}

.---------IMPORTANT NOTICE - - - - - - - - - - - ,

• OPERATOR AND PASSENGER

This motorcycle is designed to carry the operator and one passenger. Never exceed the vehicle capacity load as shown on the tire information label.

• ON-ROAD USE

This motorcycle is not equipped with a spark arrester and is designed to be used only on the road. Operation in forest, brush, or grass covered areas may be illegal. Obey local laws and regulations.

• READ OWNER'S MANUAL CAREFULLY

Pay special attention to statements preceded by the fOllowing words:

Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.

CAUTION:

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

NOTE: Gives helpful information.

This manual should be considered a permanent part of the :vehicle and should remain with the vehicle when resold.

HONDA GL1100

OWNER'S MANUAL

1980

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.

•

© Honda Motor Co., Ltd. 1979

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 machine, but also the machine's mechanical condition. A pre-ride inspection before every outing and regular maintenance are essential.

To help meet the challenges safely and enjoy the adventure fully, become thoroughly familiar with this Owner's Manual BEFORE YOU RIDE THE MOTORCYCLE. Also, for your own and your Honda's sake, please read all the written material which came with your new Honda. These items include:

*

Honda Owner's Identification Card

*

Set-up and Predelivery Checklist

*

Honda Motorcycle Emission Control System, Distributor's Warranty

*

Honda Motorcycle, Distributor's Limited Warranty

When service is required, remember that your Honda dealer knoW'S what it takes to keep your Honda going strong. If you have the required mechanical "know how" and tools, your dealer can supply you with an official Honda Shop Manual to help you perf orm many maintenance and repair tasks.

Pleasant riding and thank you for choosing a Honda'

Page

MOTORCYCLE SAFETy...................

I

Safe Riding Rules I

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

2

Modifications '" 2

Loading and Accessories ., 3

Tires 5

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

8

DESCRIPTION

Parts Location

Serial Numbers

Parts Function

Fuel

Engine Oil

Coolant

OPERATION

Pre-Ride Inspection

Starting the Engine

Break-in

Riding

Braking

Parking

Anti-theft Tips

10

10

14

16

26

28

30

32

32

33

35

36

38

39

39

CONTENTS - - - - - - - - - - -

SPECIAL PROCEDURES

Tool Kit

Page

40

41

Front Wheel Removal............

Rear Wheel Removal......

Fuse Replacement

MAINTENANCE

Maintenance Schedule

Maintenance Record

Engine Oil................

Oil Filter

Spark Plug

55

56

Idle Speed 57

Air Cleaner......................................

58

42

45

48

49

51

53

54

Crankcase Breather

Clutch

Brakes

Side Stand

Battery

CLEANING

STORAGE

EMISSION'CONTROL SYSTEM

CONSUMER INFORMATION

SPECIFICATIONS

59

59

62

65

66

68

68

69

73

I

76

p

_ - - - - - - - MOTORCYCLE SAFETY - - - - - - - -

[Md;qilH?i

Motorcycle riding requires special efforts on your part to ensure your saFet K

J' y.

now these reqUirements eJore you rt e.

SAFE RIDING RULES

1. Always make a pre-ride inspection

(page 32) before you start the engine.

You may prevent an accident or equipment damage.

2. Many accidents involve inexperienced riders.

Most states require a special motorcycle riding test or license.

Make sure you are qualified before you ride.

NEVER lend your motorcycle to an inexperienced rider.

3. Many automobile/motorcycle accidents happen because the automobile driver does not "see" the motorcyclist. Make yourself conspicuous to help avoid. the accident that wasn't your fault:

* Wear bright or n:flective clothing.

* Don't drive in another motorist's

"blind spot".

4. Obey all federal, state, and local laws and regulations.

*

Excessive speed is a factor in many accIdents.

Obey the speed limits and NEVER travel faster than

con~

ditions warrant.

* Signal before you make a turn or lane change. Your size and maneuverability can surprise other motorists.

5. Don't let other motorists suprise you.

Use extra caution at intersections parking lot entrances and exits and driveways.

'

6. Keep both hands on the handlebars and both feet on the footpegs while riding. A passenger should hold on to the motorcycle or the operator with both hands, and keep both feet on the passenger foot pegs.

PROTECTIVE APPAREL

1. Most motorcycle accident fatalities are due to head injuries: ALWAYS wear a helmet. You should also wear a face shield or goggles; boots, gloves, and protective clothing. A passenger needs the same protection.

2. The exhaust system becomes very hot during operation, and it remains hot after operation. Never touch any part of the hot exhaust system. Wear clothing that fUlly covers your legs.

3. Do not. wear loose clothing which could catch on the control levers, footpegs, or wheels.

MODIFICA nONS

Modification of the motorcycle, or removal of original equipment may render the vehicle unsafe or illegal. Obey all federal, state, and local equipment regulations.

2

LOADING AND ACCESSORIES

1>'N,i;i~iiHii

* To prevent an accident, use extreme care when adding and riding with accessories and cargo.

Addition of accessories and cargo can reduce a motorcycle's stability, performance and safe operating speed. Never ride an accessory equipped motorcycle at speeds above 80 mph. And remember that this 80 mph limit may be reduced by installation of non-Honda accessories, improper loading, worn tires and overall motorcycle condition, poor road or weather conditions, etc.

These general guidelines may help you decide whether or how to equip your motorcycle, and how to load it safely

Loading

The combined weight of the rider, passenger, cargo and all accessories must not exceed 465 Ibs (210 kg), the vehicle capacity load. Cargo weight alone should not exceed 60 lbs.

1. Keep cargo and accessory weight low and close to the center of the motorcycle. Load weight equally on both sides to minimize imbalance. As weight is located farther from the motorcycle's center of gravity, handling is proportionallyaffected.

2. Adjust tire pressure (TIRES, page 5), front fork air pressure and rear shock absorber air pressure (SUSPENSION page 8) to suit load weight and

ridin~

conditions.

3. Luggage racks are for light weight items. Do not carry more than 20 Ibs.

of cargo on a luggage rack behind the seat. Bulky items too far behind the rider may cause wind turbulence that impairs handling.

4. All cargo and accessories must be secure for stable handling. Re-check cargo security and accessory mounts frequently.

5. Do not attach large, heavy items to the handlebars, front forks, or fender.

Unstable handling or slow steering response may result.

3

Accessories

Genuine Honda accessories have been specifically designed for and tested on this motorcycle. Because the factory cannot test all other accessories, you are personally responsible for proper selection, installation, and use of non-Honda accessories. Always follow the guidelines under Loading above, and these:

1. Carefully inspect the accessory to make sure it does not obscure any lights, reduce ground clearance and banking angle, or limit suspension travel, steering travel or control operation.

2. Large fork-mounted fairings or windshields, or poorly designed or improperly mounted fairings can produce aerodynamic forces that cause unstable handling. Do not install fairings that decrease cooling air flow to the engine.

3. Accessories which alter your riding position by moving hands or feet away from controls may increase reaction time in an emergency.

4. Do not add electrical equipment that

4 will exceed the motorcycle's electrical system capacity. A blown fuse could cause a dangerous loss of lights or engine power at night or in traffic.

