow the engine and muffler to cool.

82

Servicing Your Honda

07/05/15 13:55:09 31KPS650 0092 

3.

Use a brush to remove carbon deposits from 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.

Spark Arrester

4.

Install the spark arrester and the gasket in the muffler and tighten the bolts securely.

(5) spark arrester screen

(5)

Servicing Your Honda

83

07/05/15 13:55:16 31KPS650 0093 

Suspension

Refer to

Saf ety Precautions

on page 43 .

Loose, worn, or damaged suspension components may adversely affect 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.

Front Suspension Inspection

(1)

FRONT

(1)

(1)

(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.

84

Servicing Your Honda

07/05/15 13:55:25 31KPS650 0094 

Suspension

2.

Check the security of all handlebar and fork components appear worn or damaged, see your Honda dealer for further inspection.

Rear Suspension Inspection

LEFT SIDE

(2)

(1)

RIGHT SIDE

(1)

(1) swingarm bearing

1.

Place the motorcycle on a maintenance stand.

Push hard against the side of the rear wheel and feel for any freeplay which indicates

(3)

(1) swingarm bearing

(2) shock absorber attachment points

(3) suspension linkage attachment points

(cont’d)

Servicing Your Honda

85

07/05/15 13:55:29 31KPS650 0095 

Suspension

2.

Check that the fasteners for the shock

3.

secure.

Check for oil leaks in the shock absorber. If any rear suspension components appear worn or damaged, see your Honda dealer for further inspection.

86

Servicing Your Honda

07/05/15 13:55:37 31KPS650 0096 

Brakes

Refer to

Saf ety Precautions

on page 43 .

The front brake is the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop.

Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect the brake fluid level and the brake pads for wear.

If the front brake lever freeplay does not feel within the normal range while riding, check the brake pads. If they are not worn beyond the recommended limit (page 90 ), there is probably air in the brake system. See your

Honda dealer to have the air bled from the system.

Front Brake Lever Adjustment

RIGHT HANDLEBAR

(2)

(1)

(3) (4)

(1) front brake lever

(2) rubber dust cover

(3) lock nut

(4) adjuster

Never use adjusters other than those designed for this motorcycle. Install a new adjuster from the lever side with the lock nut under the head of the adjuster.

(cont’d)

Servicing Your Honda

87

07/05/15 13:55:45 31KPS650 0097 

Brakes

1.

2.

3.

To position the brake lever farther away

4.

5.

clockwise.

To position the brake lever closer to the handgrip, turn the adjuster counterclockwise.

Tighten the lock nut. Return the dust cover to its normal position.

Apply the brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times.

6.

Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage.

Freeplay: 3/8 − 13/16 in (10 − 20 mm)

If brake lever freeplay is not within this range, see your Honda dealer.

88

Servicing Your Honda

07/05/15 13:55:54 31KPS650 0098 

Fluid Level Inspection

Front Brake Fluid Level

RIGHT

HANDLEBAR

(1)

(1) LOWER level mark

With the motorcycle in an upright position, check the fluid level.

If the level is at or below the LOWER level mark, check the brake pads for wear

(page 90 ).

Brakes

Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks.

The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an equivalent.

Brake f luid can damage plastic and painted surf aces. Handle with care.

Other Inspections

Make sure there are no fluid leaks.

Check for deterioration or cracks in the hoses and fittings.

Servicing Your Honda

89

07/05/15 13:56:03 31KPS650 0099 

Brakes

Brake Pad Wear

Brake pad wear depends on the severity of usage, the type of riding, and riding area conditions. (Generally, the pads will wear faster on wet and dirty riding terrain.) Inspect the pads at each regular maintenance interval

(page 48 ).

LEFT FRONT

(1)

(2) is worn to the cutout, replace both pads as a set.

See your Honda dealer for this service.

Other Inspections

Check that the front lever assembly is positioned properly and the securing bolts are tight.

More About: Brake Fluid

Brake fluid should be added and replaced by your Honda dealer.

The recommended brake fluid is Honda DOT 4

Brake Fluid, or any brake fluid of equal equality and performance. Use fresh brake fluid from a sealed container.

(1) front brake caliper

(2) cutouts

90

Servicing Your Honda

07/05/15 13:56:14 31KPS650 0100 

Brakes

Rear Brake Pedal Freeplay

RIGHT SIDE

Adjustment

RIGHT REAR

(2)

(1)

(1) rear brake pedal

Inspection

1.

Place your motorcycle on its side stand.

2.

Check freeplay by slowly depressing the engage.

Freeplay: 13/16 − 1 3/16 in (20 − 30 mm)

If necessary, adjust to the specified range.

(2) brake adjusting nut

(3) brake arm pin

(3)

(

) increase freeplay

( − ) decrease freeplay

1.

Adjust by turning the rear brake adjusting cut-out on the adjusting nut is seated on the

2.

3.

Apply the brake, release it, and then spin the wheel and check that it rotates freely. Repeat this procedure several times.

Check the freeplay. If you can’t adjust the freeplay properly, see your Honda dealer.

Servicing Your Honda

91

07/05/15 13:56:22 31KPS650 0101 

Brakes

confirm that there is a gap between the

(2)

(3)

(1)

(1) brake arm

(2) adjusting nut

(3) brake arm pin

After adjustment, confirm the freeplay of the brake pedal.

Brake Shoe Wear

The rear brake is equipped with an external brake wear indicator that let you check brake wear without disassembly. Application of the brake control (pedal) causes the arrow on the brake arm to move toward a reference mark on the brake panel.

RIGHT REAR

(2)

(3)

(1)

(4)

(1) arrow

(2) brake arm

(3) reference mark

(4) brake panel

92

Servicing Your Honda

07/05/15 13:56:32 31KPS650 0102 

Brakes

1.

2.

Place your motorcycle on its side stand.

Apply the brake control (pedal) and check the brake. If replacement is necessary, see your Honda dealer.

Other Inspections & Lubrication

Check that the rear pedal assembly is positioned properly and the securing bolts are tight.

Make sure the brake rod, brake arm, spring, and fasteners are in good condition.

Rear Brake Pedal Height Adjustment

RIGHT SIDE

(2)

(1)

(1) lock nut

(2) stopper bolt

1.

2.

3.

Tighten the lock nut.

Check the freeplay (page 91 ).

Servicing Your Honda

93

07/05/15 13:56:37 31KPS650 0103 

Wheels

Refer to

Saf ety Precautions

on page 43 .

