Honda CRF 70F motorcycle OWNER'S MANUAL

 OWNER'S MANUAL
USO E MANUTENZIONE
MANUAL DEL PROPIETARIO
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Honda CRF70F
OWNER’S MANUAL
USO E MANUTENZIONE
MANUAL DEL PROPIETARIO
© Honda Motor Co., Ltd. 2007
IMPORTANT INFORMATION
¢ OPERATOR ONLY. NO PASSENGER
This motorcycle is designed and constructed as an operator-only model. The seating
configuration does not safely permit the carrying of a passenger. Do not exceed the
maximum weight capacity.
e FOR OFF-ROAD USE ONLY
This motorcycle is designed and manufactured for off-road use only.
e PARENTS : READ IMPORTANT MESSAGE ON PAGE 1.
e READ THIS OWNER'S MANUAL CAREFULLY
Pay special attention to the safety messages that appear throughout the manual. These
messages are fully explained in the “A Few Words About Safety” section which appears
before the Contents page.
This manual should be considered a permanent part of the motorcycle and should remain
with the motorcycle when resold.
Honda CRF70F
OWNER’S MANUAL
SE
—
All information in this publication is based on the latest production information
available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the
right to make changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written permission.
WELCOME
Your new motorcycle presents you with an invitation to adventure and a challenge to master
the machine. Your safety depends not only on your own alertness and familiarity with the
motorcycle, but also the motorcycle’s mechanical condition. À pre-ride inspection before
every outing and regular maintenance are essential.
To help meet the challenges safely and enjoy the adventure fully, become thoroughly
familiar with this Owner’s Manual BEFORE YOU RIDE THE MOTORCYCLE.
As you read this manual, you will find information that is preceded by a symbol. This
information is intended to help you avoid damage to your motorcycle, other property, or the
environment.
When service is required, remember that your Honda dealer knows your motorcycle best. H
you have the required mechanical “know-how” and tools, your dealer can supply you with an
official Honda Shop Manual to help you perform many maintenance and repair tasks.
Pleasant riding, and thank you for choosing a Honda !
* The following codes in this manual indicate each country.
ED | (Europe)
U Australia
* The specifications may vary with each locale.
A FEW WORDS ABOUT SAFETY
Your safety, and the safety of others, is very important. And operating this motorcycle safely
is an important responsibility.
To help you make informed decisions about safety, we have provided operating procedures
and other information on labels and in this manual. This information alerts you to potential
hazards that could hurt you or others.
Of course, it is not practical or possible to warn you about all hazards associated with
operating or maintaining a motorcycle. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
e Safety Labels — on the motorcycle.
e Safety Messages — preceded by a safety alert symbol À and one of three signal words:
DANGER, WARNING, or CAUTION.
These signal words mean:
A DANGER | You WILL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
A WARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
À CAUTION 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 manual is filled with important safety information — please read it carefully.
OPERATION
page page
1 MOTORCYCLE SAFETY 30 ESSENTIAL INDIVIDUAL
1 IMPORTANT MESSAGE TO COMPONENTS
PARENTS 30 IGNITION SWITCH
3 IMPORTANT SAFETY 31 ENGINE STOP SWITCH
INFORMATION
5 PROTECTIVE APPAREL
7 LOAD LIMITS AND GUIDELINES
11 PARTS LOCATION
14 MAJOR COMPONENTS
(Information you need to operate
this motorcycle)
14 BRAKES
19 CLUTCH
20 FUEL
24 ENGINE OIL
25 TYRES
page
32
32
33
FEATURES
(Not required for operation)
SEAT
SIDE COVER
page
34 OPERATION
PRE-RIDE INSPECTION
STARTING THE ENGINE
RUNNING-IN
RIDING
HIGH ALTITUDE RIDING
BRAKING
PARKING
ANTETHEFT TIPS
MAINTENANCE
page
45 MAINTENANCE
THE IMPORTANCE OF
MAINTENANCE
MAINTENANCE SAFETY
SAFETY PRECAUTIONS
MAINTENANCE SCHEDULE
TOOL KIT
SERIAL NUMBERS
COLOUR LABEL
AIR CLEANER
ENGINE OIL
SPARK PLUG
IDLE SPEED
THROTTLE OPERATION
VALVE CLEARANCE
SPARK ARRESTER
DRIVE CHAIN |
WHEEL RIMS AND SPOKES
WHEEL REMOVAL
BRAKE SHOE WEAR
FRONT SUSPENSION
REAR SUSPENSION
SIDE STAND
page
82 CLEANING
85 STORAGE GUIDE
85 STORAGE
87 REMOVAL FROM STORAGE
88 SPECIFICATIONS
MOTORCYCLE SAFETY
IMPORTANT MESSAGE TO
PARENTS
Your child's safety is very important to
Honda. That's why we urge you to read this
message before you let any young person
ride this motorcycle. Off-road riding can be
fun. But as with riding a bicycle, bad
judgements can result in injuries, and we
don't want that to happen ! As a parent, you
can help prevent accidents by making good
decisions about if, when, and how your
youngster rides this motorcycle.
Riding Readiness
The first decision you'll need to make is
whether your youngster is ready to ride.
Riding readiness varies widely from one
person to another, and age and size are not
the only factors.
PHYSICAL ABILITY is an important
consideration. For example, riders must be
big enough to hold the motorcycle up, get
on, and comfortably sit on the seat with
both feet touching the ground. They should
also be able to easily reach and work the
brakes, the throttle and all other controls.
ATHLETIC ABILITY is necessary for
riding a motorcycle. Generally speaking,
your youngster should be good at riding a
bicycle before getting on a motorcycle. Can
your youngster judge speeds and distances
on a bicycle and react with proper hand and
foot actions ? Anyone who does not have
good coordination,balance, and agility is not
ready to ride this motorcycle.
MENTAL AND EMOTIONAL MATURITY
are requirements for safe riding. Does your
youngster think through problems and
come to logical solutions? On a bicycle,
does your youngster obey safe riding rules ?
Be honest! Young people who take
unnecessary risks, make bad judgements
and don't obey rules are not ready to ride
this motorcycle.
Instruction and Supervision
If you decide that your youngster is ready to
safely operate this motorcycle, make sure
both of you carefully read and understand
the Owner's Manual before riding. Also be
sure that your youngster has a helmet and
other appropriate riding equipment and
always wears it when operating the vehicle
or sitting on it.
GOOD INSTRUCTION is an important part
of hands-on training. The teacher can either
be you or another responsible adult who has
experience with off-road motorcycle riding.
(For help in finding a qualified instructor,
talk with your Honda dealer.) Even if you're
not the main teacher, it's up to you to
ensure your youngster's safety. Remember,
learning to ride a motorcycle is a gradual
step-by-step process. It takes time, patience
and practice — many hours over a period of
weeks or months.
SUPERVISION is another important
obligation of parents. Even after youngsters
have become skilled off-road riders, they
should always ride with adult supervision. It
helps to regularly remind young riders of
basic safety rules and cautions. And
remember, it's your responsibility to see
that the vehicle is properly maintained and
kept in safe operating condition.
SAFE AND RESPONSIBLE RIDING must
be an ongoing commitment—by you and
your youngster. When you both put safety
first, you can enjoy more peace of mind, and
your youngster can enjoy more hours of
safe off-road riding.
For your convenience, this CRF70F comes
with an ignition switch and key. Remove the
key when the motorcycle is parked to help
prevent unauthorized use.
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.
This motorcycle has been designed for
younger riders, as well as for smaller adults.
However, not all youngsters are physically
or emotionally ready to ride. Therefore,
before parents allow any youngster to ride
this motorcycle, we urge them to carefully
read the Important Message to Parents on
page 1.
There is much that you can do to protect
yourself when you ride. You'll find many
helpful recommendations throughout this
manual. Following are a few that we
consider most important.
Always Wear a Helmet
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 5).
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 offroad use only. The
tyres are not made for pavement, and the
motorcycle does not have turn signals and
other features required for use on public
roads. If you need to cross a paved or public
road, get off and walk your motorcycle
across.