5. This motorcycle was not designed to pull a sidecar or trailer. Handling may be seriously impaired if so equipped.

6. Any modification of the cooling system may cause overheating and serious engine damage.

Do not modify the radiator shrouds or install accessories which block or deflect air away from the radiator.

-

TIRES: TUBELESS

This motorcycle is equipped with tubeless tires, valves, and wheel rims. Use only tires marked "TUBELESS" and tubeless valves on rims marked "TUBELESS TIRE APPLI-

CABLE".

Proper air pressure will provide maximum stability, riding comfort and tire life.

Check tire pressure frequently and adjust if necessary.

NOTE:

*

Tire pressure should be checked when the tires are "cold", before you ride.

*

Tubeless tires have some degree of selfsealing ability if they are punctured, and leakage is often very slow. Inspect very closely for punctures, especially if the tire is not fully inflated.

Dry weight

Curb weight (wet) kg (lbs) 267 (589) kg (lbs) 290 (639)

Gross vehicle weight rating kg (lbs)

501 (1105)

Vehicle capacity load kg (lbs) 210 (465)

Tire size

Front Rear

110/90-19 130/90-17

62H 68H

Cold tire pressures kg/cm

(psi)

2

Up to

90 kg

(200 lbs) load

90 kg

(2001bs) load to vehicle capacity load

2.25 (32)

2.25 (32)

Tire brand

TUBELESS ONLY

BRIDGESTONE S703

DUNLOP F11

2.25 (32)

2.8 (40)

G504

K127

5

6

Check the tires for cuts, imbedded nails or other sharp objects. Check the rims for dents or deformation.

If there is any damage, see your authorized Honda dealer for repair, replacement, and balancing.

11£Q.1;I~i!UiJ

* Improper tire inflation will cause abnormal tread wear and create a safety hazard.

tlnderinflation may result in the tire slipping on, or coming off of the rim.

* Operation with excessively worn tires is hazardous and will adversely affect traction and handling.

Replace tires before tread depth at the center of the tire reaches the following limit:

Front:

Rear:

Minimum tread depth

1.5 mm 0/16 in)

2.0 mm (3/32 in)

Repair/Replacement;

See your authorized Honda Dealer f?t

b ·i;PiiU1

* The use of tires other than those listed on the tire information label may adversely affect handling.

.

* Do not install tube-type tires on tubeless rims. The beads may not seat and the tires could slip on the rims, causing tire deflation.

* Proper wheel balance is necessary for safe, stable handling of the motorcycle. Do not remove or change any wheel balance weights.

When wheel balancing is required, see your authorized Honda dealer. Wheel balancing is required after tire repair or replacement.

* Do not exceed 50 mph for the first 24 hours. after tire repair, or repair failure and tire deflation may result. Never use a repaired tire at speeds over 80 mph.

* Replace the tire if the sidewall is punctured or damaged. Sidewall flexing may cause repair failure and tire deflation.

CAUTION:

* Do not try to remove tubeless tires without special tools and rim protectors.

You may damage the rim sealing surface or disfigure the rim.

7

8

SUSPENSION

The front and rear suspension of this motorcycle can provide the desired ride under various rider/cargo weights and driving conditions through adjustment of the air pressure.

The recommended pressures under normal conditions are:

Front 1.0-1.5 kg/cm

2

Rear 2.0-3.0 kg/cm 2

(14-21 psi)

(28-42 psi)

Low air pressure settings provide a softer ride and are for light loads and smooth road conditions. High air pressure settings provide a firmer rlde and are for heavy loads and rough road conditions.

Front Air Rear Air

Pressure Pressure

Rider/

Load

Conditions

Driving

Conditions

1.0 kg/cm

2

(14 psi)

2.0 kg/em'

(28 psi)

One Ordinary or city road driving t ~ ~ t

1.5 kg/cm

2

3.0 kg/em' Up to Rough road

(21 psi) (42 psi) vehicle capacity driving load

Check and adjust air pressure when the front fork tubes and rear shock absorbers are cold before riding.

1. Place the motorcycle on its center stand.

Do not use the side stand or you will get false pressure readings.

2. Remove the front fork air valve cap (1) and rear shock absorber air valve cap

(2).

3. Check the air pressure using the pressure gauge supplied in the tool tray.

NOTE:

*

Some pressure will be lost when removing the gauge from the valve. Determine the amount of loss and compensate accordingly.

4. Add air to the recommended pressure.

NOTE:

* We recommend that you do not exceed recommended air pressure or the ride will be harsh and uncomfortable.

(?1'd\;iiifml

* If the rear suspension air pressure warning light comes on while riding, reduce speed to below 50 mph and proceed immediately to the nearest filling station to add air. Do not continue riding because stability and handling may be adversely affected.

(1) Valve cap (front) (2) Valve cap (rear)

9

10

PARTS LOCATION

D E S C R I P T I O N - - - - - - - - - -

( 1) Fuel filler cap

( 2) Compartment lock

( 3) Tool tray

( 4) Fuse box and ACC terminal

( 5) Horn button

( 6) Turn signal switch

( 7) Headlight dimmer switch

( 8) Clutch lever

( 9) Left rear view mirror

(10) Choke knob

(II) Speedometer

(12) Coolant temperature gauge

(13) Warning and indicator lights

(14) Fuel gauge

(15) Tachometer

(16) Front brake fluid reservoir

(17) Right rear view mirror

(18) Front brake lever

(19) Engine stop switch

(20) Throttle grip

(21) Starter button

(22) Ignition switch

(23) Coolant reserve tank cap

\

'-------~

11

I

12

(

/

/

I

(3)

(1) Cooling fan

cb®

(2) Fuel filler cap

Fuel valve

(4) Gear change pedal

(5) Center stand

(6) Side stand

(7) Battery

(1) Final drive gear oil filler cap

(2) Passenger foot peg

(3) Rear brake fluid reservoir

(4) Operator footpeg

(5) Rear brake pedal

(6) Engine Oil inspection window

(7) Engine oil filler cap

13

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. , _

ENGINE NO.

_

The VIN, Vehicle Identification Number

(l), is on the Safety Certification Label affixed to the left side of the steering head. This number is the same as the frame number (2) stamped on the right side of the steering head.

14

(1) VIN number (2) Frame number

The engine number (3) is stamped on the top right side of the crankcase.

L

(3) Engine number

15

PARTS FUNCTION

Instruments and Indicators

The indicators and warning lights are grouped between the instruments. Their functions are described in the tables on the following pages.

USA model:

Odometer and tripmeter read in miles.

Canadian model:

Odometer and trip meter read in kilometers.

( 1 ) Tripmeter

( 2 ) Speedometer

( 3 ) Odometer

( 4) Left turn signal indicator

( 5 ) Coolant temperature gauge

( 6 ) Fuel gauge

( 7 ) Right turn signal indicator

( 8 ) Tachometer

( 9 ) Tachometer red zone

(10) Tripmeter reset knob

(11) Oil pressure warning light

(12) High beam indicator

(13) Neutral indicator

(14) R~ar suspension air pressure warning light

16

Ref. No.

1

2

3

4

5

6

7

8

9

10

Description

Tripmeter

Speedometer

Function

Shows mileage per trip.

Shows driving speed, 0 to 85 mph.

Odometer

Left turn signal indicator (amber)

Coolant temperature gauge

Shows accumulated mileage.

Flashes when left turn signal operates.