Maintenance of spoke tension and wheel trueness (roundness) is 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. Neglecting this maintenance may also cause rim or spoke damage. 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.

94

Servicing Your Honda

07/05/15 13:56:43 31KPS650 0104 

Wheel Rims & Spokes

REAR

(1)

(2)

Wheels

1.

for damage.

2.

3.

Rotate the wheel slowly to see if it appears to ‘‘wobble.’’ If it does, the rim is out of round or not ‘‘true.’’ If the wobble is noticeable, see your Honda dealer for inspection.

(3)

(1) wheel rim

(2) spoke

(3) rim lock

Servicing Your Honda

95

07/05/15 13:56:51 31KPS650 0105 

Wheels

Front Wheel Removal

RIGHT FRONT

(1)

(2)

(3)

(1) axle holder nuts

(2) axle holder

(3) front axle shaft

96

Servicing Your Honda

(1)

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.

3.

Remove the wheel and side collars.

Avoid depressing the brake lever when the wheel is off the motorcycle. This will force the caliper pistons out of the cylinders. The result will be loss of brake fluid. If this occurs, the brake system will require service.

See your Honda dealer for this service.

07/05/15 13:57:01 31KPS650 0106 

Installation

RIGHT FRONT

(4)

(4) UP mark

1.

2.

3.

Reverse the removal procedure. Install the side collars into the wheel.

Insert the front axle shaft through the wheel hub and left fork leg.

Tighten the front axle shaft to the specified torque:

54 lbf·ft (73.5 N·m, 7.5 kgf·m)

Wheels

4.

5.

6.

7.

upward and first tighten the upper axle holder nuts until lightly seated, then tighten the lower axle holder nuts until lightly seated.

Operate the front brake and pump the fork several times.

First tighten the upper axle holder nuts to the specified torque, then tighten the lower axle holder nuts to the same torque:

9 lbf·ft (12 N·m , 1.2 kgf·m)

After installing the wheel, apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely.

Check front brake adjustment (page 87 ).

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.

Servicing Your Honda

97

07/05/15 13:57:14 31KPS650 0107 

Wheels

Rear Wheel Removal

RIGHT REAR

(2)

(1)

LEFT REAR

(5)

(3)

(6)

(4)

(1) brake adjusting nut

(2) brake rod

(3) brake arm

(6)

(4) rear axle nut

(5) rear axle shaft

(6) chain adjusters

Removal

1.

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.

2.

3.

pedal.

4.

5.

wheel can be moved all the way forward for maximum drive chain slack.

Unscrew the rear axle nut. Pull the rear axle shaft out. Push the wheel forward and derail the drive chain from the rear sprocket.

Remove the wheel and side collar.

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.

98

Servicing Your Honda

07/05/15 13:57:23 31KPS650 0108 

RIGHT REAR

(9)

(7) lug

(8) slot

(9) brake panel

(8)

(7)

Wheels

Installation

1.

Reverse the removal procedure. Install the side collar into the wheel. Make sure the lug

2.

3.

4.

5.

( ) in the brake panel ( 9 ). Check that the chain adjusters are installed properly.

Adjust the drive chain (page 109 ).

Tighten the rear axle nut to the specified torque:

80 lbf·ft (108 N·m , 11.0 kgf·m)

Adjust the rear brake (page 91 ).

Apply the rear brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times.

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.

Servicing Your Honda

99

07/05/15 13:57:35 31KPS650 0109 

Tires & Tubes

Refer to

Saf ety Precautions

on page 43 .

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.

Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed.

Follow all instructions in this owner’s manual regarding tire inflation and maintenance.

The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage,

100

Servicing Your Honda

and our recommendations on tire repair and replacement.

Air Pressure

Properly inflated tires provide the best combination of handling, tread life, and riding comfort. Generally, underinflated tires wear unevenly, adversely affect handling, and are more likely to fail from being overheated.

Underinflated tires can also cause wheel damage in rocky terrain. Overinflated tires make your motorcycle ride harshly, are more prone to damage from surface hazards, and wear unevenly.

Make sure the valve stem caps are secure. If necessary, install a new cap.

07/05/15 13:57:43 31KPS650 0110 

Tires & Tubes

Always check air pressure when your tires are

‘‘cold.’’ If you check air pressure when your tires are ‘‘warm’’

− even if your motorcycle has only been ridden for a few miles − the readings will be higher. If you let air out of warm tires to match the recommended cold pressures, the tires will be underinflated.

The correct ‘‘cold’’ tire pressures are:

Front

Rear

15 psi (100 kPa , 1.0 kgf/cm )

15 psi (100 kPa , 1.0 kgf/cm )

If you decide to adjust tire pressures for a particular riding condition, make changes a little at a time.

Inspection

A flat tire or blowout is 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 137 .

(1)

(1) tire tread depth

Servicing Your Honda

101

07/05/15 13:57:51 31KPS650 0111 

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.

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.

Tube Replacement

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 137 .

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

101

.

102

Servicing Your Honda

07/05/15 13:57:59 31KPS650 0112 

Tire Replacement

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.

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.

Tires & Tubes

Front

Rear

Type

80/100-21 NHS

100/100-18 NHS bias-ply, tube

Use a replacement tire equivalent to the original.

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.

Have the wheel balanced after a new tire is installed.

We recommend that tires be replaced by your Honda dealer.

Servicing Your Honda

103

07/05/15 13:58:05 31KPS650 0113 

Side Stand

Refer to

Saf ety Precautions

on page 43 .

LEFT SIDE

1.

2.

and loss of tension.

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.

(1)

(1) side stand spring

104

Servicing Your Honda

07/05/15 13:58:15 31KPS650 0114 

Drive Chain

Refer to

Saf ety 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 is 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 is in neutral.

It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule.

Inspection

LEFT SIDE

(1)

(1) drive chain

1.

midway between the sprockets. Drive chain slack should allow the following vertical movement by hand:

13/16 − 1 3/16 in (20 − 30 mm)

(cont’d)

Servicing Your Honda

105

07/05/15 13:58:23 31KPS650 0115 

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: damaged rollers loose pins dry or rusted links kinked or binding links excessive wear damaged or missing O-rings

Replace the drive chain (page 111 ) if it has damaged rollers, loose pins, or kinks that cannot be freed. Lubricate the drive chain

(page 110 ) if it appears dry or shows signs

106

Servicing Your Honda

4.

of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed.

wear. If the chain slider and lower slider are your Honda dealer replace the slider.