Take Time to Learn and Practice
Developing off-road riding skills is a gradual,
step-by-step process. Start by practicing at
low speeds in a safe area and slowly build
your skills. Personal instruction from an
experienced rider can also be valuable.
If you need assistance, ask your dealer
about riding groups in your area.
Be Alert for Off-Road Hazards
The terrain can present a variety of
challenges when you ride off-road.
Continually “read” the terrain for
unexpected turns, drop-offs, rocks, ruts, and
other hazards. Always keep your speed low
enough to allow time to see and react to
hazards.
Ride Within Your Limits
Pushing the limits is another major cause of
motorcycle accidents. Never ride beyond
your personal abilities or faster than
conditions warrant. Remember that alcohol,
drugs, fatigue and inattention can
significantly reduce your ability to make
good judgements and ride safely.
Don’t Drink and Ride
Alcohol and riding don’t mix. Even one
drink can reduce your ability to respond to
changing conditions, and your reaction time
gets worse with every additional drink. So
dont drink and ride, and dont let your
friends drink and ride either.
Keep Your Bike in Safe Condition
For safe riding, it's important to inspect
your motorcycle before every ride and
perform all recommended maintenance.
Never exceed load limits, and only use
accessories that have been approved by
Honda for this motorcycle. See page 7 for
more details.
Others
* This motorcycle is not equipped with
lights. Don't ride at night.
PROTECTIVE APPAREL
For your safety, we strongly recommend
that you always wear an approved
motorcycle helmet, eye protection, boots,
gloves, long pants, and a long-sleeved jersey,
shirt or jacket whenever you ride. Although
complete protection is not possible, wearing
proper gear can reduce the chance of injury
when you ride.
Following are suggestions to help you
choose proper gear. |
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. 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:
e Sturdy off-road motorcycle boots to help
protect your feet, ankles, and lower legs.
e Off-road motorcycle gloves to help
protect your hands.
e Riding pants with knee and hip pads, a
riding jersey with padded elbows, and a
chest/shoulder protector.
LOAD LIMITS AND GUIDELINES
Your Honda was designed as a rider-only
motorcycle. It was not designed to carry a
passenger or cargo. A passenger or cargo
could interfere with your ability to move
around to maintain your balance and control
of the motorcycle.
In addition, exceeding the weight limits or
carrying an unbalanced load can seriously
affect your motorcycle’s handling, braking,
and stability. Adding accessories or making
modifications that change this motorcycle’s
design and performance can also make it
unsafe. Also, the weight of any accessories
will reduce the maximum load the
motorcycle can carry.
The following pages give more specific
information on loading, accessories and
modifications.
Loading
How much weight you put on your
motorcycle, and how you load it, are
important to your safety. If you decide to
carry cargo, you should be aware of the
following information.
Overloading or carrying a passenger
can cause a crash and you can be
seriously hurt or killed.
Follow all load limits and other loading
guidelines in this manual.
Load Limits
Following are the load limits for your
motorcycle:
Maximum weight capacity:
60 kg (132 Ibs)
Includes the weight of the rider and any
accessories
Loading Guidelines
As discussed on page 7, we recommend
that you do not carry any cargo on this
motorcycle. However, if you decide to carry
cargo, ride at reduced speeds and follow
these common-sense guidelines:
e Keep cargo small and light. Make sure it
cannot easily be caught on brush or other
objects, and that it does not interfere with
your ability to shift position to maintain
balance and stability.
e Place weight as close to the center of the
motorcycle as possible.
e Do not attach large or heavy items (such
as a sleeping bag or tent) to the
handlebar, fork, or front fender.
e Make sure that all cargo is tied down
securely.
e Never exceed the maximum weight limit.
eCheck that both tyres are properly
inflated (page 25).
Accessories and Modifications
Modifying your motorcycle or using non-
Honda accessories can make your
motorcycle unsafe. Before you consider
making any modifications or adding an
accessory, be sure to read the following
information.
Improper accessories or modifications
can cause a crash in which you can be
seriously hurt or killed.
Follow all instructions in this owner's
manual regarding accessories and
modifications.
Accessories
We strongly recommend that you use only
genuine Honda accessories that have been
specifically designed and tested for your
motorcycle. Because Honda cannot test all
other accessories, you must be personally
responsible for proper selection, installation
and use of non-Honda accessories. Check
with your dealer for assistance and always
follow these guidelines:
* Make sure the accessory does not reduce
ground clearance and lean angle, limit
suspension travel or steering travel, alter
your riding position or interfere with
operating any controls.
Modifications
We strongly advise you not to remove any
original equipment or modify your
motorcycle in any way that would change its
design or operation. Such changes could
seriously impair your motorcycle’s handling,
stability and braking, making it unsafe to
ride.
Removing or modifying your exhaust
system (such as the spark arresters or
mufflers) or other equipment can also make
your motorcycle illegal.
10
PARTS LOCATION
Front brake lever
\
Throttle grip
Engine stop switch
Fuel fill cap
11
Oil filler cap/dipstick
Ignition switch
Kickstarter Foot peg Rear brake pedal
12
Choke lever
Shift lever
Fuel valve
Side stand Foot peg
13
MAJOR COMPONENTS
(Information you need to operate this motorcycle)
BRAKES
Front Brake
Brakes are items of personal safety and
should always be maintained in proper
adjustment.
The distance the front brake lever or rear
brake pedal moves before the brake starts
to engage is called freeplay.
Measured at the tip of the front brake lever
(1), freeplay should be maintained at:
20—30 тит (0.8—1.2 in)
Adjust the freeplay of the brake lever with
the front wheel pointed straight ahead.
Adjustment:
ack the rubber dust cover (2).
Loosen the lock nut (3) and turn the
adjuster (4). Tighten the lock nut (3)
and check the adjustment.
14
(1) Front brake lever
2) (3)
(2) Dust cover (A) Decrease freeplay
(3) Lock nut (B) Increase freeplay
(4) Front brake cable
adjuster
2. If the adjuster is threaded out near its
limit or the correct freeplay cannot be
obtained using the cable adjuster (4),
loosen the lock nut (3) and turn in the
cable adjuster (4) completely. Tighten
the lock nut (3) and install the rubber
dust cover.
3. TS the front brake cable guide bolt
5).
(5)
IZ >
y AL
и /
(5) Cable guide bolt
4. Loosen the lock nut (6) at the lower end
of the cable. Turn the adjusting nut (7) to
obtain the specified freeplay. Tighten the
lock nut and check the adjustment.
If proper adjustment cannot be obtained by
this method, see your Honda dealer.
(7)
(6) Lock nut
(7) Adjusting nut
(A) Decrease freeplay
(B) Increase freeplay
15
5. Apply the brake several times and check
for free wheel rotation after the brake
lever is released.
Tighten the front brake cable guide bolt.
After adjustment, push the brake arm (8)
to confirm that there is proper freeplay.
(8)
(8) Brake arm
After adjustment, confirm the freeplay of
the brake lever.
16
Other Checks:
Check the brake cable for kinks or signs of
wear that could cause sticking or failure.
Lubricate the brake cable with a
commercially available cable lubricant to
prevent premature wear and corrosion.
Make sure the brake arm, spring and
fasteners are in good condition.
Rear Brake
Brake Adjustment:
1. Place the motorcycle on its side stand.
2. Measure the distance the rear brake
pedal (1) moves before the brake starts
to take hold.
Freeplay should be;
20—30 mm (0.8— 1.2 in)
(1)
(1) Rear brake pedal
3. If adjustment is necessary, turn the rear
brake adjusting nut (2).
(2) ©)
(2) Rear brake adjusting nut
(3) Brake arm pin
(A) Decrease freeplay
(B) Increase freeplay
17
Adjust by turning the rear brake adjusting
nut a half-turn at a time. Make sure the cut-
out on the adjusting nut is seated on the
brake arm pin (3) after making final
freeplay adjustment.
4. Apply the brake several times and check
for free wheel rotation after the brake
pedal is released.
If proper adjustment cannot be obtained by
this method, see your Honda dealer.