Shows coolant temperature (see page 19).

Fuel Gauge

Shows approximate fuel supply available (see page

19).

Right turn signal indicator (amber)

Flashes when right turn signal operates.

Tachometer Shows engine rpm.

Do not operate engirie in red zone when avoidable.

NEVER operate beyond red zone.

Tachometer red zone CAUTION:

Exceeding recommended maximum engine rpm may cause serious engine damage.

Tripmeter reset knob

Resets tripmeter to zero (0). Turn knob in direction shown.

17

18

Ref. No.

11

12

13

14

Description

Oil pressure warning light (red)

High beam indicator

(blue)

Neutral indicator

(green)

Function

Lights when engine oil pressure is below nonnal operating range. Should light when ignition switch is ON and engine is not running. Should go out when engine starts, except for occasional flickering at or near idling speed when engine is wann.

CAUTION:

Running the engine with insufficient oil pressure will cause serious engine damage.

Lights when headlight is on high beam.

Rear suspension air pressure warning light (red)

Lights when transmission is in neutral.

Light should c?me on for 5 seconds after turning the ignition sWitch on, then go out.

If light does not come on or comes on and does not go out, there is a fault in the pressure warning system.

If light comes on while riding over 10 mph, rear suspension air pressure must be increased.

'f

. .

the rear suspenslOn air pressure warning light comes on while riding, reduce speed to below 50 mph and preceed. immediately t~ the '!e'!rest filling station to 'add air. Do not contmue "dmg because stability and handling may be adversely affected.

Coolant Temperature Gauge

When the needle reaches the blue mark, the engine is warm enough to ride. Normal operating temperature is within the white band.

If the needle enters the red zone, stop the engine and checY the reserve tank coolant level.

Read pages 30-31 and do not drive the motorcycle until the pro blem has been corrected.

CAUTION:

Exceeding maximum running temperature may cause serious engine damage.

Fuel Gauge

The fuel gauge shows the approximate fuel supply available. At F(full) there is

20 liters (5.3

US gal), including the reserve supply. When the gauge needle first points to RES there is about 6 liters

(1.6 US gal) left in the tank. Refill the tank as soon as possible.

If the main fuel supply runs out, the last 4 liters

(1.1 US gal) can be used by turning the fuel valve to RES.

19

Ignition Switch

The ignition switch ( I) is below the indicator panel.

Key Position

P (parking)

ON

20

ACC

OFF

LOCK (steering lock)

(1) Ignition switch _

Function

For parking the motorcycle near traffic.

The taillight is on, but all other lights are off. The ACC terminal is on. The engine cannot be started.

Headlight, taillight and meter lights are on and other lights can be operated. Engine can be started.

All electrical circuits are off except for

ACC terminal.

Engine and lights cannot be operated.

Steering is locked. Engine and lights cannot be operated.

Key Removal

Remove the key

Key cannot be removed

Key cannot be removed

Remove the key

Remove the key

Engine Stop Switch

The three position engine stop switch (I) is next to the throttle grip. In "RUN", the engine will operate. In either "OFF" position the engine will not operate. This switch is intended primarily as a safety or emergency switch and should normally remain in "R UN".

NOTE:

If your motorcycle is stopped with the ignition switch "ON" and the engine stop switch "OFF", the headlight and taillight will still be on, resulting in battery discharge.

Starter Button

The starter button (2) is below the engine stop switch ( 1).

When the starter button is pressed the starter motor will crank the engine and the headlight will automatically go out during starting, but the taillight will stay on.

See pages 33-34 for the starting procedure.

(l) Engine stop switch (2) Starter button

21

The three controls next to left handlebar grip are:

Headlight Dimmer Swit<;~ {I)

Select "HI" for high beam, "LO" for low beam.

Turn Signal Switch (2)

Move to "L"· to signal a left turn, "R" to signal a right turn. Return to the center

(off) when finished.

Horn Button (3)

Press the button to sound the horn.

22

(1) Headlight dimmer switch

(2) Turn signal switch (3) Horn button

Steering Lock

To lock the steering, turn the handlebars all the way to the left or right and turn the ignition key (l) to "LOCK" while pushing in. Remove the key.

* Do not tum the key to "LOCK" while riding the motorcycle.

Helmet Holder

The helmet holder (1) is on the right side of the frame above the crankcase.

Hang your helmet on the holder pin (3) and push the pin in to lock it To unlock insert the ignition key (2) 'and turn it coun terclockwise.

I\J',?·j;i:iiU1

The helmet holder is designed for use while parked. Do not operate the motorcycle with a helmet attached to the holder.

The helmet may interfere with the rear wheel, possibly stopping the wheel.

(1) Ignition key (A) Push in

(B) Turn to "LOCK"

(l)

(2)

Helmet holder

Ignition key

(3) Holder pin

23

Top Compartment

Use the ignition key to open the top compartment cover. The tool tray (l) is under the forward cover. The owner's manual and other documents should be stored in the plastic bag in this tray. When washing your motorcycle, be careful not to flood the compartment.

Seat

The seat can be set in three positions. To adjust, remove the bolt on each side, move the seat and retighten the bolts securely.

After adjustment make sure the seat is secure and your riding position is comfortable.

(1)

24

Tool tray

(1) Seat mounting bolt

ACC Terminal

The ACC terminal (I) is in the fuse box (2) in the top compartment aild provides 12V

DC power for electr.ical accessories.

A maximum of 60 Watts (5 amps) may be connected to the terminal. Higher current demands may blow the fuse or discharge the battery.

Review the LOADING AND ACCEC-

SORIES WARNING (pages 3-4) before installing accessories.

Connect accessory electrical leads securely, and keep them insulated, away from hot parts and sharp edges.

(1) ACC terminal (2) FUse box

25

FUEL

Fuel Valve

The three way fuel valve (1) is on the left side near the carburetor.

"OFF"

At "OFF", fuel cannot flow from the tank to the carburetors. Turn the valve "OFF" whenever the motorcycle is not in use.

"ON"

At "ON", fuel will flow from the main fuel supply to the carburetors.

"RES"

At "RES", fuel will flow from the reserve fuel supply to the carburetors. 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 approximately 4 liters (1.1

US gal).

NOTE:

Do not operate the motorcycle with the fuel valve at RES after refueling. You could run out of fuel, with no reserve.

* Know how to operate the fuel valve while riding the motorcycle. You may avoid a sudden stop in traffic.

* Be careful not to touch any hot engine parts while operating the fuel valve.

ON OFF

RES

(l) Fuel valve

26

Fuel Tank

Fuel tank capacity is 20 liters (5.3 US gal) including 4 liters (1.1

US gal) in the reserve supply. To open the filler cap

(1), open the rear top compartment cover with ignition key and then turn the fuel filler cap (l) counterclockwise.

Any automotive gasoline with a pump octane number (R ; M) of 86 or higher, or a research octane number of 91 or higher, may be used.

If "knocking" or "pinging" occurs, try a different brand of gasoline or higher octane grade.

1'?t&.j;i~iiHa

* This fuel system is pressurized. Open the filler cap slowly.

*

Gasoline is extremely flammable and is explosive under certain conditions.

Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the motorcycle is refueled or stored.

* Do not overfill the tank (there should be no fuel in the filler neck)_ After refueling, make sure the filler cap is closed securely.