Replace the chain guide slider if the chain is visible through the wear inspection window

Replace the chain roller if it is smaller than

0.7 in (18 mm).

07/05/15 13:58:33 31KPS650 0116 

LEFT SIDE

(6)

(4) (2)

(3)

Drive Chain

To check the chain’s service limit, measure the distance between a span of 41 pins, from pin center to pin center. If the distance exceeds the service limit, the drive chain is worn out and should be replaced.

(6)

(7)

(5)

(2) chain slider

(3) chain guide slider

(4) chain roller

(5) lower slider

(6) cutouts

(7) wear inspection window

5.

Replace the drive chain if chain slack is excessive when the rear axle is moved to the farthest limit of adjustment. Excessive slack indicates the chain is worn beyond its service limit.

Measure a span of 41 pins

New Chain:

Service Limit:

25.0 in (635 mm)

25.1 in (637 mm)

This motorcycle has a staked master link drive chain which requires a special tool for cutting and staking. Do not use an ordinary master link with this chain.

(cont’d)

Servicing Your Honda

107

07/05/15 13:58:39 31KPS650 0117 

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

Teeth

Worn Sprocket

Teeth

REPLACE REPLACE

Use of a new chain with worn sprockets will cause rapid chain wear.

Normal Sprocket Teeth

GOOD

108

Servicing Your Honda

07/05/15 13:58:50 31KPS650 0118 

Adjustment

LEFT REAR

(5)

RIGHT REAR

(4)

(1)

(1) rear axle shaft

(2) rear axle nut

(3) chain adjusters

(4) index marks

(5) stopper pins

(3) (2)

(4)

(3)

(5)

Drive Chain

1.

2.

Turn both the right and left chain adjusters

3.

slack.

After adjusting, be sure the same adjuster

4.

5.

6.

Tighten the rear axle nut to the specified torque:

80 lbf·ft (108 N·m , 11.0 kgf·m)

Recheck drive chain slack.

Check rear brake pedal freeplay and adjust as necessary (page 91 ). Freeplay is affected when repositioning the rear wheel to adjust drive chain slack.

If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly.

Servicing Your Honda

109

07/05/15 13:58:56 31KPS650 0119 

Drive Chain

Lubrication

Lubricate only with SAE 80 or 90 gear oil.

Commercial chain lubricants may contain solvents which could damage the rubber

O-rings.

Lubricate every 300 miles (500 km) or sooner if chain appears dry.

The O-rings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents.

110

Servicing Your Honda

07/05/15 13:59:04 31KPS650 0120 

Removal, Cleaning & Replacement

Your motorcycle has an endless (riveted master link) type chain. It should only be removed or replaced by your Honda dealer.

When the drive chain becomes extremely dirty, it should be cleaned prior to lubrication.

1.

Clean the side surfaces of the chain with a dry cloth.

2.

Do not brush the rubber O-rings. Brushing will damage them. Use of a solvent may also damage the O-rings.

Inspect the drive chain for possible wear or damage. Replace the drive chain if it has damaged rollers, loose fitting links, or otherwise appears unserviceable.

Replacement chain:

DID 520VD or

RK 520SMOZ2

Drive Chain

3.

4.

Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed.

Lubricate the drive chain.

Servicing Your Honda

111

07/05/15 13:59:12 31KPS650 0121 

Battery

Your motorcycle has a maintenance-free type battery. You do not have to check the battery electrolyte level or add distilled water as you would with a conventional-type battery.

Your battery is a maintenance-f ree type and can be permanently damaged if the cap strip is removed.

Electrical accessories use current from the battery –– even when the ignition is OFF.

Limited operation also allows the battery to discharge. If you have electrical accessories on your motorcycle –– or do not ride frequently, we recommend that you charge the battery frequently (see

Battery Charging,

page 116 ).

If you do not expect to ride your motorcycle for at least two weeks, we recommend you remove the battery –– or at least disconnect the battery cables (negative cable first).

If you plan to store your motorcycle, see

Battery Storage,

page 113 .

If your battery seems weak and/or is leaking electrolyte (causing slow starting or other electrical problems), see your Honda dealer.

WARNING:

compounds.

Battery posts, terminals and related accessories contain lead and lead

Wash hands after handling.

112

Servicing Your Honda

07/05/15 13:59:19 31KPS650 0122 

Battery Storage

Refer to

Saf ety Precautions

on page 43 .

If you plan to store your motorcycle, we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life.

If you do not remove the battery, we recommend disconnecting the battery cables

(negative cable first).

You will get the best storage results from removing the battery and slow (trickle) charging it every 30 days (see

Battery

Charging,

page 116 ).

Battery

Before you remove the battery, be sure to read all the information that follows, as well as the information on the battery label.

The battery gives off explosive hydrogen gas during normal operation.

A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you.

Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance.

Servicing Your Honda

113

07/05/15 13:59:28 31KPS650 0123 

Battery

The battery is located in the battery compartment behind the left side cover.

Removal

1.

Make sure the ignition switch is OFF.

2.

Remove the left side cover (page 58 ).

3.

LEFT SIDE

(3)

(2)

4.

Disconnect the negative (

) terminal lead the positive (

3

5.

compartment.

(1)

(4)

(1) battery holder

(2) negative (

(3) positive (

) terminal lead

) terminal lead

(4) battery

114

Servicing Your Honda

07/05/15 13:59:35 31KPS650 0124 

6.

7.

8.

9.

Charge the battery (see following section), unless you have been riding regularly.

Store your battery in an easy-to-reach location off the floor, in an area protected from freezing temperatures and direct sunlight.

Clean the battery box after removing the battery for storage. Dry the battery box and, if paint is missing, re-paint the area.

Slow charge the battery (see following section) once every 30 days.

Battery

Installation

1.

Reinstall in the reverse order of removal. Be sure to connect the positive (

) terminal

2.

first, then the negative ( − ) terminal.

Check all bolts and other fasteners are secure.

Servicing Your Honda

115

07/05/15 13:59:42 31KPS650 0125 

Battery

Battery Charging

Refer to

Saf ety Precautions

on page 43 .

(1) for home charging. These units can be left connected for long periods without risking damage to the battery. However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions.

Avoid using an automotive-type battery charger. An automotive charger can overheat a motorcycle battery and cause permanent damage.