After adjustment, push the brake arm (4)
to confirm that there is a gap between the
adjusting nut (2) and the brake arm pin(3).
18
(2)
(3)
(2) Adjusting nut
(3) Brake arm pin
(4) Brake arm
After adjustment, confirm the freeplay of
the brake pedal.
Other Checks:
Make sure the brake rod, brake arm, spring
and fasteners are in good condition.
CLUTCH
Adjustment:
I. Loosen the adjuster lock nut (1).
2. Turn the clutch adjuster (2) clockwise
one turn; do not turn excessively.
3. Slowly turn the adjuster counterclockwise
until a slight resistance is felt.
4. From this position, turn the adjuster
clockwise 1/8 to 1/4 turn, and tighten the
lock nut.
5. After adjustment, test ride the motorcycle
to be certain the clutch operates properly.
The engine should start easily with the
kickstarter without the clutch slipping.
When shifting gears, the clutch operation
should be smooth and light, especially when
shifting into neutral.
If proper adjustment cannot be obtained or
the clutch does not work correctly, see your
Honda dealer.
(2)
(1) Lock nut (2) Clutch adjuster
FUEL
Fuel Valve
The three way fuel valve (1) is on the left
side near the carburetor.
OFF
With the fuel valve in the OFF position, fuel
cannot flow from the tank to the carburetor.
Turn the valve OFF whenever the
motorcycle is not in use.
ON
With the fuel valve in the ON position, fuel
will flow from the main fuel supply to the
carburetor.
RES
With the fuel valve in the RES position, fuel
will flow from the reserve fuel supply to the
carburetor. Use the reserve fuel only when
the main supply is gone. Refill the tank as
soon as possible after switching to RES.
The reserve fuel supply is:
0.7 0 (0.18 US gal , 0.15 Imp gal)
20
Remember to check that the fuel valve is in
the ON position each time you refuel. If the
valve is left in the RES position, you may
run out of fuel with no reserve.
OFF
(1)
(1) Fuel valve
Fuel Tank
The fuel tank capacity including the
reserve supply is;
5.0 2 (1.32 US gal , 1.10 Imp gal)
To open the fuel fill cap (1), pull the
breather tube (2) from the front number
plate (3). Turn the fuel fill cap
counterclockwise,
Do not overfill the tank. There should be
no fuel in the filler neck (4).
After refueling, be sure to tighten the fuel
fill cap firmly by turning it clockwise. Insert
the breather tube into the front number
plate.
A WARNING
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
e Stop the engine and keep heat,
sparks, and flame away.
e Refuel only outdoors.
* Wipe up spills immediately.
(2)
(1) Fuel fill cap
(3) Front number plate
(2) Breather tube
(4) Filler neck
21
Use unleaded or low-lead petrol with a
research octane number of 91 or higher.
We recommend that you use unleaded
petrol because it produces fewer engine and
spark plug deposits and extends the life of
exhaust system components.
22
If “spark knock” or “pinking” occurs at a
steady engine speed under normal load,
change brands of petrol. If spark knock or
pinking persists, consult your Honda dealer.
Failure to do so is considered misuse, and
damage caused by misuse is not covered by
Honda's Limited Warranty.
Occasionally you may experience light
spark knock while operating under heavy
loads. This is no cause for concern, it simply
means your engine is operating efficiently.
Petrol Containing Alcohol
If you decide to use a petrol containing
alcohol (gasohol), be sure it’s octane rating
is at least as high as that recommended by
Honda. There are two types of “gasohol”:
one containing ethanol, and the other
containing methanol. Do not use petrol that
contains more than 10 % ethanol. Do not use
petrol containing methanol (methyl or wood
alcohol) that does not also contain
cosolvents and corrosion inhibitors for
methanol. Never use petrol containing more
than 5 % methanol, even if it has cosolvents
and corrosion inhibitors.
Fuel system damage or engine performance
problems resulting from the use of fuels
that contain alcohol is not covered under
the warranty. Honda cannot endorse the
use of fuels containing methanol since
evidence of their suitability is as yet
incomplete.
Before buying fuel from an unfamiliar
station, try to find out if the fuel contains
alcohol. If it does, confirm the type and
percentage of alcohol used. If you notice
any undesirable operating symptoms while
using a petrol that contains alcohol, or one
that you think contains alcohol, switch to a
petrol that you know does not contain
alcohol.
23
ENGINE OIL
Engine Oil Level Check
Check the engine oil level each day before
operating the motorcycle.
The oil filler cap/dipstick (1) is at the rear
of the right crankcase cover and contains a
dipstick for measuring the oil level. Oil level
must be maintained between the upper (2)
and lower (3) level marks on the oil filler
cap/ dipstick.
1. Hold the motorcycle upright on firm level
ground.
2. Start the engine and let it idle for 3—5
minutes. |
3.Stop the engine. After 2—3 minutes,
remove the oil filler cap/dipstick, wipe it
clean, and reinsert the oil filler cap/
dipstick without screwing it in. Remove
the oil filler cap/dipstick. The oil level
should be between the upper and lower
level marks on the oil filler cap/dipstick.
4. If required, add the specified oil (see
page 56) up to the upper level mark. Do
not overfill.
24
5. Reinstall the oil filler cap/dipstick. Check
for oil leaks.
Running the engine with insufficient oil can
cause serious engine damage.
(1) Oil filler cap/dipstick
(2) Upper level mark
(3) Lower level mark
TYRES |
To safely operate your motorcycle, the tyres
must be the proper type (off-road) and size,.
in good condition with adequate tread, and
correctly inflated.
INTENTA
Using tyres that. are excessively worn
or improperly inflated can cause a
crash in which you can be seriously
hurt or killed.
Follow all instructions in this owner's
manual regarding tyre inflation and
maintenance.
Air Pressure
Properly inflated tyres provide the best
combination of handling, tread life, and
riding comfort. Generally, underinflated
tyres wear unevenly, adversely affect
handling, and are more likely to fail from
being overheated. Underinflated tyres can
also cause wheel damage in rocky terrain.
Overinflated tyres make your motorcycle
ride harshly, are more prone to damage
from surface hazards, and wear unevenly.
Make sure the valve stem caps are secure.
If necessary, install a new cap.
25
Always check air pressure when your tyres
are “cold.” If you check air pressure when
your tyres are “warm” — even if your
motorcycle has only been ridden for a few
miles — the readings will be higher. If you
let air out of warm tyres to match the
recommended cold pressures, the tyres will
be underinflated.
The recommended “cold” tyre pressures
are:
Front 100 kPa
{1.0 kgf/cm? , 15 psi)
Rear 100 kPa
{1.0 kgf/cm? , 15 psi)
26
Inspection
Whenever you check the tyre pressures,
you should also examine the tyre treads and
sidewalls for wear, damage, and foreign
objects:
Look for:
¢ Bumps or bulges in the side of the tyre or
the tread. Replace the tyre if you find any
bumps or bulges.
e Cuts, splits or cracks in the tyre. Replace
the tyre if you can see fabric or cord.
e Excessive tread wear.
Also, if you hit a pothole or hard object, pull
to the side of the road as soon as you can
safely and carefully inspect the tyres for
damage.
Tread Wear
Replace tyres before tread depth at the
center of the tyre reaches the following (1)
limit:
Minimum tread depth
Front: 3.0 mm (0.12 in)
Rear: 3.0 mm (0.12 in)
(1) Tyre tread depth
27
Tube Repair and Replacement
If a tube is punctured or damaged, you
should replace it as soon as possible. A tube
that is repaired may not have the same
reliability as a new one, and it may fail while
you are riding.
If you need to make a temporary repair by
patching a tube or using an aerosol sealant,
ride cautiously at reduced speed and have
the tube replaced before you ride again.
Any time a tube is replaced, the tyre should
be carefully inspected as described on page
26
28
Tyre Replacement
The tyres that came on your motorcycle
were designed to match the performance
capabilities of your motorcycle and provide
the best combination of handling, braking,
durability and comfort.
Installing improper tyres on your
motorcycle can affect handling and
stability. This can cause a crash in
which you can be seriously hurt or
killed.