(l) Fuel filler cap

27

ENGINE OIL

Check engine oil level each day before operating the motorcycle.

I. Put the motorcycle on its center stand on level ground.

2. Check the oil level in the oil inspection window (.3) on the lower right side of the crankcase. The oil level should be between the upper (I) and lower (2) level marks.

If the inside of the window is dirty, turn the wiper (4) to clean the window.

3. If required, remove the filler cap (5), add the specified oil up to the upper level mark, and replace the filler cap.

CAUTION:

Running the engine with insufficient oil can cause serious engine damage.

28

(1) Upper level mark

(2) Lower level mark

(3) Inspection window

(4) Wiper

,

~

(5) Filler cap

Engine.oil Recommendation

USE HONDA 4-STROKE OIL OR AN

EQUIV ALENT.

Use only high detergent, premium quality motor oil certified to meet or exceed

U.S.

automobile manufacturer's requirements for Service Classification SE. Motor oils intended for Service SE will show this designation on the container. The use of special oil additives is unnecessary and will only increase operating expenses.

CAUTION:

* Engine oil is a major factor affecting the performance and service life of the engine.

Non-detergent, vegetable, or castor based racing oils are not recommended.

Recommended Oil Viscosity

SAE lOW-40

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

-20

-30 -20 -10 10 20 30 40 C

29

COOLANT

Coolant Recommendation

The owner must properly maintain the coolant to prevent freezing, overheating, and corrosion.

Use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommendeQ for use in aluminum engines. (SEE ANTIFREEZE CONTAINER

LABEL).

CAUTION:

Hard water or salt water is harmful to aluminum.

The factory provides a 50/50 solution of antifreeze and water in the GLIIOO.

This coolant solution is recommended for most operating temperatures and provides good corrosion protection.

A higher concentration of antifreeze decreases the cooling .system performance and is recommended only when ·additional protection against freezing is needed. A concentration of less than 40/60 (40% antifreeze) will not provide proper corrosion protection. Dur-

30 ing freezing temperatures, check the cooling system frequently and add higher concentrations of antifreeze if required.

See your authorized Honda dealer.

Inspection

Check coolant level in the reserve tank

(I) while engine is at normal operating

(l) Reserve tank

(2) FULL mark

(3) LOW mark

(4) Reserve tank cap

temperature. Add coolant to the reserve tank as required, to bring coolant level to the FULL mark (2).

If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your authorized Honda dealer for repair.

Do not remove the radiator cap.

* Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result.

*

Keep hands and clothing away from the cooling fan, as it starts automatically.

31

OPERATION - - - - - - - - - -

PRE-RIDE INSPECTION

If the Pre-ride Inspection is not performed, serious damage or an accident may result.

Inspect your motorcycle every day before you start the engine. The items listed here will only take a few minutes, and in the long run they can save you time, expense, and possibly your life.

1. Engine oil level -- add engine oil if required (page 28). Check for leaks.

2. Fuel level fill fuel tank when necessary (pages 19, 26- 27). Check for leaks.

3. Coolan t level - add coolan t if required

(pages 30-31). Check for leaks.

4. Front and rear brakes check operation; make sure there is no brake fluid leakage (pages 62-64).

5. Tires check condition and pressure

(pages 5-7).

32

6. Throttle-check for smooth opening and closing in all steering positions.

7. Lights and horn - check that headlight, tail/stoplight, turn signals, indicators and horn function properly.

8. Engine stop switch - check for proper function (page 21).

Correct any discrepancy before you ride.

Contact your authorized Honda dealer for assistance if you cannot correct the problem.

STARTING THE ENGINE

Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas.

NOTE:

*

Do not use the electric starter for more than 5 seconds at a time. Release the starter button for approximately 10 seconds before pressing it again.

*

The electric starter will work when the transmission is in gear wi th the clu tch disengaged.

*

Do not flood the engine by twisting the throttle repeatedly.

The carburetors have an accelerator pump.

PREPARATION

Make sure the transmission is in neutral and the engine stop switch is at "RUN".

Turn the fuel valve "ON". Insert the key and turn the ignition switch "ON".

Check that the red oil pressure warning light comes on.

STARTING PROCEDURE

To restart a warm' engine, follow ·the procedure for "High Air Temperature"

Normal Air Temperature

I 0°-35°C (50° -95°F)

I. Pull the choke knob (I) up all the way to "Fully Closed" (A).

2. Start the engine, leaving the throttle closed.

(I) Choke knob

...

(A) Fully Closed

(B) Fully Open

33

CAUTION:

* The oil pressure warning light should go off a few seconds after the engine starts.

If the light stays on, stop the engine immediately and check engine oil level.

Do not operate the engine with insufficient oil pressure.

3. Immediately after the engine starts, operate the choke knob to keep fast idle at 1,500-2,500 rpm.

4. About a half minute after the engine starts, push the choke konb down all the way to "Fully Open" (B).

5.

If idling is unstable, open the throttle slightly.

High Air Temperature

35°C (95°F) or above

I. Do not use the choke.

2. Open the throttle slightly.

3. Start the engine.

Low Air Temperature

10°C (50°F) or below

1. Follow steps 1 and 2 under "Normal

Air Temperature".

2. When engine rpm begins to pick up, operate the ch.oke knob to keep fast idle at 2,500-3,500 rpm.

3. To speed warm up, open and close the th.rottle; keeping engine rpm below

3,500.

4. About 5 minutes after the engine starts, push the choke knob down all the way to "Fully Open" (B).

5. Continue warming up the engine by opening and closing the th.rottle until it will idle smoothly.

CAUTION:

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

34

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 "OFF" and push the choke knob down to Full Open (B).

Open the throttle fully and crank the engine with the electric starter for 5 seconds.

Turn the engine stop switch

"ON" and follow the High Air Temperature Starting Procedure.

BREAK-IN

During the first 600 miles (l,000 km), do not operate the motorcycle at more than

80% of the lower RED ZONE RPM limit in any gear. Avoid full throttle operation, and do not operate for a long time at one speed.

During initial break-in, newly machined surfaces will be in contact with each other and these surfaces will wear in quickly.

Break-in maintenance at 600 miles

(lOOOkm) is designed to compensate for this initial minor wear. Timely performance of the break-in maintenance will ensure optimum service life and performance from the engine.

NOTE: (USA ONLY)

After break-in maintenance, remove the

"BREAK-IN" caution label from the speedometer lens.

35

RIDING

* Review Motorcycle Safety (pages 1- 9) 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.

* Do not downshift when traveling at a speed that would force the engine to overrev in the next lower gear, or cause the rear wheel to lose traction.

Proper shifting will provide better fuel economy.

When changing gears under normal conditions, use the shifting points recommended by Honda as follows:

Shifting Up:

From 1st to 2nd 19 mph (30 km/h)

From 2nd to 3rd 25 mph (40 km/h)

From 3rd to 4th 31 mph (50 km/h)

From 4th to 5th 37 mph (60 km/h)

Shifting Down:

From 5th to 4th 25 mph (40 km/h)

From 4th to 3rd 19 mph (30 km/h)

Disengage the clutch when the speed drops below 9 mph (15 km/h), when engine roughness is evident, or when engine stalling is imminent; and shift down to 1st gear for acceleration.