(1) ‘‘trickle’’ charger

Be sure to read the information that came with your battery charger and follow the instructions on the battery. Improper charging may damage the battery.

116

Servicing Your Honda

07/05/15 13:59:49 31KPS650 0126 

Appearance Care

Refer to

Saf ety 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.

General Recommendations

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.

Servicing Your Honda

117

07/05/15 14:00:01 31KPS650 0127 

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 button brake master cylinder under fuel tank drive chain carburetor

High pressure water (or air) can damage certain parts of your motorcycle.

Washing Your Motorcycle with a Mild

Detergent

1.

2.

3.

4.

5.

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.

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.

118

Servicing Your Honda

07/05/15 14:00:06 31KPS650 0128 

6.

7.

8.

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.

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.

Appearance Care

Servicing Your Honda

119

07/05/15 14:00:09 31KPS650 0129 

120

Servicing Your Honda

07/05/15 14:00:13 31KPS650 0130 

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.

Tips

Preparing for a Ride .....................................

.122

Transporting Your Honda ............................

.124

Storing Your Honda .....................................

.126

You & the Environment ...............................

.129

Tips

121

07/05/15 14:00:21 31KPS650 0131 

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.

What to Take to the Riding Area

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

Care of the Unexpected,

Taking

which begins on page

131

.

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: a tool kit tire repair supplies and tools, tubes, and tires extra parts, such as control levers, cables, and spark plugs wire, duct tape, and rope extra gasoline

122

Tips

07/05/15 14:00:26 31KPS650 0132 

For safety, all refueling should be done at a gas station on the way to the riding area or at your base camp.

Preparing for a Ride

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 6 ).

What to Take on the Trail

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.

Tips

123

07/05/15 14:00:33 31KPS650 0133 

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 is off.

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.

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.

124

Tips

07/05/15 14:00:38 31KPS650 0134 

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.

Transporting Your Honda

Tips

125

07/05/15 14:00:42 31KPS650 0135 

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 before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your motorcycle running again.

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.

126

Tips

07/05/15 14:00:50 31KPS650 0136 

Preparation for Storage

1.

2.

3.

Change the engine oil (page 66 ).

Fill the fuel tank. Make sure the fuel fill cap is properly installed.

Check that the fuel valve is OFF.

Storing Your Honda

4.

Drain the carburetor into an approved gasoline container and dispose of it in an approved manner (page 129 ). If storage will last longer than one month, carburetor draining is important, to assure proper performance after storage.

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

127

07/05/15 14:01:02 31KPS650 0137 

Storing Your Honda

5.

6.

7.

Remove the battery and charge it fully. Store it in an area protected from freezing temperatures and direct sunlight. Slow charge the battery (page 116 ) once a month.

Wash and dry your motorcycle.

Lubricate the drive chain (page 110 ).

8.

9.

Inflate the tires to their recommended pressures (page 100 ).

Store your motorcycle in an unheated area, free of dampness, away from sunlight, with a minimum of daily temperature variation.

10.

Cover your motorcycle with a porous material. Avoid using plastic or similar nonbreathing, coated materials that restrict air flow and allow heat and moisture to accumulate.

Removal from Storage

1.

2.

3.

4.

5.

6.

Uncover and clean your motorcycle.

If your motorcycle has been stored for more than four months − change the engine oil

(page 66 ).

If your motorcycle has been stored for more than two months − drain and replace the fuel.

Charge the battery (page 116 ) as required.

Install the battery.

Lubricate the drive chain (page 110 ).

Perform a pre-ride inspection (page 24 ), then test-ride your motorcycle at low speeds.

128

Tips

07/05/15 14:01:09 31KPS650 0138 

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.

You & the Environment

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

129

07/05/15 14:01:13 31KPS650 0139 

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.

130

Tips

07/05/15 14:01:17 31KPS650 0140 

With all the challenges you can encounter offroad, there’s a chance that sometime something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride. Also review the tips in

Preparing f or a Ride

(page 122 ).

Taking Care of the Unexpected

General Guidelines .......................................

.132

If Your Engine Quits or Won’t Start ...........

.133

If You Have a Flat Tire ................................

.137

If a Fuse Blows ............................................

.138

If You Crash .................................................

.140

If You Lose Your Key .................................

.141

If a Component Fails ...................................

.142

If Your Battery Is Low (or Dead) ................

.143

Taking Care of the Unexpected

131

07/05/15 14:01:24 31KPS650 0141 

Taking Care of the Unexpected

General Guidelines

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.

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.

132

Taking Care of the Unexpected

07/05/15 14:01:31 31KPS650 0142 

If 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 Your Engine Quits or Won’t Start

Proper operation and maintenance can prevent starting and engine performance problems. In many cases, the cause of the problem may be a simple operational oversight.

Taking Care of the Unexpected

If you have a problem starting the engine

− or experience poor engine performance

− the following information may help you. If you can’t correct the problem, see your Honda dealer.

If your motorcycle won’t start, listen as you press the start button. If you don’t hear the starter motor turning, refer to the

Starter motor doesn’t operate

symptom. If you can hear the starter motor working normally, refer to the

Starter motor works, but the engine won’t start

symptom.

Taking Care of the Unexpected

133

07/05/15 14:01:42 31KPS650 0143 

Taking Care of the Unexpected

SYMPTOM:

Starter motor doesn’t operate.

POSSIBLE CAUSE ignition switch OFF transmission not in neutral

WHAT TO DO

Turn the ignition switch ON.

Shift into neutral.

blown fuse Replace with a new fuse of the same rating (page battery lead loose low (or dead) battery faulty starter motor

Tighten the battery lead.

Charge the battery (page

116

).

). If charging doesn’t help, see your Honda dealer.

If all possible causes are negative, the starter motor may be faulty. See your Honda dealer.

138

134

Taking Care of the Unexpected

07/05/15 14:01:56 31KPS650 0144 

Taking Care of the Unexpected

SYMPTOM:

Starter motor works, but the engine won’t start.

POSSIBLE CAUSE WHAT TO DO out of fuel flooded engine loose or unconnected spark

Fill the fuel tank.

See F looded Engine (page 31 ).

Install the spark plug cap securely. If the engine still won’t plug cap loose battery cables weak battery start, see your Honda dealer.

Tighten the battery terminal bolts.

Charge the battery (page 116 ). If charging doesn’t help, see your Honda dealer.

SYMPTOM:

Engine starts, but runs poorly.