Always use the size and type of tyres
recommended in this owner's manual.
The recommended tyres for your
motorcycle are:
Front: 2.50-14 4PR
Rear: 3.00-12 4PR
Type: bias-ply, tube
Whenever you replace a tyre, use one that
is equivalent to the original and be sure the
wheel is balanced after the new tyre is
installed.
Also remember to replace the inner tube
whenever you replace a tyre. The old tube
will probably be stretched, and if installed in
a new tyre, it could fail.
29
ESSENTIAL INDIVIDUAL COMPONENTS
IGNITION SWITCH
The ignition switch (1) is located below
the fuel tank.
The ignition switch is used to prevent
unauthorized use of the motorcycle.
Before riding, insert the key and turn it to
the ON position.
After parking the motorcycle, remove the
key.
(1) Ignition switch
Key Position Function Key Removal
OFF The engine cannot be operated. Key can be
removed
e (ON) With the engine stop switch at () (RUN) and | Key cannot be
the transmission in neutral, the engine can be | removed
started.
30
ENGINE STOP SWITCH
The engine stop switch (1) is next to the
left handlebar grip. When the switch is in
the () (RUN) position, the engine will
operate. When the switch is in the
by (OFF) position, the engine will not
operate. This switch is intended primarily as
a safety or emergency switch and should
normally remain in the (7) (RUN) position.
A D 0
— 7 |
ВЕ — CC
Y +
(1) Engine stop switch
31
FEATURES
Not required for operation)
EAT
Removal:
1. Remove the bolts A (1) on each side of
the rear fender.
2. Remove the bolts B (2) under the rear
fender.
3. Pull both side cover prongs (3) out of the
rubber grommets (4).
4. Slide the seat and rear fender back.
Installation:
1. Align the locating slot (5) under the front
of the seat with the pin (6) on the rear of
the fuel tank.
2. Align the locating prongs (7) on the
bottom of the seat with the hooks (8) on
the frame.
3. Slide the seat into position.
4. Align the side cover prongs with the
rubber grommets. Press the side cover
into position.
5. Install the bolts and tighten them.
32
Nm
3)
(1) Bolts A (5) Slot
(2) Bolts B (6) Pin
(3) Side cover prongs (7) Seat prongs
(4) Rubber grommets
(8) Hooks
SIDE COVER
Removal:
1. Remove the bolt (1) securing the side
cover.
2. Pull the side cover prong (2) out of the
rubber grommet (3).
Installation: |
1. Attach the side cover on the rear frame.
2.Align the side cover prong with the
rubber grommet. Press the side cover
into position.
3. Install the securing bolt and tighten it.
Use the same procedure to remove and
install the left side cover.
(1) Bolt
(2) Prong
(3) Grommet
33
OPERATION
PRE-RIDE INSPECTION
For your safety, it is very important to take
a few moments before each ride to walk
around your motorcycle and check its
condition. If you detect any problem, be
sure you take care of it, or have it corrected
by your Honda dealer.
Improperly maintaining this motorcycie
or failing to correct a problem before
riding can cause a crash in which you
can be seriously hurt or killed.
Always perform a pre-ride inspection
before every ride and correct any
problems.
34
1. Engine oil level—add engine oil if
required (page 56). Check for leaks.
2. Fuel level —fill fuel tank when necessary
(page 21). Check for leaks.
3. Front and rear brakes—check operation
and if necessary, adjust freeplay (pages
14 — 18).
4. Tyres—check condition and pressure
(pages 25 — 29).
5. Spokes — check and tighten if necessary
(page 74 ).
6. Drive chain — check condition and slack
(page 69 ). Adjust and lubricate if
necessary.
7. Chain slider — check slider wear (page
70).
8. Throttle — check for smooth opening and
full closing in all steering positions.
Adjust freeplay if necessary (pages 64 —
65).
9. Spark plug and high tension terminal —
check for looseness.
10. Engine stop switch—check for proper
function (page 31).
11. Nuts, bolts, fasteners — check the front
and rear wheels to see that the axle nuts
are tightened securely. Check security of
all other nuts, bolts, and fasteners.
35
STARTING THE ENGINE
Always follow the proper starting procedure
described below.
Your motorcycle’s exhaust contains
poisonous carbon monoxide gas. High
levels of carbon monoxide can collect
rapidly in enclosed areas such as a garage.
Do not run the engine with the garage door
closed. Even with the door open, run the
engine only long enough to move your
motorcycle out of the garage.
36
Preparation
Before starting, insert the key and turn the
ignition switch ON.
Make sure that the transmission is in
neutral. Turn the engine stop switch to
O (RUN) and the fuel valve ON.
Starting Procedure
To restart a warm engine, follow the
procedure for “High Air Temperature.”
Normal Air Temperature
10° —35°C (50° — 95° F)
1. Pull the choke lever (1) up all the way to
Fully ON (A).
A)
>
| Cy STJF
(1) Choke lever (A) Fully ON
(B) Fully OFF
2. With the throttle slightly open, operate
the kickstarter. Kick from the top of the
stroke through to the bottom with a rapid,
continuous motion.
Allowing the kickstarter to snap back freely
against the pedal stop can damage the
engine case.
3. Warm up the engine by opening and
closing the throttle slightly.
4. About a quarter minute after the engine
starts, push the choke lever (1) down all
the way to Fully OFF (B).
o. If idling is unstable, open the throttle
slightly.
37
High Air Temperature
35°C (95°F) or above
1. Do not use the choke.
2 Start the engine following step 2 under
“Normal Air Temperature.”
Low Air Temperature
10°C (50°F) or below
1. Follow steps 1-2 under “Normal Air
Temperature”.
2 Warm up the engine by opening and
closing the throttle slightly.
3 Continue warming up the engine until it
runs smoothly and responds to the
throttle, when the choke lever (1) is at
Fully OFF (B).
38
Extended use of the choke may impair
piston and cylinder wall lubrication and
damage the engine.
Flooded Engine
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel.
To clear a flooded engine, turn the engine
stop switch to $8 (OFF) and push the
choke lever down to Fully OFF (B). Open
the throttle fully and crank the engine
several times with the kickstarter. Turn the
engine stop switch to () (RUN) and open
the throttle slightly; start the engine using
the kickstarter.
RUNNING-IN
Help assure your motorcycle’s future
reliability and performance by paying extra
attention to how you ride during the first
operating day or 25 km (15 miles).
During this period, avoid full-throttle starts
and rapid acceleration.
39
RIDING
Review Motorcycle Safety (pages 1 —10)
before you ride.
Make sure the side stand is fully retracted
before riding the motorcycle. If the stand is
extended, it may interfere with control
during a left turn.
Make sure you understand the function of
the side stand mechanism. (See MAIN-
TENANCE SCHEDULE on page 48 and
explanation for SIDE STAND on page 81).
1. After the engine has warmed up, the
motorcycle is ready for riding.
2. Close the throttle and raise the shift lever
to shift into 1st (low) gear.
40
3. Increase engine speed by gradually
opening the throttle.
4. When your speed increases, close the
throttle and shift to 2nd gear by raising
the shift lever.
5. This sequence is repeated to shift to 3rd
gear.
6. Raise the pedal to shift to a higher gear
and depress the pedal to shift to a lower
gear. Each stroke of the pedal engages
the next gear in sequence. The pedal
automatically returns to the horizontal
position when released.
„о
Shifting pattern
* Do not downshift when traveling at a
speed that would force the engine to
overrev in the next lower gear; the rear
wheel may lose traction, resulting in a
possible loss of vehicle control.
e Do not shift gears without closing the
throttle. The engine and drive train could
be damaged by overspeed and shock.
e Do not tow the motorcycle or coast for
long distances while the engine is off.
The transmission will not be properly
lubricated and damage may result.
* Do not run the engine at high rpm with
the transmission in neutral. Serious
engine damage may result.
41
HIGH ALTITUDE RIDING
When operating this motorcycle at high
altitude the air-fuel mixture becomes overly
rich. Driveability and performance may be
reduced and fuel consumption increased.