36

Shifting pattern

CAUTION:

* Do not shift gears without disengaging the clutch and closing the throttle.

The engine and drive train could be damaged by overspeed and shock.

* 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 exceed 6,500 rpm when running the engine without a load.

Serious engine damage may result.

NOTE:

*

The battery will not charge while the engine speed is below 950 rpm. Avoid idling for prolonged periods, or continuous operation below 950 rpm.

37

BRAKING

I. For nonnal braking, gradually apply both front and rear brakes while downshifting to suit your road speed.

2. For maximum deceleration, close the throttle and apply the front and rear brakes firmly.

Disengage the clutch before the motorcycle stops.

1'lfd,!;i~iiHfi

* Indepenaent use of only the front or rear brake reduces stopping performance.

Extreme braking may cause either wheel to lock, reducing control of the motorcycle.

* When possible, reduce speed or brake before entering a turn. 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. For your safety, exercise extreme caution when braking, accelerating, or turning.

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

Continuous brake application can overheat the brakes and reduce their effectiveness.

38

PARKING

I.

After stopping the motorcycle, shift the transmission into neutral, turn the fuel valve "OFF" and tum the ignition switch "OFF".

2. Use the side or center stand to support the motorcycle while parked.

CAUTION:

Park the motorcycle on firm, level ground to prevent overturning.

3.

Lock the steering to help prevent theft

(page 23).

NOTE:

* When stopping for a short time near traffic at night, the ignition switch may be turned to "P" and the key removed.

This will tum on the taillight to make the motorcycle more visible to traffic.

The battery will discharge if the ignition switch is left at "P" for too long a time.

NAME:_

ADDRESS:

ANTI-THEFT TIPS

I. Always lock the steering and never leave the key in the ignition switch. This sounds simple but people do forget.

2. Be sure the registration information for your motorcycle is accurate and current.

3. Park your motorcycle in a locked garage whenever possible.

4. Use an additional anti-theft device of good quality.

5..

Put your name, address, and phone number in this Owner's Manual and keep it on your motorcycle at all times.

Many times stolen motorcycles are recovered by the Owner's Manual which is still on them.

PHONE NO.:_

39

- - - - - - - - SPECIAL PROCEDURES - - - - - - - - -

These special procedures are intended to help you out in case of trouble on the road: a flat tire, or a blown fuse. In case of a flat tire, you can remove the entire wheel and take it to a qualified repair facility. Refer to Tires on page S. Because of the critical nature of wheel attachment, you should proceed to an authorized Honda dealer as soon as possible after repair to verify proper assembly.

Stop the engine and support the motorcycle securely on a level surface before performing these procedures.

40

TOOL KIT

The tool kit (1) and air pressure gauge are stored in the top compartment. Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. The air pressure gauge can be used for checking tire pressure as well as front and rear suspension air pressure.

* Lever for screwdriver

*

8 x l2mm open end wrench

* lOx l2mm open end wrench

* lOx 14mm open end wrench

* Pliers

*

NO.2 screwdriver

*

No.2 phillips screwdriver

*

No.3 phillips screwdriver

*

Screwdriver grip

* Handlebar

*

Spark plug wrench

* l7mm wrench

* 19mm wrench

*

24 mm wrench and handle lever

* 6mm hex. wrench

* 8mm hex. wrench

* 10 x l2mm wrench

* Feeler gauge-O.l mm (0.003 in.),

0.35 mm (0.014

in.) and 0.7 mm

(0.028 in.)

* Tool bag

* Air pressure gauge

(1) Tool kit

41

FRONT WHEEL REMOVAL

1. Raise the front wheel off the ground by placing a support block under the engine.

2. Remove the speedometer cable set screw (1) and disconnect the speedometer cable (2).

3. Remove either caliper assembly by loosening tb.e caliper bolts (3).

CAUTION:

Support the caliper assembly so that it does not hang from the brake hose. Do not twist the brake hose.

4. Remove the front axle holder nuts (4) and axle holders (5).

5. Remove the wheel.

(4) Axle holder nu ts

(5) Axle holders

NOTE:

*

Do not depress the brake lever when the wheel is off the motorcycle. The caliper piston will be forced out of the cylinder with subsequent loss of brake fluid.

If this occurs, servicing of the brake system will be necessary.

See your authorized Honda dealer.

Installa tion

1.

Lower the forks lightly so that the hollows in the fork legs rest on top of the axle.

CAUTION:

When installing the wheel, fit the brake disc (7) carefully between the brake pads to avoid damaging the pads.

2. Install the axle holders (5) with the

"F" arrow forward and hand tighten the holder nuts (4) with flat washers and lockwasher. Make sure the speedometer cable gear box is horizontal.

3. Fit the brake caliper over the disc, install the caliper bolts (3), and tighten them to 3-4 kg-m (22-29 ft-Ibs) torque.

4. Tighten the axle holder nuts (4) on the left axle holder (speedometer gearbox side) to 3-4 kg-m (22-29 ft-Ibs) torque, starting with the forward nuts.

5. Measure the clearance between the outside surface of the brake disc (7) and the rear of the caliper holder (6) with a

0.7mm

(0.028

in.) feeler gauge.

If

~

,

(6) Caliper holder

(7) Disc

43

the gauge inserts easily, tighten the nuts on the right axle holder to 3-4 kg-m

(2229 ft-lbs) starting with the forward nuts.

6. If the feeler gauge cannot be inserted easily, move the fork leg outward until the gauge can be inserted and tighten the holder nuts (4) with the gauge inserted. After tightening, remove the gauge.

7. Check that the other three corners of the caliper holder (6) have a clearance of at least 0.7mm (0.028 in.) between caliper holder and disc.

8. After installing the wheel, apply the brakes several times and check for free wheel rotation when released.

* Failure to provide adequate disc to caliper holder clearance may damage the brake discs and impair braking efficiency.

*

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

(8) Feeler gauge

44

REAR WHEEL REMOVAL

1. Place the motorcycle on its center stand.

2. Support the rear wheel so it will not dTop when the shock absorbers are disconnected.

3. Remove the lower shock absorber bolts ( I).

4. Raise rear wheel so the axle will clear the muffler when removed.

5. Remove the cotter pin (2) from the axle and remove the axle nut (3).

~ r

6. Remove the axle holding bolt (4).

7. Pull out the rear axle (5).

CAUTION:

* Support the caliper assembly and swingarm before removing the rear axle so that it does not hang from the brake hose. Do not twist the brake hose.

(l)

----.........--_

.....

Lower shock absorber bolt

(2) Cotter pin (3) Axle nut

.

~

(4) Axle holding bolt (5) Axle

45

8. Move the wheel to the left side to separate it from the final drive gear case.

9. Remove the wheel.

NOTE:

*

Do not depress the brake pedal while the wheel is off the motorcycle. The caliper piston will be forced out of the cylinder with subsequent loss of brake fluid.

If this occurs, servicing of the brake system will be necessary.

See your authorized Honda dealer.

Installation

Reverse the removal procedure. Be sure the splines on the wheel hub fit into the final drive case.

NOTE:

Tighten the axle nut to 8.0-10.0

kg-m

(58-72 ft-Ibs) torque. Tighten the shock absorber bolts (I) to 3.0-4.0

kg-m (22-

29 ft-Ibs) torque. Tighten the axle holding bolt (2) to 2.4-2.9

kg-m (17-21 ft-lbs) torque.