POSSIBLE CAUSE idles roughly, too fast, stalls

WHAT TO DO

Check engine idle adjustment (page 79 ). If the problem runs erratically, misfires blubbers (rich fuel mixture) persists, see your Honda dealer.

See your Honda dealer.

See your Honda dealer.

Taking Care of the Unexpected

135

07/05/15 14:02:06 31KPS650 0145 

Taking Care of the Unexpected

SYMPTOM: sooty exhaust (rich fuel mixture)

Engine starts, but runs poorly. (cont’d)

POSSIBLE CAUSE WHAT TO DO

See your Honda dealer.

detonates or pings under load

If applicable, switch to the recommended octane gasoline

(page

59

) or change your brand of gasoline. If the afterfires (backfires) pre-ignition (runs on after ignition switched OFF) problem persists, see your Honda dealer.

See your Honda dealer.

See your Honda dealer.

136

Taking Care of the Unexpected

07/05/15 14:02:13 31KPS650 0146 

If You Have a Flat Tire

How you handle a flat tire on the trail depends on how serious the tube or tire damage is, and what tools and supplies you have with you.

If you have a slow leak or a minor puncture, there are two ways to try making a temporary repair:

Use an aerosol tire sealer to seal the puncture and inflate the tube. (This can be done without removing the tire or wheel.)

Use a tube patch kit to repair the puncture.

(This requires removing the tire.)

Taking Care of the Unexpected

If the leak is 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 103 ). Replacing a tube or tire involves removing and re-installing the wheel

(pages 96 , 98 ).

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.

Taking Care of the Unexpected

137

07/05/15 14:02:18 31KPS650 0147 

Taking Care of the Unexpected

If a Fuse Blows

All of the electrical circuits on your motorcycle have a fuse to protect them from damage caused by excess current flow (short circuit or overload).

If something electrical on your motorcycle stops working, the first thing you should check for is a blown fuse.

Check the fuse before looking elsewhere for another possible cause of the problem. Replace the blown fuse and check component operation.

138

Taking Care of the Unexpected

07/05/15 14:02:30 31KPS650 0148 

Taking Care of the Unexpected

The fuse is located behind the left side cover.

Recommended Fuse main fuse 7.5 A

1.

To prevent an accidental short circuit, turn the ignition switch OFF before checking or replacing the fuse.

2.

side cover (page 58 ).

3.

4.

5.

starter magnetic switch.

Pull the fuse out. If the main fuse is blown

6.

7.

8.

Reconnect the wire connector.

Install the starter magnetic switch.

Install the left side cover.

LEFT SIDE

(4)

(1)

(2)

(6)

(5)

(3)

(1) main fuse

(2) starter magnetic switch

(3) battery box

(4) wire connector

(5) blown fuse

(6) spare main fuse

Taking Care of the Unexpected

139

07/05/15 14:02:36 31KPS650 0149 

Taking Care of the Unexpected

If You Crash

Personal safety is 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 is 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.

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.

140

Taking Care of the Unexpected

07/05/15 14:02:40 31KPS650 0150 

Taking Care of the Unexpected

If You Lose Your Key

Be sure to record your key number in the

Ref erence

Quick

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 it 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

141

07/05/15 14:02:46 31KPS650 0151 

Taking Care of the Unexpected

If a Component Fails

The drive chain, 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 chain breaks or does other damage when it comes off, you may not be able to make a trailside repair.

If any component of the front brake system is damaged, you may be able to ride carefully back to your base using the rear brake for slowing or stopping.

If the clutch lever breaks, you may be able to temporarily switch the front brake lever to the clutch side, then ride carefully back to 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 is any doubt, it’s best to be conservative and safe.

142

Taking Care of the Unexpected

07/05/15 14:02:51 31KPS650 0152 

Taking Care of the Unexpected

If Your Battery Is Low (or Dead)

Jump starting is not recommended, especially if you use an automobile battery. The greater amperage of an automobile battery when the car engine is running can damage your motorcycle’s electrical system.

Bump starting is also not recommended.

If you can’t charge the battery or it appears unable to hold a charge, contact your Honda dealer.

Taking Care of the Unexpected

143

07/05/15 14:02:54 31KPS650 0153 

144

Taking Care of the Unexpected

07/05/15 14:02:58 31KPS650 0154 

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 ..................................

.146

Specifications ...............................................

.148

Break-in Guidelines .....................................

High Altitude Carburetor Adjustment .........

.153

.154

Emission Control Systems ...........................

.155

Oxygenated Fuels .........................................

.160

Technical Information

145

07/05/15 14:03:05 31KPS650 0155 

Vehicle Identification

RIGHT SIDE

Serial Numbers

The VIN and engine serial number are required when you register your motorcycle. They may also be required when ordering replacement parts. You may record these numbers in the

Quick Ref erence

section at the rear of the manual.

steering head.

side of the engine.

(1) VIN

LEFT SIDE

(2) engine number

(2)

(1)

146

Technical Information

07/05/15 14:03:10 31KPS650 0156 

Color Label & Code

behind the left side cover (page 58 ).

The color code is helpful when ordering replacement parts. You may record the color and code in the

Quick Ref erence

section at the rear of the manual.

LEFT SIDE

Vehicle Identification

(1)

(1) color label

Technical Information

147

07/05/15 14:03:19 31KPS650 0157 

Specifications

Dimensions

Overall length

Overall width

Overall height

Wheelbase

81.1 in (2,059 mm)

31.5 in (801 mm)

45.9 in (1,167 mm)

54.0 in (1,372 mm)

Fuel & Lubricants

Fuel tank capacity

Fuel tank reserve

Fuel recommendation

Engine oil capacity

1.85 US gal (7.0 ) including reserve

0.34 US gal (1.3 ) premium unleaded gasoline, pump octane number of 91 or higher after draining:

1.1 US qt (1.0 ) after disassembly:

1.3 US qt (1.2 )

148

Technical Information

07/05/15 14:03:30 31KPS650 0158 

Fuel & Lubricants

Engine oil recommendation

Drive chain lubricant

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

4-stroke oil (USA &

Canada) or Honda 4stroke oil (Canada only), or an equivalent motorcycle oil

Pro Honda Chain

Lube or an equivalent, or SAE

80 or 90 gear oil

Specifications

Fuel & Lubricants

Air cleaner oil Pro Honda (USA only) or Honda

(Canada only) Foam

Filter Oil or an equivalent

Capacities

Passenger capacity

Maximum weight capacity

Cargo capacity operator only; no passenger

220 lbs (100 kg) none

Engine Specifications

Displacement

Bore & stroke

Compression ratio

13.6 cu-in (223 cm )