The carburetor can be modified to
compensate for this high altitude richness,
however it must be returned to standard
specifications before extended operation at
low altitudes (below 1,200 m, 4,000 feet).
See your Honda dealer for this high altitude
modification.
Sustained operation at lower altitudes with
high altitude carburetor modifications may
cause engine overheating and damage.
42
BRAKING
For normal braking, gradually apply both
the front and rear brakes while
downshifting to suit your road speed.
For maximum deceleration, close the
throttle and apply the front and rear brakes
firmly.
Important Safety Reminders:
e Independent operation of only the brake
lever or brake pedal reduces stopping
performance.
e Extreme application of the brake controls
may cause wheel lock, reducing control of
the motorcycle.
* When possible, reduce speed or brake
before entering a turn; closing the
throttle or braking in mid-turn may cause
wheel slip. Wheel slip will reduce control
of the motorcycle.
* When riding in wet or rainy conditions, or
on loose surfaces, the ability to maneuver
and stop will be reduced. All of your
actions should be smooth under these
conditions. Rapid acceleration, braking or
turning may cause loss of control. For
your safety, exercise extreme caution
when braking, accelerating or turning.
e When descending a long, steep grade,
use engine compression braking by down-
shifting, with intermittent use of both
brakes.
Continuous brake application can
overheat the brakes and reduce their
effectiveness.
PARKING
1. After stopping the motorcycle, shift the
transmission into neutral and turn the
fuel valve OFF. Turn the engine stop
switch 23 (OFF).
2.Use the side stand to support the
motorcycle while parked.
Park the motorcycle on firm, level ground to
prevent it from falling over.
H you must park on a slight incline, aim the
front of the motorcycle uphill to reduce the
possibility of rolling off the side stand or
overturning.
3. Turn the ignition switch OFF and remove
the key.
ANTI-THEFT TIPS
1. Be sure the registration information for
your motorcycle is accurate and current.
2. Park your motorcycle in a locked garage
whenever possible.
3. Use an additional anti-theft device of
good quality.
4. Put your name, address and phone
number in this Owner’s Manual and keep
it on your motorcycle at all times. Many
times stolen motorcycles are identified by
information in the Owner's Manuals
which are still with them.
NAME:
ADDRESS:
PHONE NO:
MAINTENANCE
THE IMPORTANCE OF
MAINTENANCE
A well-maintained motorcycle is essential
for safe, economical, and trouble-free riding.
It will also help reduce air pollution. Careful
pre-ride inspections and good maintenance
are especially important because your
motorcycle is designed to be ridden over
rough off-road terrain.
To help you properly care for your
motorcycle, this section of the manual
provides a Maintenance Schedule.
The service intervals in this schedule are
based on average riding conditions.
More frequent service is needed if you
subject your motorcycle to severe use (such
as competition) or ride in unusually wet or
dusty areas.
Frequent servicing of the air cleaner is
especially important to help you avoid a
possible costly engine repair.
If your motorcycle overturns or becomes
involved in a crash, be sure your Honda
dealer inspects all major parts, even if you
are able to make some repairs.
I: TCR
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.
45
MAINTENANCE SAFETY
This section includes instructions on some
important maintenance tasks. You can
perform some of these tasks with the tools
provided — if you have basic mechanical
skills.
Other tasks that are more difficult and
require special tools are best performed by
professionals. Wheel removal should
normally be handled only by a Honda
technician or other qualified mechanic;
instructions are included in this manual only
to assist in emergency service.
Some of the most important safety
precautions follow. However, we cannot
warn you of every conceivable hazard that
can arise in performing maintenance. Only
you can decide whether or not you should
perform a given task.
46
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.
SAFETY PRECAUTIONS
e Make sure the engine is off before you
begin any maintenance or repairs. This
will help eliminate several potential
hazards:
+ Carbon monoxide poisoning from
engine exhaust.
Be sure there is adequate ventilation
whenever you operate the engine.
* Burns from hot parts.
Let the engine and exhaust system cool
before touching.
* Injury from moving parts.
Do not run the engine unless instructed
to do so.
e Read the instructions before you begin,
and make sure you have the tools and
skills required.
* 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.
e To reduce the possibility of a fire or
explosion, be careful when working
around petrol. Use only nonflammable
solvent, not petrol, to clean parts. Keep
cigarettes, sparks and flames away from
all fuel-related parts.
Remember that your Honda dealer knows
your motorcycle best and is fully equipped
to maintain and repair it.
To ensure the best quality and reliability,
use only new genuine Honda parts or their
equivalents for repair and replacement.
47
MAINTENANCE SCHEDULE
Perform the Pre-ride Inspection {page 34 ) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R:REPLACE A:ADJUST L: LUBRICATE
The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating
condition. Maintenance work should be performed in accordance with standards and specifications of Honda by
properly trained and equipped technicians. Your Honda dealer meets all of these requirements.
* Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified. Refer to the Official Honda Shop Manual.
** In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Honda recommends that your Honda dealer should road test your motorcycle after each periodic maintenance is
carried out.
NOTE: (1) Service more frequently when ridden in wet or dusty conditions.
48
FREQUENCY CONS VER — REGULER MAINT. INTERVAL
FIRST
TO
N 24 P
IL
ENGINE OIL CENTRIFUGAL
FIL
49
50
FREQUENCY | WHICHEVER — | INITIAL
SPARK ARRESTER
COMES
FIRST
REGULER MAINT. INTERVAL
Every 500
I
I
Every 1,600
TO
TOOL KIT
The spark plug wrench (1) and its handle
(2) are stored in the tool bag (3).
3)
(2)
(1) Spark plug wrench
(2) Handle
(3) Tool bag
51
SERIAL NUMBERS
The frame and engine serial numbers are
required when registering your motorcycle.
They may also be required by your dealer
when ordering replacement parts.
Record the numbers here for your
reference.
FRAME NO.
(1) Frame number
52
The frame number (1) is stamped on the
left side of the steering head.
The engine number (2) is stamped on the
left side of the engine.
ENGINE NO.
(2) Engine number
COLOUR LABEL
The colour label (1) is attached to the
frame behind the left side cover (page 33 ).
It is helpful when ordering replacement
parts. Record the colour and code here for
your reference.
COLOUR
CODE
(1)
E
E Br
(1) Colour label
53
AIR CLEANER
Refer to the Safety Precautions on page 47 .
The air cleaner element should be serviced
at regular intervals (page 49). If your
motorcycle is operated in dusty areas, more
frequent servicing will be required. Your
Honda dealer can help you to determine the
correct service interval for your particular
riding conditions.
(2)
(1) Attaching screws
(2) Air cleaner housing cover
b4
1. Remove the two attaching screws (1),
the air cleaner housing cover (2) and air
cleaner (3).
2. Wash the air cleaner in clean, nonflam-
mable or high flash point solvent and let it
dry thoroughly.
Never use petrol or low flash point solvents
for cleaning the air cleaner. A fire or explo-
sion could result.
(3) (2)
(3) Air cleaner
3. Soak the air cleaner in gear oil (SAE 80 —
90) until saturated, then squeeze out the
excess oil.
4. Reinstall the air cleaner.
5. Reinstall the air cleaner housing cover
(2), aligning its projection (4) with the
projection (5) on the air cleaner housing
6).
(5) (4)
(2) Air cleaner housing cover
(4) Projection
(5) Projection
(6) Air cleaner housing
55
ENGINE OIL
Refer to the Safety Precautions on page 47 .
Oil Recommendation
API SG or higher except
classification oils labeled as
energy conserving
on the circular API
service label
Viscosity SAE 10W-30
JASO T 903 MA
standard
Suggested Oil
Honda “4- STROKE MOTORCYCLE
OIL” or equivalent.
56
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.
Viscosity:
Viscosity grade of engine oil should be
based on average atmospheric temperature
“in your riding area. The following provides a
guide to the selection of the proper grade or
viscosity of oil to be used at various
atmospheric temperatures.
10W-30 10
-30 -20 -10 0 10 20 30 40 50°C
i 1 4 | l — J
20 0 20 40 60 80 100 120°F
57
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.