CAUTION:

* When installing the wheel, fit the brake disc between the brake pads carefully.

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

46

CAUTION:

* Always replace used cotter pins with new ones.

1?f,?,!;i~ii:rtJ

*

If a torque wrench was not used for installation. see your dealer as soon as possible to verify proper assembly.

47

FUSE REPLACEMENT

The fuse box (l) is located in the top compartment.

Open the top compartment cover and remove the tool tray for access to fuses. Spare fuses are loacted in the fuse box.

The specified fuses are SA, lOA, and lSA.

Always make sure the new fuse is the same as the old one. When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system.

See your authorized Honda dealer for repair. The main fuse (3), located near the battery on the positive lead, is 30A.

1 1 4 14

.1;1

~iiU£i

* Never use a fuse with a different rating from that specified. Serious damage to the electrical system ora fire may result, causing a dangerous loss of lights or engine power at night or in traffic.

CAUTION:

Turn the ignition switch "OFF" before checking or replacing fuses to prevent accidental short-circuiting.

48

(1) Fuse box (2) Spare fuse (3) Main fuse (4) Spare main fuse

MAINTENANCE - - - - - - - - - -

• The U.S. Environmental Protection Agency requires manufacturers to certify that motorcycles built after December 31, 1977 will comply with applicable emissions standards during their useful life, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Warranty for

Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect (USA ONLY) .

• When service is required, remember that your authorized Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it.

The scheduled maintenance may also be performed by a qualified service facility that normally does this kind of work; or you may perform most of the work yourself if you are mechanically qualified and have the proper tools and service data.

• These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions will require more frequent service than specified in the MAINTENANCE SCHEDULE. Consult your authorized Honda dealer for recomendations applicable to your individual needs and use.

49

* If your motorcycle is overturned or involved in a collision, inspect control levers, cables, brake hoses, calipers, accessories, and other vital parts for damage. Do not ride the motorcycle if damage impairs safe operation.

Have your Honda dealer inspect the major components including frame, suspension and steering parts for misalignment and damage that you may not be able to detect.

* Stop the engine and support the motorcycle securely on a level surface before performing any maintenance.

* Use new, genuine Honda parts or their equivalent for maintenance and repair.

Parts which are not of equivalent quality may impair the safety of your motorcycle and the effective operation of the emission control systems.

The Vehicle Emission Control Information label (I) is attached to the right lower frame member. (U.S.A. ONLY)

(1) Vehicle Emission Control Information Label

50

MAINTENANCE SCHEDULE

Perfonn Pre-ride Inspection (Page 32) at each scheduled maintenance period.

I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.

C: Clean R: Replace A: Adjust L: Lubricate

~

'"

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* FUEL LINES

* FUEL FILTER

* THROTTLE OPERATION

*

CARBURETOR-CHOKE

AIR CLEANER

Q

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~

...:I

>'-l

~

CRANKCASE BREATHER

SPARK PLUGS

'" VALVE CLEARANCE

ENGINE OIL

ENGINE OIL FILTER

Z o * CARBURETOR-SYNCHRONIZE

;;:; *

CARBURETOR-IDLE SPEED

:g

RADIATOR COOLANT

>'-l

*

RADIATOR CORE

* HOSES & CONNECTIONS

OF COOLING SYSTEM

WHICHEVER

COMES

FIRST

...

EVERY

+1 ODOMETER READING [NOTE (3)]

....

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R R R Page

C C C C C C Page

R R R R R R Page

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58

59

56

R Pages 54-55

R Page 55

I

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57

30-31

I I I I

51

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* DRIVE SHAFT JOINT

FINAL DRIVE LUBRICANT

BATTERY

0

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BRAKE FLUID

BRAKE PAD WEAR

BRAKE SYSTEM

~

* BRAKE LIGHT SWITCH

Z * HEADLIGHT AIM

0

Vi en

CLUTCH

SIDE STAND

~

* SUSPENSION

Z

* NUTS, BOLTS, FASTENERS

~

** WHEELS

** STEERING HEAD BEARING

WHICHEVER

COMES

FIRST

+

EVERY

MONTH

MONTH I

2 YEARS*R

I

+ ODOMETER READING [NOTE (3)]