2.58

× 2.61 in

(65.5

× 66.2 mm)

9.0 : 1

Technical Information

149

07/05/15 14:03:41 31KPS650 0159 

Specifications

Engine Specifications

Valve clearance

(cold)

Spark plug

(standard)

Spark plug

(cold climate; below 5°C, 41°F)

Spark plug gap

Intake:

Exhaust:

0.004 in

(0.10 mm)

0.004 in

(0.10 mm)

DPR8EA-9 (NGK) or

X24EPR-U9 (DENSO)

DPR7EA-9 (NGK) or

X22EPR-U9 (DENSO)

Idle speed

0.031

− 0.035 in

(0.80

− 0.90 mm)

1,400 ± 100 rpm

Power Transmission

Primary reduction

Gear ratio, 1st

2nd

3rd

4th

5th

6th

Final reduction

Final drive

3.090

2.769

1.941

1.450

1.148

0.960

0.812

3.846

chain

150

Technical Information

07/05/15 14:03:53 31KPS650 0160 

Power Transmission

Drive chain freeplay

New chain length

Used chain service limit length

13/16 − 1 3/16 in

(20 − 30 mm)

25.0 in (635 mm) distance between a span of 41 pins

25.1 in (637 mm) distance between a span of 41 pins

Specifications

Chassis & Suspension

Caster

Trail

Tire size, front

Tire size, rear

26°45’

4.4 in (111 mm)

80/100-21 NHS

100/100-18 NHS

Tire type

Tire pressure, front

(cold)

Tire pressure, rear

(cold)

Suspension, front

Suspension, rear bias-ply, tube

15 psi

(100 kPa , 1.0 kgf/cm )

15 psi

(100 kPa , 1.0 kgf/cm )

8.5 in (216 mm) axle travel

9.1 in (230 mm) axle travel

Technical Information

151

07/05/15 14:04:00 31KPS650 0161 

Specifications

Electrical

battery generator

Fuse

main

12 V − 4 Ah

0.06 kW/5,000 rpm

7.5 A

Torque Specifications

Oil drain bolt

Front wheel axle

Axle holder nuts

Rear wheel axle

11 lbf·ft

(15 N·m , 1.5 kgf·m)

54 lbf·ft

(73.5 N·m, 7.5 kgf·m)

9 lbf·ft

(12 N·m , 1.2 kgf·m)

80 lbf·ft

(108 N·m , 11.0 kgf·m)

152

Technical Information

07/05/15 14:04:04 31KPS650 0162 

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.

Break-in Guidelines

Technical Information

153

07/05/15 14:04:09 31KPS650 0163 

High Altitude Carburetor Adjustment

At high altitude, the standard carburetor airfuel 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.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each

1,000-foot (300-meter) increase in altitude. The

154

Technical Information

effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When the carburetor has been modif ied f or high altitude operation, the air-f uel mixture will be too lean f or low altitude use. Operation at altitudes below 5,000 f eet (1,500 meters) with a modif ied 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 f actory specif ications.

07/05/15 14:04:15 31KPS650 0164 

Exhaust Emission Requirements

The U.S. Environmental Protection Agency

(EPA), the California Air Resources Board

(CARB), and Environment Canada (EC) require that your motorcycle comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided.

The Vehicle Emission Control Information

REAR FENDER

(1)

(2)

(1) vehicle emission control information label

(2) vehicle emission control information label (Canada only)

Emission Control Systems

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

155

07/05/15 14:04:20 31KPS650 0165 

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 is toxic.

Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.

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.

156

Technical Information

07/05/15 14:04:25 31KPS650 0166 

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 is 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:

1.

Removal of, or puncturing the muffler, baffles, header pipes, or any other component which conducts exhaust gases.

2.

3.

4.

Removal of, or puncturing of any part of the intake system.

Lack of proper maintenance.

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

157

07/05/15 14:04:30 31KPS650 0167 

Emission Control Systems

2.

3.

4.

5.

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:

1.

Hard starting or stalling after starting

Rough idle

Misfiring or backfiring during acceleration

After-burning (backfiring)

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.

158

Technical Information

07/05/15 14:04:34 31KPS650 0168 

Fuel Permeation Emission Control System

This vehicle complies with the Fuel Permeation

Emission Control regulations of the U.S.

Environmental Protection Agency (EPA), the

California Air Resources Board (CARB), and

Environment Canada (EC).

The fuel tank, fuel hoses, and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control technologies.

Tampering with the fuel tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations.

Emission Control Systems

Technical Information

159

07/05/15 14:04:40 31KPS650 0169 

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.

160

Technical Information

07/05/15 14:04:45 31KPS650 0170 

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.

Oxygenated f uels can damage paint and plastic. Damage caused by spilled f uel is not covered under warranty.

Technical Information

161

07/05/15 14:04:48 31KPS650 0171 

162

Technical Information

07/05/15 14:04:52 31KPS650 0172 

This section contains information on your warranty and how to get an official Honda service manual.

Consumer Information

Authorized Manuals .....................................

.164

Warranty Coverage ......................................

.167

Warranty Service ..........................................

.168

Contacting Honda ........................................

The Honda Rider’s Club (USA only) ..........

.169

.170

Your Honda Dealer ......................................

.171

Consumer Information

163

07/05/15 14:04:59 31KPS650 0173 

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.

61KPS05

61CM002

Description

2008 CRF230F Service Manual

Common Service Manual

31KPS650 2008 CRF230F Owner’s Manual

Pr ices ar e subject to change without notice and without incur r ing obligation.

Price Each

$48.00

$48.00

$16.00

164

Consumer Information

07/05/15 14:05:08 31KPS650 0174 

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 No.

Item Description Qty.

Price

Each

Total

Price

Prices are subject to change without notice and without incurring obligation.

Orders are mailed within 10 days. Please allow adequate time for delivery.

Sub Total

Purchaser’s Sales

Tax

Mich. Add 6 %

Calif. Add 8.25 %

Handling Charge

Grand Total

$5.00

Consumer Information

165

07/05/15 14:05:21 31KPS650 0175 

S

H

I

P

T

O

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

City

Daytime Telephone Number ( )

State

Apartment Number

Zip Code

P

A

Y

M

E

N

T

Check or money order enclosed payable to Helm Inc.

U.S. funds only. Do not send cash.