GA 2 ——
MA+—e
PRODUCT MEETING JASO T 903
COMPANY GUARANTEEING THIS MA PERFORMANCE:
(1) Code number of the sales company
of the oil
(2) Oil classification
58
Engine Oil
Engine oil quality is the chief factor
affecting engine service life. Change the
engine oil as specified in the maintenance
schedule (page 49 ).
When running in very dusty conditions, oil
changes should be performed more
frequently than specified in the
maintenance schedule.
Please dispose of used engine oil in a
manner that is compatible with the
environment. We suggest you take it in a
sealed container to your local recycling
center or service station for reclamation. Do
not throw it in the trash or pour it on the
ground or down a drain.
Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis,
it is still advisable to thoroughly wash your
hands with soap and water as soon as possi-
ble after handling used oil.
If a torque wrench is not used for this
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Change the engine oil with the engine at
normal operating temperature and the
motorcycle on its side stand to assure
complete and rapid draining. |
59
1. Remove the oil filler cap/dipstick (1)
from the right crankcase cover.
2. Place a drain pan under the crankcase
and remove the oil drain bolt (2).
3. Operate the kickstarter several times
while turned the engine stop switch at
52 (OFF) to drain any oil which may be
left in the engine.
4. Check that the sealing washer (3) on the
drain bolt is in good condition and install
the bolt. Replace the sealing washer
every other time the oil is changed, or
each time if necessary.
Oil Drain Bolt Torque:
25 N-m (2.5 kgf-m , 18 Ibf-ft)
5. Fill the crankcase with the recommended
grade oil; approximately:
0.6 2 (0.6 US qt, 0.5 Imp at)
60
6. Reinstall the oil filler cap/ dipstick.
7. Start the engine and let it idle for 2—3
minutes.
8. Stop the engine and check that the oil
level is at the upper level mark on the oil
filer cap/dipstick with the motorcycle
upright on firm, level ground.
Make sure there are no oil leaks.
(1)
› 0 A O
© Rox) Ú
3)
(2)
(1) Oil filler cap/dipstick (3) Sealing washer
(2) Oil drain bolt
SPARK PLUG
Refer to the Safety Precautions on page 47 .
Recommended plugs:
Standard:
CR6HSA (NGK) or
U20FSR-U (DENSO)
For cold climate: (Below 5°C, 41°F)
CR5HSA (NGK) or
U16FSR-U (DENSO)
For extended high speed riding:
CR7HSA (NGK) or
U22FSR-U (DENSO)
For most riding conditions this spark plug
heat range number is satisfactory. However,
if the motorcycle is going to be operated for
extended periods at high speeds or near
maximum power in hot climates, the spark
plug should be changed to a colder heat
range (a higher number).
Never use a spark plug with an improper
heat range. Severe engine damage could
result.
1. Disconnect the spark plug cap.
2. pican any dirt from around the spark plug
ase.
3. Remove the spark plug.
4. Visually inspect the spark plug electrodes
for wear. The center electrode should
have square edges and the side electrode
should not be eroded.
5. Discard the spark plug if there is
apparent wear or if the insulator is
cracked or chipped.
61
6. Check the spark plug gap ( 1) using a
wire-type feeler gauge. If adjustment is
necessary, bend the side electrode (2)
carefully.
The gap should be:
0.6—0.7 mm (0.02— 0.03 in)
(2)
(1)
(1) Spark plug gap (2) Side electrode
62
7. Make sure the plug washer is in good
condition.
8. With the plug washer attached, thread
the spark plug in by hand to prevent
cross-threading.
9. Tighten the spark plug:
e If the old plug is good:
1/8 turn after it seats.
e If installing a new plug, tighten it twice
to prevent loosening:
a) First, tighten the plug:
NGK: 1 turnafter it seats.
DENSO: 3/4 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again:
1/8 turn after it seats.
An improperly tightened spark plug can
damage the engine. If a plug is too loose, a
piston may be damaged. If a plug is too tight,
the threads may be damaged.
10. Reinstall the spark plug cap. Take care to
avoid pinching any cables or wires.
IDLE SPEED
Refer to the Safety Precautions on page 47 .
Idle Speed:
The engine must be at normal operating
temperature for accurate idle speed
adjustment. 10 minutes of stop-and-go riding
is sufficient.
Do not attempt to compensate for faults in
other systems by adjusting idle speed. See
your Honda dealer for regularly scheduled
carburetor adjustments.
(A) Decrease
(B) Increase
(1) Throttle stop screw
(2) Air screw
1. Warm up the engine and hold the
motorcycle upright.
2. Connect a tachometer to the engine.
3. Adjust idle speed with the throttle stop
screw (1).
Idle speed (In neutral):
1,700 — 100 min” (rpm)
Idle Mixture:
1. Adjust the fuel mixture by turning the air
screw (2) clockwise until you hear the
engine miss or decrease in speed, then
counterclockwise until the engine again
misses or decreases in speed. Set the air
screw exactly between these two extreme
positions. |
From a fully closed position, the correct
setting (between extremes of rich and
lean) will be approximately:
1—1/2
2. If the idle speed changes after adjusting
fuel mixture, readjust the idle speed by
turning the throttle stop screw.
63
THROTTLE OPERATION
Refer to the Safety Precautions on page 47 .
Cable Inspection:
1. Check for smooth rotation of the throttle
grip from the fully open to the fully
closed position at both full steering
positions.
2. Inspect the condition of the throttle cable
(1) from the throttle grip down to the
carburetor. If the cable is kinked, chafed
or improperly routed, it should be
replaced and/or rerouted.
3. Lubricate the cable with a commercially
available cable lubricant to prevent
premature wear and corrosion.
64
(1) Throttle cable
Freeplay Adjustment;
1. Adjust freeplay with the throttle cable
adjuster (1). Measured in grip rotation,
the standard throttle grip freeplay is:
2.0—6.0 mm (0.08—0.24 in)
2. To adjust the freeplay, loosen the lock
nut (2) and turn the adjuster.
3. After adjustment, check again for smooth
rotation of the throttle grip from the fully
closed to the fully open position with the
steering to the full right and left as well
as straight ahead.
If proper throttle freeplay cannot achieved,
contact your Honda dealer.
(1) Cable adjuster
(2) Lock nut
(A) Decrease freeplay
(B) Increase freeplay
65
VALVE CLEARANCE
Refer to the Safety Precautions on page 47 .
Excessive valve clearance will cause noise
and eventual engine damage. Little or no
clearance will prevent the valve from
closing and cause valve damage and power
loss. Check valve clearance when the
engine is cold at the specified intervals.
(2)
(1) T mark
66
(2) Index mark
The checking or adjusting of the clearance
should be performed while the engine is
cold. The clearance will change as the
engine temperature rises.
1. Remove the left crankcase cover.
2. Remove the adjusting hole caps.
3. Rotate the flywheel counterclockwise
until the T mark (1) on the flywheel lines
up with the index mark (2) on the
crankcase. In this position, the piston may
either be on the compression or exhaust
stroke.
The adjustment must be made when the
piston is at the top of the compression
stroke when both the intake and exhaust
valves are closed.
This condition can be determined by
moving the rocker arms. If they are free,
it is an indication that the valves are
closed and that the piston is on the
compression stroke. If they are tight and
the valves are open, rotate the flywheel
360° and realign the T mark to the index
mark.
4. Check the clearance of both valves by
inserting a feeler gauge (3) between the
adjusting screw (4) and the valve stem.
Clearance should be: (3)
0.05 mm (0.002 in) |
If it is necessary to make an adjustment,
loosen the adjusting screw lock nut (5)
and turn the adjusting screw so there is a
slight resistance when the feeler gauge is
inserted.
After completing the adjustment, tighten
the adjusting screw lock nut while
holding the adjusting screw to prevent it
from turning.
Finally, recheck the clearance to make
sure that the adjustment has not been
disturbed.
(5)
(3) Feeler gauge
(4) Adjusting screw
(5) Adjusting screw lock nut
67
SPARK ARRESTER 1. Remove the bolts (1), the spark arrester
Refer to the Safety Precautions on page 47. р and the gasket (3) from the muffler
4).