....&

~~~~r ~,

Refer to

L L L

I

I I I I

I

I

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I Pages 66-67

I I I I I I *R Pages 62-63

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I I I

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I

Page 64

I I Pages 59-61

I Page 65

I

* Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the official HONDA shop manual.

** In the interest of safety, we recommend these items be serviced ONLY by an authorized HONDA dealer.

NOTES: (I) Service more frequently when riding in dusty areas.

(2) Service more frequently when riding in rain or at full throttle (USA ONLY).

(3) For higher odometer readings, repeat at the frequency interval established here.

I 52

MAINTENANCE RECORD

Miles

600

Performed by

4,000

8,000

12,000

16,000

20,000

Odometer Date

24,000

• Make sure that whoever performs the maintenance completes this record.

All scheduled maintenance, including the 600 mile break-in maintenance, is considered a normal owner operating cost and will be charged for by your dealer.

• Detailed receipts verifying the performance of required maintenance should be retained. These receipts should be transferred with the motorcycle to the new owner if the motorcycle is sold.

53

ENGINE OIL

Engine oil quality is the chief factor affecting engine service life. Change the engine' oil when specified by the maintenance schedule.

NOTE:

*

Change engine oil with the engine warm and the motorcycle on its center stand to assure complete and rapid draining.

1. To drain the oil, remove the oil filler cap (I), drain plug (2), oil filter bolt

(3) and cover (4).

2. Check that the sealing washer on the drain plug is in good condition, and install the plug.

3. Check that the oil filter bolt and cover a-rings are in good condition, and install the cover, aligning recess in the filter cover with boss on the water pump cover.

54

(l )

,

Oil filler cap (2) Drain plug

(3) Oil filter bolt

4.

Fill the crankcase with approximately

3.2

liters (3.4

U.S. quarts) of the recommended grade oil and install the oil filler cap.

Start the engine and let it idle for a S.

few minutes.

6. Stop the engine. Make sure the oil level is at the upper level mark and there are no oil leaks.

NOTE:

When running in very dusty conditions, oil changes should be performed more frequently than specified. in the maintenance schedule.

2. Insert a new oil filter element. Check that the O-rings are in good condition and that all parts are installed as shown.

3.

Install the oil filter cover and tighten the oil filter bolt.

Oil Filter Bolt Torque:

2.7-3.3

kg-m (20-24 ft-lb)

4. Perform steps 4 to 6 of Engine Oil

Change.

OIL FILTER

NOTE:

*

Change the oil filter after draining engine oil.

I. Remove the oil filter bolt, and pull the oil filter elemen't (I) out of the oil filter cover.

(I) Filter element (2) O-rings

55

SPARK PLUGS

Recommended plugs:

USA model

Standard:

X24ES-U (ND) or D8EA (NGK)

For cpld-climate: (Below SoC, 41°F)

X22ES-U (ND) or D7EA (NGK)

For extended high speed driving:

X27ES:U (ND) or D9EA (NGK)

Canadian model

Standard:

X24ESR-U (ND) or DR8ES-L (NGK)

For cold climate: (Below SoC, 41°F)

X22ESR-U (ND) or DR7ES (NGK)

For extended high speed driving:

X27ESR-U (ND) or DR8ES (NGK)

1. Clean any dirt from around the spark plug base.

2. Disconnect the spark plug caps.

Remove and discard the spark plugs.

3. Make sure the new spark plug gap (1) is 0.6-0.7 mm (0.024-0.028 in) using a wire type feeler gauge.

If adjustment is necessary, bend the side electrode (2)

56 carefully.

4. With the plug washers attached, thread the new spark plugs in by hand to prevent crossthreading.

S. Tighten the spark plugs 1/2 tum with a spark plug wench to compress the washer.

6. Reinstall the spark plug caps.

CAUTION:

* The spark plug must be securely tightened. An improperly tightened plug can become very hot and possibly damage the engine.

*

Never use a spark plug with an improper heat range.

---CD

1

(1)

I

Spark plug gap (2) Side electrode

IDLE SPEED

The idle speed adjustment procedure given here should only be used when changes in altitude affect normal idle speed at set by your dealer. See your authorized Honda dealer for regularly scheduled carburetor adjustments, including individual carburetor adjustment and synchronization.

NOTE:

*

The engine must be warm for accurate idle speed adjustment. Ten minutes of stop-and-go riding is sufficient.

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

2. Adjust idle speed with the throttle stop screw.

Idle Speed: 950 ± 100 rpm

(In neutral)

(1) Throttle stop screw (A) Increase

(B) Decrease

57

AIR CLEANER

The air cleaner should be serviced at regular intervals (page 51). When riding in dusty areas, more frequent service may be necessary.

1. Open the top compartment. Remove the tool tray.

2. Remove the wing nut (1) and air cleaner cover (2).

3. Remove and discard the air cleaner element (3).

4. Insert a new air cleaner element.

S. Install removed parts in the reverse order of removal.

58

(l)Wing nut (2) Air Cleaner cover (3) Air cleaner element

CRANKCASE BREATHER

(U.S.A. ONLY)

1. Loosen the lower clamp of the transparent tube. Remove the storage tank mounting bolt and the storage tank.

2. Empty the deposits.

3. Install the tank.

NOTE:

* Service more frequently when ridden in rain or at full throttle, or service if the deposit level can be seen in the transparent section of the drain tube.

CLUTCH

Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep; or if the clutch slips, causing acceleration to lag behind engine speed.

Normal clutch lever free play is 5~15mm

(l /4-1 /2 in) at the lever.

1. Loosen the lock nut (2) and turn the clutch cable adjuster (3). Tighten the lock nut (2), and check adjustment.

5-15mm

(114-112 in)

~

(1) Storage tank (l) Cl utch lever

59

2.

If the correct free play cannot be obtained using the cable adjuster (3), loosen the lock nut (2) and turn the cable adjuster in all the way. Tighten the lock nut.

3. At the lower end of the cable, loosen the lock nut (4), and turn the cable adjuster (5) to give about 16 mm (5/8 in) free play at the clutch lever, and tighten the lock nut.

4. Make the final free play adjustment at the clut.ch hand lever.

5. Start the engine pull in the clutch lever and shift into gear. Make sure that the engine does not stall, and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. The motorcycle should start smoothly and accelerate gradually.

NOTE:

*

If proper adjustment cannot be obtained or the clutch does not work correctly, see your authorized Honda dealer.

(2) Lock nut

60

(3) Clutch cable adjuster (4) Lock nut (5) Clutch cable adjuster

Other Checks:

Check the clutch cable for kinks or signs of wear that could cause sticking or failure.

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

61

BRAKES

Both front and rear brakes are of the hydraulic disc type.

As the brake 'pads wear, brake fluid level drops, automatically compensating for wear.

There are no adjustments to perform, but fluid level and pad wear· must be inspected periodically. The syst,em must be inspected frequently to ensure there are no fluid leaks.

NOTE:

* If the brake lever or pedal travel become excessive and the friction pads are not worn beyond the recommended limit (page 64), there is probably air in the brake system and it must be bled.

See your authorized Honda dealer.

r?tNj;j~iiH?i

.

* Brake fluid may cause irritation. A void contact with skin or eyes.

/11 case of contact, flush thoroughly with water and call a doctor if your eyes were exposed.

.

62

Front Brake Fluid Level:

Remove the reservoir cap and diaphragm.

Whenever the level is lower than the lower level mark (2) on the front reservoir fill the reservoiT with DOT 3 BRAKE

FLUID from a sealed container, up to the upper level mark (I).

Reinstall the diaphragm, and the reservoir cap. Tighten the screws securely.

CAUTION:

* When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out.

(FRONT) (l) Upper level mark

(2) Lower level mark

* Use only DOT 3 brake fluid from a sealed container.

* Handle brake fluid with care because it can damage paint and plastics as used for instrument lenses and fairings.

* Never aI/ow contaminants (dirt, water, etc.) to enter the brake fluid reservoir.

Rear Brake Fluid Level:

Remove the reservoir cap, washer and diaphragm.

Whenever the level is lower than the lower level mark (4) on the rear reservoir, fill the reservoir with DOT 3

BRAKE FLUID from a sealed contaIner, up to the upper level mark (3). Re.install

the diaphragm and washer, and tighten the reservoir cap securely.

CAUTION:

* Use only DOT 3 brake fluid from a sealed container.