Account Number MasterCard

VISA

Discover

Customer Signature

Check here if your billing address is different from the shipping address shown above.

Date

Expiration: Mo. Yr.

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

166

Consumer Information

07/05/15 14:05:28 31KPS650 0176 

Your new Honda is covered by these warranties:

Motorcycle Limited Warranty

Exhaust Emission Warranty

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.

Warranty Coverage

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

167

07/05/15 14:05:33 31KPS650 0177 

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 is 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.

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.

168

Consumer Information

07/05/15 14:05:41 31KPS650 0178 

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 is 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):

Contacting Honda

Motorcycle Division, American Honda Motor

Co., Inc., P.O. Box 2200, Torrance, CA 90509-

2200, 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: name, address, and telephone number product model, year, and VIN date of purchase dealer name and address

We will likely ask your Honda dealer to respond, or possibly acknowledge your comments directly.

Consumer Information

169

07/05/15 14:05:44 31KPS650 0179 

The Honda Rider’s Club (USA only)

You may be eligible for a Honda Rider’s Club of America (HRCA) membership with the purchase of your new Honda. You can log on to the HRCA Clubhouse website for details at

www.hrca.honda.com.

170

Consumer Information

07/05/15 14:05:50 31KPS650 0180 

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 Honda Genuine

Parts, Pro Honda products, Honda Genuine

Accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts.

You’ll also find comparable quality in the accessories and products available from the parts department.

Your Honda Dealer

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

171

07/05/15 14:05:54 31KPS650 0181 

Table of Contents

The following presents the contents of each section of your owner’s manual.

MOTORCYCLE SAFETY ...........................

.1

Important Safety Information ..........................

.2

Loading, Accessories & Modifications ...........

.5

Loading ........................................................

.5

Accessories & Modifications .......................

.7

Safety Labels ....................................................

.9

OPERATING CONTROLS ........................

.11

Operation Component Locations ...................

.12

Operating Controls .........................................

.15

Fuel Valve ..................................................

.15

Choke Lever ...............................................

.16

Ignition Switch ...........................................

.17

Start Button ................................................

.18

Engine Stop Button ....................................

.18

Front Brake Lever ......................................

.18

Throttle .......................................................

.18

Clutch Lever ...............................................

.19

Shift Lever .................................................

.19

172

Table of Contents

Rear Brake Pedal ........................................

.19

Side Stand ..................................................

.19

BEFORE RIDING .......................................

Are You Ready to Ride?

................................

.21

.22

Protective Apparel .....................................

.22

Is Your Motorcycle Ready to Ride?

Pre-ride Inspection

..............

.....................................

.24

.24

BASIC OPERATION & RIDING ..............

.27

Safe Riding Precautions .................................

.28

Starting & Stopping the Engine .....................

.29

Preparation .................................................

.29

Starting Procedure ......................................

.29

Flooded Engine ..........................................

.31

How to Stop the Engine .............................

.32

Shifting Gears ................................................

.33

Braking ...........................................................

.35

Parking ...........................................................

Post-ride Inspection .......................................

.37

.38

07/05/15 14:05:58 31KPS650 0182 

SERVICING YOUR HONDA ....................

.39

Bef ore You Service Your Honda

The Importance of Maintenance ....................

.41

Maintenance Safety ........................................

.43

Important Safety Precautions .....................

.43

Maintenance Schedule ...................................

.45

Maintenance Record ......................................

Competition Inspection ..................................

.49

.50

Service Preparations

Maintenance Component Locations ..............

.53

Tools ...............................................................

.56

Side Cover Removal ......................................

.57

Service Procedures

Fluids & Filters

Fuel .................................................................

.59

Engine Oil

Air Cleaner

......................................................

.62

.....................................................

.68

Crankcase Breather ........................................

.72

Table of Contents

Engine

Throttle ...........................................................

.73

Clutch System ................................................

Engine Idle Speed ..........................................

.76

.79

Spark Plug ......................................................

Spark Arrester ................................................

.80

.82

Chassis

Suspension .....................................................

.84

Brakes .............................................................

.87

Wheels ............................................................

.94

Tires & Tubes ...............................................

.100

Side Stand ....................................................

Drive Chain ..................................................

.104

.105

Electrical

Battery ..........................................................

.112

Appearance Care ..........................................

.117

Table of Contents

173

07/05/15 14:06:02 31KPS650 0183 

Table of Contents

TIPS .............................................................

.121

Preparing for a Ride .....................................

.122

Transporting Your Honda ............................

.124

Storing Your Honda .....................................

.126

You & the Environment ...............................

.129

TAKING CARE OF THE

UNEXPECTED ..........................................

.131

General Guidelines .......................................

.132

If Your Engine Quits or Won’t Start ...........

.133

If You Have a Flat Tire ................................

.137

If a Fuse Blows ............................................

.138

If You Crash .................................................

.140

If You Lose Your Key

If a Component Fails

.................................

...................................

.141

.142

If Your Battery Is Low (or Dead) ................

.143

TECHNICAL INFORMATION

Vehicle Identification

..............

..................................

.145

.146

Specifications ...............................................

.148

Break-in Guidelines .....................................

High Altitude Carburetor Adjustment .........

.153

.154

Emission Control Systems ...........................

.155

Oxygenated Fuels .........................................

.159

174

Table of Contents

07/05/15 14:06:06 31KPS650 0184 

CONSUMER INFORMATION ...............

.163

Authorized Manuals .....................................

.164

Warranty Coverage

Contacting Honda

......................................

Warranty Service ..........................................

.168

........................................

.167

.169

The Honda Rider’s Club (USA only) ..........

.170

Your Honda Dealer ......................................

.171

Table of Contents

TABLE OF CONTENTS ..........................

.172

INDEX .........................................................

.176

QUICK REFERENCE

Table of Contents

175

07/05/15 14:06:11 31KPS650 0185 

Index

A

accessories ........................................................

.7

air cleaner .......................................................

air pressure, tires ..........................................

.68

.100

altering your motorcycle arrester, spark

..................................

.................................................

.8

.82

B

battery ...........................................................

.112

brakes, fluid level ...................................................

.89

lever, front ..................................................

.18

lever, front adjustment ...............................

.87

pad wear .....................................................

.90

pedal, rear ...................................................

.19

shoe wear ....................................................

.92

braking ...........................................................

.35

break-in guidelines .......................................

.153

176

Index

button, engine stop .................................................