The exhaust system spark arrester must be 2. Use a brush to remove carbon deposits
purged of accumulated carbon periodically from the spark arrester screen. Be
(see Maintenance Schedule for servicing careful to avoid damaging the spark
period, page 50 ). arrester screen. The spark arrester must
be free of breaks and holes. Replace, if
The exhaust system becomes very hot necessary. Check the gasket. Replace, if
during operation and remains hot for a necessary.
period of time after stopping the engine. 3. Install the spark arrester and the gasket
Allow the exhaust system to cool before in the muffler and tighten the bolts
performing this operation. securely.
о © 9
(1) Bolts (3) Gasket
(2) Spark arrester (4) Muffler
68
DRIVE CHAIN
Refer to the Safety Precautions on page 47 .
The service life of the drive chain is
dependent upon proper lubrication and
adjustment. Poor maintenance can cause
premature wear or damage to the drive
chain and sprockets.
The drive chain should be checked and
lubricated as part of the Pre-ride Inspection
(page 34 ). Under severe usage, or when
the motorcycle is ridden in unusually dusty
or muddy areas, more frequent
maintenance will be necessary.
Inspection:
I. Turn the engine off, place the motorcycle
on its side stand and shift the
transmission into neutral.
2. Check slack in the lower drive chain run
midway between the sprockets.
Drive chain slack should be adjusted to
allow the following vertical movement by
hand:
10—20 тт (0.4— 0.8 тп)
3. Roll the motorcycle forward. Stop. Check
the drive chain slack. Repeat this
procedure several times. Drive chain
slack should remain constant. If the chain
is slack only in certain sections, some
links are kinked and binding. Binding and
kinking can frequently be eliminated by
lubrication.
Excessive chain slack may allow the drive
chain to damage the engine cases.
(1) Drive chain
69
4. Check the chain slider (2) for wear.
If the ridge (3) in the center of the slider
is worn, have your Honda dealer replace
the chain slider.
(2) Chain slider
(3) Ridge
70
5. Measure a section of the drive chain to
determine whether the chain is worn
beyond its service limit. Remove the drive
chain and measure the distance between
a span of pins from pin center to pin
center. If the distance exceeds the service
limit, the chain is worn out and should be
replaced.
New Chain:
1,080 mm (42.5 in)
Service Limit:
1,101 mm (43.3 in)
Measure a span of : 85 pins.
6. Inspect the sprocket teeth for possible
wear or damage.
Damaged sprocket Worn sprocket
Teeth Teeth
Replace Replace
Normal sprocket Teeth
GOOD
If the drive chain or sprockets are
excessively worn or damaged, they should
be replaced. Never use a new chain with
worn sprockets; rapid chain wear will result.
Adjustment:
If the drive chain requires adjustment, the
procedure is as follows;
1. Place a support block under the engine to
raise the rear wheel off the ground.
2. Loosen the rear axle nut (1).
(1) Rear axle nut
(2) Adjusting nut
(3) Adjuster index mark
(4) Graduated scale
71
3. Turn the adjusting nut (2) on both the
right and left chain adjusters an equal
number of turns to increase or decrease
chain slack.
Align the chain adjuster index marks (3)
with the corresponding scale graduations
(4) on both sides of the swingarm.
If the drive chain slack is excessive when
the rear axle is moved to the furthest limit
of adjustment, the drive chain is worn and
must be replaced.
4. Tighten the axle nut to:
59 N-m (6.0 kgf-m , 43 Ibf-ft)
5. Tighten the adjusting nuts.
6. Recheck drive chain slack.
7. Rear brake pedal freeplay is affected
when repositioning the rear wheel to
adjust drive chain slack. Check rear brake
pedal freeplay and adjust as necessary
(page 17 ).
72
If a torque wrench is not used for this
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Lubrication:
Use SAE 80 or 90 gear oil or a commercially
prepared drive chain lubricants in
preference to motor oil or other lubricants.
Saturate each chain link joint so that the
lubricant penetrates between the link plates,
pins, bushings, and rollers.
Removal and Cleaning:
When the drive chain becomes dirty, it
should be removed and cleaned prior to
lubrication.
1. With the engine off, carefully remove the
master link retaining clip (1) with a pair
of pliers. Do not bend or twist the clip.
Remove the master link. Remove the
drive chain from the motorcycle.
2. Clean the drive chain in high flash-point
solvent and allow it to dry. Inspect the
drive chain for possible wear or damage.
Replace any chain that has damaged
rollers, loose fitting links, or otherwise
appears unserviceable.
Never use petrol or low flash point solvents
for cleaning the drive chain. A fire or
explosion could result.
3. Inspect the sprocket teeth for possible
wear or damage.
4. Lubricate the drive chain (page 72).
5. Pass the chain over the sprockets and join
the ends of the chain with the master link.
For ease of assembly, hold the chain ends
against adjacent rear sprocket teeth while
inserting the master link.
The master link is the most critical part
affecting the security of the drive chain.
Master links are reusable, if they remain
in excellent condition, but it is
recommended that a new master link
retaining clip be installed whenever the
drive chain is reassembled.
Install the master link retaining clip so
that the closed end of the clip will face
the direction of forward wheel rotation.
(1) Retaining clip
WHEEL RIMS AND SPOKES
Refer to the Safety Precautions on page 47.
1. Inspect the wheel rims (1) and spokes
(2) for damage.
2. Tighten any loose spokes.
3. Check wheel rim runout. If runout is
noticeable, see your Honda dealer for
inspection.
Maintenance of spoke tension and wheel
trueness are critical to safe motorcycle
operation. During the first 150 km (100
miles), spokes will loosen more rapidly due
to initial seating of parts. Excessively loose
spokes may result in high speed instability
and possible loss of control.
74
(1) Wheel rim
(2)
WHEEL REMOVAL
Refer to the Safety Precautions on page 47 .
Front Wheel Removal
1. Raise the front wheel off the ground by
placing a support block under the engine.
2. Loosen the cable guide bolt (1).
3. Disconnect the front brake cable (2)
from the brake arm (3).
4. Remove the front axle nut (4) and front
axle. The front wheel can now be
removed.
3)
(1) Cable guide bolt (4) Front axle nut
(2) Front brake cable (5) Lug
(3) Brake arm (6) Slot
Installation: |
I. Reverse the removal procedure. Make
sure that the lug (5) on the fork leg is
located in the slot (6) in the brake panel.
Be sure to tighten the axle nut to:
59 N-m (6.0 kgf-m , 43 Ibf-ft)
2. Check front brake adjustment.
3. 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.
If a torque wrench was not used for
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.
75
Rear Wheel Removal
1. Raise the rear wheel off the ground by
placing a support block under the engine.
2. Unscrew the rear brake adjuster (1).
3. Press and release the rear brake pedal
and disconnect the brake rod (2) from
the brake arm (3).
4. Loosen the adjusting nut (4) on the chain
adjuster on both sides.
0_ Y
Y TU
(4) gy a
©
Bea 4
1 yl _ / 5
(3)
(1) Brake adjuster (3) Brake arm
(2) Brake rod (4) Adjusting nut
76
5. Unscrew the axle nut (5) and pull out the
axle. Push the wheel forward and derail
the drive chain from the rear sprocket.
Tilt the motorcycle to one side so that the
wheel can be removed.
(5) (4)
(5) Axle nut
Installation;
I. Reverse the removal procedure. Make
sure that the lug (1) on the swingarm is
located in the slot (2) in the brake panel.
Tighten the axle nut to:
59 N-m (6.0 kgf-m , 43 Ibf-ft)
2. Adjust the drive chain (pages 71 — 72).
3. Adjust the brake (page 17 ).
4. Apply the brake several times and check
for free wheel rotation after the brake
pedal is released.
If a torque wrench was not used for
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.
(1) Lug
(2) Slot
77
BRAKE SHOE WEAR
Refer to the Safety Precautions on page 47.
The front and rear brakes are equipped
with brake wear indicators.
When the brake is applied, an arrow (1)
attached to the brake arm (2) moves
toward a reference mark (3) on the brake
panel (4). If the arrow aligns with the
reference mark on full application of the
brake, the brake shoes must be replaced.
See your Honda dealer for this service.
When the brake service is necessary, see
your Honda dealer. Use only Honda
Genuine Parts or its equivalent.
78
(FRONT BRAKE»
le
(1) ES }
(1) Arrow
(2) Brake arm
(3) Reference mark
(4) Brake panel
FRONT SUSPENSION
Refer to the Safety Precautions on page 47 .
Check the fork operation by locking the
front brake and pumping the forks up and
down several times. The suspension should
function smoothly, with no oil leakage from
the fork legs. Damaged, binding, or leaking
fork should be repaired before the
motorcycle is operated. Check security of
all fork and handlebar mounting bolts (1).
(1) Mounting bolts
Operating the motorcycle with loose,
worn, or damaged steering or front
suspension components may adversely
affect vehicle handling and stability.
If any suspension components appear
worn or damaged, consult your Honda
dealer for further inspection. The suspen-
sion components are directly related to
safety and your Honda dealer is qualified
to determine whether or not replacement
parts or repairs are needed.
79
REAR SUSPENSION
Refer to the Safety Precautions on page 47 .
Check the rear suspension periodically by
careful visual examination. Note the
following items:
1. Swingarm bushings (1) should be
checked by pushing hard against the side
of the rear wheel while the motorcycle is
on a support block and feeling for
looseness of the bushings.
2. Check all suspension component
attachment points (2) for security of
their fasteners.
3. Check for oil leaks in the shock absorber
units.
If any suspension components appear worn
or damaged, consult your Honda dealer for
further inspection. The suspension
components are directly related to safety
and your Honda dealer is qualified to deter-
mine whether or not replacement parts or
repairs are needed.
80
(1) Bushings
(2) Attachment points
SIDE STAND
Refer to the Safety Precautions on page 47 .
Check the side stand spring (1) for damage
and loss of tension, and the side stand
assembly for freedom of movement.
If the side stand is squeaky or stiff, clean
the pivot area and lubricate the pivot bolt
with clean engine oil.
(1) Side stand spring
81
CLEANING
Clean your motorcycle regularly to protect
the surface finishes and inspect for damage,
wear and oil leakage.
Avoid cleaning products that are not
specifically designed for motorcycle or
automobile surfaces.
They may contain harsh detergents or
chemical solvents that could damage the
metal, paint, and plastic on your motorcycle.
If your motorcycle is still warm from recent
operation, give the engine and exhaust
system time to cool off.
We recommend avoiding the use of high
pressure water spray (typical in coin-
operated car washes).
High pressure water (or air) can damage
certain parts of the motorcycle.
82
High pressure washer spray can damage
certain parts of your motorcycle. If you use
a high pressure washer, avoid spraying the
following areas:
Wheel Hubs
Muffler Outlet
Under Seat
Engine Stop Switch
Under Fuel Tank
Drive Chain
Carburetor
Ignition Switch
Washing the motorcycle
1. Rinse the motorcycle thoroughly with
cool water to remove loose dirt.
2. Clean the motorcycle with a sponge or
soft cloth using cool water.
Avoid directing water to muffler outlets
and electrical parts.
3. Clean the plastic parts using a cloth or
sponge dampened with a solution of mild
detergent and water. Rub the soiled area
gently rinsing it frequently with fresh
water.
Take care to keep brake fluid or chemical
solvents off the motorcycle.
They will damage the plastic and painted
surfaces.
4. After cleaning, rinse the motorcycle
thoroughly with plenty of clean water.
Strong detergent residue can corrode
alloy parts.
5. Dry the motorcycle, start the engine, and
let it run for several minutes.
6. Test the brakes before riding the
motorcycle. Several applications may be
necessary to restore normal braking
- performance. |
7. Lubricate the drive chain immediately
after washing and drying the motorcycle.
Braking efficiency may be temporarily
impaired immediately after washing the
motorcycle.
Anticipate longer stopping distance to avoid
a possible accident.
83
Finishing Touches
After washing your motorcycle, consider
using a commercially-available spray
cleaner/polish or quality liquid or paste wax
to finish the job. Use only a non-abrasive
polish or wax made specifically for
motorcycles or automobiles. Apply the
polish or wax according to the instructions
on the container.
84
STORAGE GUIDE
Extended storage, such as for winter,
requires that you take certain steps to
reduce the effects of deterioration from
non-use of the motorcycle. In addition,
necessary repairs should be made BEFORE
storing the motorcycle; otherwise, these
repairs may be forgotten by the time the
motorcycle is removed from storage.
STORAGE
1. Change the engine oil.
2. Drain the fuel tank and carburetor into an
approved petrol container.
Reinstall the fuel fill cap on the tank.
To assure proper performance after storage
lasting more than one month, it is important
to drain the carburetor.
AWARNING
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
e Stop the engine and keep heat,
sparks, and flame away.
e Refuel only outdoors.
e Wipe up spills immediately.
85
3. To prevent rusting in the cylinder,
perform the following:
e Remove the spark plug cap from the
spark plug. Using tape or string, secure
the cap to any convenient plastic body
part so that it is positioned away from
the spark plug.
e Remove the spark plug from the
engine and store it in a safe place. Do
not connect the spark plug to the spark
plug cap.
e Pour a tablespoon (15—20 ст) о?
clean engine oil into the cylinder and
cover the spark plug hole with a piece
of cloth.
e Crank the engine several times to
distribute the oil.
e Reinstall the spark plug and spark plug
cap.
86
4. Wash and dry the motorcycle. Wax all
painted surfaces. Coat chrome with
rustinhibiting oil.
5, Lubricate the drive chain (page 72 ).
6. Inflate the tyres to their recommended
pressures. Place the motorcycle on blocks
to raise both tyres off the ground.
7. Cover the motorcycle (don’t use plastic or
other coated materials) and store in an
unheated area, free of dampness with a
minimum of daily temperature variation.
Do not store the motorcycle in direct
sunlight.
REMOVAL FROM STORAGE
1. Uncover and clean the motorcycle.
Change the engine oil if more than 4
months have passed since the start of
storage.
2. Perform all Pre-ride Inspection checks
(page 34).
3. Test ride the motorcycle at low speeds in
a safe riding area away from traffic.
87
SPECIFICATIONS
DIMENSIONS
Overall length
Overall width
Overall height
Wheelbase
CAPACITIES
Engine oil After draining
After disassembly
Fuel tank
Fuel reserve
Passenger capacity
Maximum weight capacity
88
1,569 mm (61.8 in)
694 mm (27.3 in)
885 mm (34.8 in)
1,063 mm (41.9 in)
(0.6 US gt, 0.5 Imp at)
(0.8 US gt , 0.7 Imp gt)
(1.32 US gal, 1.10 Imp gal)
(0.18 US gal, 0.15 imp gal)
erator only; no passenger
60 kg (132 Ibs)
ENGINE
Bore and stroke
Compression ratio
Displacement
Spark plug
Standard
For cold climate
(Below 5°C, 41°F)
For extended high speed
riding
Spark plug gap
Idle speed
Valve clearance (Cold)
47.0 X 41.4 mm (1.85 x 1.63 in)
9.0: 1
71.8 em? (4.38 cu-in)
CR6HSA (NGK) or
U20FSR-U (DENSO)
CR5HSA (NGK) or
U16FSR-U (DENSO)
CR7HSA (NGK) or
U22FSR-U (DENSO)
0.6—0.7 mm (0.02—0.03 in)
1,700 + 100 min” (rpm)
intake 0.05 mm (0.002 in)
Exhaust 0.05 mm (0.002 in)
89
CHASSIS AND SUSPENSION
Caster
Trail
Tyre size, front
Tyre size, rear
Tyre type
POWER TRANSMISSION
Primary reduction
Gear ratio, 1st
2nd
3rd
Final reduction
90
26°12’
61.5 mm (2.42 in)
2.50-14 APR
3.00-12 4PR
bias-ply, tube
3.722
3.272
1.666
1.190
2.400