.18

start .............................................................

.18

C

capacity, fuel carburetor,

..................................................

.60

high altitude adjustment ...........................

.154

idle speed ....................................................

.79

choke lever cleaner, air

.....................................................

.16

......................................................

.68

cleaning, appearance care clutch system,

............................

.117

adjustment ..................................................

.76

lever ............................................................

.19

color label .....................................................

.147

competition inspection ...................................

.50

07/05/15 14:06:17 31KPS650 0186  consumer information ..................................

.163

controls, operating ..........................................

.11

cover removal, side ........................................

.57

crankcase breather ..........................................

.72

customer service ...........................................

.169

D

drive chain ....................................................

.105

E

education, rider ........................................

emission control systems

.3, 171

.............................

.155

emission requirements .................................

.155

engine number ..............................................

.146

engine, flooded idle speed ....................................................

.79

pinging

.......................................................

.31

.......................................................

.59

Index

starting ........................................................

.29

stop button ..................................................

.18

stopping ......................................................

.32

won’t start ................................................

environment, protecting ...............................

.133

.129

F

filter, air ..........................................................

.68

flat tire ..........................................................

.137

flooded engine, starting fork

.................................

.................................................................

.31

.84

front brake, lever ............................................................

.18

lever freeplay front suspension

.............................................

.87

.............................................

.84

front wheel removal .......................................

.97

(cont’d)

Index

177

07/05/15 14:06:23 31KPS650 0187 

Index

fuel, recommendation .........................................

.59

oxygenated ...............................................

tank capacity

.159

..............................................

.60

valve ...........................................................

.15

G

gap, spark plug gasohol

...............................................

.........................................................

.80

.159

gasoline ..........................................................

.59

gears, shifting .................................................

.33

H

high altitude adjustment

Honda, contacting

...............................

........................................

.154

.169

Honda service manual ..................................

.164

I

idle speed, engine inspection, competition

...........................................

.79

................................................

.50

post-ride .....................................................

.38

pre-ride .......................................................

.24

L

lever, clutch ..........................................................

.19

front brake ..................................................

.18

shift ............................................................

limit, weight

.19

.....................................................

.6

loading ..............................................................

.5

178

Index

07/05/15 14:06:29 31KPS650 0188 

Index

M

maintenance, component locations record

..................................

.53

.........................................................

.49

safety ..........................................................

.43

schedule ......................................................

.45

manual, service .............................................

.164

modifications ...................................................

.8

O

oil, engine .......................................................

.62

operating controls ...........................................

.11

operation component locations ......................

.12

oxygenated fuels ..........................................

.159

P

parking ...........................................................

pedal, rear brake .............................................

.37

.19

pinging, engine ...............................................

.60

plug, spark ......................................................

post-ride inspection ........................................

.80

.38

pre-ride inspection ..........................................

.24

R

reserve capacity, fuel tank .............................

.60

rider training .............................................

.3, 171 riding, basic operation ...........................................

.27

before .........................................................

.21

clothing .......................................................

.22

precautions .................................................

.28

safety ............................................................

.2

rim lock ..........................................................

.96

Index

179

07/05/15 14:06:33 31KPS650 0189 

Index

S

schedule, maintenance service,

...................................

.45

customer ...................................................

.169

manuals warranty

....................................................

.164

...................................................

.168

shifting gears ..................................................

.33

shoe, brake .....................................................

side cover, removal ........................................

.92

.57

side stand ................................................

.19, 104 spark arrester spark knock

..................................................

....................................................

.82

.59

spark plug .......................................................

specifications ...............................................

.80

.148

stand, side ...............................................

.19, 104 start button ......................................................

.18

starting, engine ...............................................

stop button, engine .........................................

.29

.18

stopping engine storage

..............................................

..........................................................

.32

.127

180

Index

suspension, front ............................................................

.84

rear ..............................................................

.85

T

throttle, freeplay operation .....................................................

.18

tires,

......................................................

.73

air pressure flat

...............................................

............................................................

.100

.137

replacing ...................................................

.103

tools ................................................................

.56

towing .............................................................

.34

training, rider ............................................

.3, 171 transporting ..................................................

troubleshooting, starting ..............................

.124

.133

07/05/15 14:06:37 31KPS650 0190 

Index

V

valve, fuel .......................................................

.15

vehicle identification no. (VIN) ...................

.146

W

warranty, coverage extended

...................................................

.167

...................................................

.167

service ......................................................

.168

washing your motorcycle .............................

.119

weight limit ......................................................

.6

wheels .............................................................

.94

Index

181

07/05/15 14:06:45 31KPS650 0191 

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.

How To Avoid Costly Repairs

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).

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:

Quick Reference

07/05/15 14:06:50 31KPS650 0192 

Record important information here:

VIN

Engine No.

Ignition Key No.

Color Label

Owner’s:

Name

Address

City/State

Phone

Dealer’s:

Name

Address

City/State

Phone

Service Mgr.

Quick Reference

Quick Reference

07/05/15 14:07:06 31KPS650 0193 

Quick Reference

Initial Maintenance

Regular

Maintenance

Pre-ride Inspection

Fuel/Capacity

Engine Oil

Maximum Weight

Capacity

Tires

Tire Pressure (cold)

Spark Plug

Fuse about 100 miles (150 km) or 1 month.

about every 600 miles (1,000 km) or 6 months.

Check the following items each time before you ride (page 24 ): tires, spokes & rims, leaks, engine oil, fuel, drive chain, cables, nuts & bolts, spark plug & cap, throttle, brakes, and clutch lever.

premium unleaded gasoline, pump octane number of 91 or higher tank: 1.85 US gal (7.0 ) reserve: 0.34 US gal (1.3 )

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 4-stroke oil or equivalent

220 lbs (100 kg) rider only (no passenger or cargo) and any accessories

Front:

Rear:

80/100-21 NHS

100/100-18 NHS

Type:

Front: bias-ply, tube

15 psi (100 kPa , 1.0 kgf/cm )

Rear: 15 psi (100 kPa , 1.0 kgf/cm )

DPR8EA-9 (NGK) or X24EPR-U9 (DENSO) main: 7.5 A

Quick Reference

07/05/15 14:07:13 31KPS650 0194 

These symbols are used in Operating Controls section:

SYMBOL COMPONENT

OFF choke lever

ON

− ignition switch

OFF − ignition switch

START button

Quick Reference

SEE PAGE

16

17

17

18

Quick Reference

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