* Handle brake fluid with care because it can damage paint and electric wires.

* Never aI/ow contaminants (dirt, water, etc.) to enter the brake fluid reservoir.

(REAR) (3) Upper level mark

(4) Lower level mark

63

Brake Pad Wear

Brake pad wear will depend upon the severity of usage, type of driving, and condition of the roads. The pads will wear faster on dirty and wet roads. Inspect the pads visually during all regular service intervals to determine the pad wear.

Remove the inspection window cap (1).

If either pad is worn to the red line (2), both pads must be replaced.

Other Checks:

Make sure that there are no fluid leaks.

Check for deterioration and cracks of the hoses and fittings.

FRONT (1) Inspection window cap

(2) Red line

64

REAR (1) Inspection window cap

(2) Red line

SIDE STAND

Check the rubber pad for deterioration and wear.

It must be replaced if any wear extends to the wear line (1) as shown.

Check the side stand spring for damage and loss of tension; and check the side stand assembly for freedom of movement.

See your authorized Honda dealer for replacement.

o

(l)Wear line x

65

BATTERY

If the motorcycle is operated with insufficient battery electrolyte, sulfation c;lnd battery plate damage will occur.

If rapid loss of electrolyte is experienced, or if your battery seems to be weak, causing slow starting or other electrical problems, see your authorized Honda deaier.

Battery Electrolyte

The battery (l) is under the seat. Remove the left side cover to check the battery electrolyte.

The electrolyte level must be maintained between the upper (3) and lower (4) level marks on the side of the battery.

If the electolyte level is low, remove the filler caps (2). Carefully add distilled water to upper level mark, using a small syringe or plastic funnel.

NOTE:

*

Use only distilled water in the battery.

Tap water will shorten the service life of the battery.

(1) Battery

(2) Filler caps

(3) Upper level mark

(4) Lower level mark

66

l

The battery contains suI/uric acid. A void contact with skin, eyes or clothing. Antidote: EXTERNAL-Flush with water

INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. Eyes: Flush with water and get prompt medical attention. Batteries produce explosive gases.

Keep sparks, flame, cigarettes away.

Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

CAUTION:

The battery breather tube must be routed as shown on the label. Do not bend or twist the breather tube. A bent or kinked breather tube may pressurize the battery and damage its case.

CAUTION

67

C L E A N I N G - - - - - - - -

Clean your motorcycle regularly to protect the surface finishes and inspect for damage, wear, and oil or hydraulic fluid seepage.

CAUTION:

A void spraying high pressure water (typical in coin-operated car washes) at the following areas:

Brake master cylinders

Radiator fins

Wheel hubs

Muffler outlets

Top compartment

Under seat

Ignition switch

Steering lock

Handlebar switches

L After cleaning, rinse the motorcycle thoroughly with plenty of clean water.

Strong detergent residue can corrode alloy parts.

2. Dry the motorcycle, start the engine, and let it run for several minutes.

68

Braking performance may be impaired immediately after washing the motorcycle.

3. Test the brakes before riding the motorcycle in traffic.

Several applications may be necessary to restore normal braking performance.

S T O R A G E - - - - - - - -

Storage for more than a month, or winter storage requires maintenance to prevent corrosion and deterioration of the fuel tank, tires, and battery. See your authorized Honda dealer for this service.

-----EMISSION

CONTROL SYSTEM

(U.S.A. O N L Y ) - - - - -

• Sources of Emissions

The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons 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 lean carburetor settings and other systems to reduce carbon monoxide and hydrocarbons.

• Exhaust Emission Control System

The exhaust emission control system is composed of lean carburetor settings, and no adjustments should be made except idle speed adjustment with the throttle stop screw.

The exhaust emission control system is separate from the crankcase emission control system.

69

J

• Crankcase Emission Control System

The engine is equipped with a closed crankcase system to prevent discharging crankcase vapors into the atmosphere.

Blow-by gas is returned to the combustion chambers through the air cleaner and carburetors.

<:=

Fresh Air

_ Blow-by Gas

70

• Problems which may affect Motorcycle Emissions

If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your local Honda Motorcycle Dealer.

Symptoms:

I. Hard starting or stalling after starting

2. Rough idle

3. Misfiring or backfiring during accelera tion

4. After-burning (backfiring)

5. Poor performance (driveability) and poor fuel economy

71

I

CONSUMER INFORMATION

I

VEHICLE STOPPING DISTANCE

This figure indicates braking performance that can be met or exceeded by the vehicles to which it applies without locking the wheels under different conditions of loading.

The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions.

Description of vehicles to which this table applies: HONDA GL 1100

Fully Operational Service Brake

Load

Light

Maximum a

50 100 150

Stopping Distance in Feet from 60mph.

200

73

74

ACCELERATION AND PASSING ABILITY

This figure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, in the situations diagrammed on the next page.

The low-speed pass assumes an initial speed of 20 MPH and a limiting speed of 35 MPH. The high-speed pass assumes an initial speed of 50 MPH and a limiting speed of 80 MPH.

NOTICE: The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions.

Description of vehicles to which this table applies: HONDA GL 1100

SUMMARY TABLE:

Low-speed pass

...... 354 Feet; 7.2 Seconds

High-speed pass

...... 901 Feet; 8.7 Seconds

LOW-SPEED

INITIAL SPEED: 20MPH LIMITING SPEED: 35MPH

" TOTAL PASSING DISTANCE, F E E T - I

TOTAL PASSI NG TI ME, SECONDS

.1 .

-=+-----------_._-----------~

~

CJ[J--------------DID

55' CONSTANT 20MPH

~

TRUCK

HIGH- SPEED

INITIAL SPEED: 50MPH

" TOTAL PASSING DISTANCE, FEET

LIMITING SPEED: 80MPH

"

TOTAL PASSING TIME, SECONDS

/

~--------------------------------~

j-1oo'--l 1-100'--1

I

~-COOS~m5~PH--~

55

TRUCK

75

- - - - - - - - - SPECIFICATIONS - - - - - - - - -

ITEM

DIMENSIONS

Overall length

Overall wid th

Overall height

Wheel base

Ground clearance

WEIGHT

Dry weight

CAPACITIES

Engine oil

Final drive gear oil

Fuel tank

Fuel reserve

Cooling system capacity

Passenger capacity

Vehcile capacity load limit

2,345 mm (92.3 in)

920 mm (36.2 in)

1,195 mm (47.0 in)

1,605 mm (63.2 in)

145 mm (5.7 in)

267 kg (589 lbs)

3.2 liter (3.4 US qt, 2.8 Imp qt) after draining

150 cc (5.9 oz)

20 liter (5.3 US gal, 4.4 Imp gal)

4 liter (1.1

US gal, 0.9 Imp gal)

3.4 liter (3.6 US qt, 3.0 Imp qt)

Operator and one passenger

210 kg (465Ibs)

76

ITEM

ENGINE

Bore and stroke 75.0 x 61.4 mm (2.95 x 2.42 in)

Spark plug

Compression ratio

Displacement

9.2 : 1

1,085 cc (66.2 cu-in) --

USA model Canadian model

Standard X24ES-U (ND) or

D8EA (NGK)

X24ESR-U (ND) or

DR8ES-L (NGK)

For cold climate

(Below SaC, 41 of)

X22ES-U (ND) or

D7EA (NGK)

X22ESR-U (ND) or

DR7ES (NGK)

For extended high speed riding

Spark plug gap

Valve clearance (cold)

X27ES-U (ND) or

D9EA (NGK)

X27ESR-U (ND) or

DR8ES (NGK)

0.6-0.7 mm (0.024-0.028 in)

Intake 0.10 mm (0.004 in)

Exhaust 0.13 mm (0.005 in)

950 ± 100 rpm Idle speed

77

ITEM

CHASSIS AND SUSPENSION

Caster

Trail

Tire size, front

Tire size, rear

POWER TRANSMISSION

Primary reduction

Secondary reduction

Gear ratio, 1st

2nd

3rd

4th

5th

Final reduction

ELECTRICAL

Battery

Generator

FUSE

60°50'

134 mm (5.3 in)

110/90-1962H

130/90-17 68H

1.708

0.973

2.500

1.667

1.286

1.065

0.909

3.091

12V-20AH

A.C. generator 0.3 kW/5,000 rpm

SA, lOA and 15A

30A (Main fuse)

ITEM

LIGHTS

Headlight

Tail/stoplight

Turn signal light

Meter lights

Neutral indicator light

Turn signal indicator light

High beam indicator light

Oil pressure warning light

H4 BULB (Philips 12342/99, or equivalent) l2V-3/32cpNO.1157

l2V-32 cp NO.:

FRONT 1034

REAR 1073 l2V-2 cp NO. 57 l2V-2 cp NO. 57 l2V-2 cp NO. 57 l2V-2 cp NO. 57 l2V-2 cp NO. 57

79

, . . - - - - - - - - OWNER SATISFACTION - - - - - - - - - - - - - ,

Your satisfaction and goodwill are important to your dealer and to us. Normally, any problems with the operation of your vehicle will be handled by your dealer's Service Department. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur. If your problem has not been handled to your satisfaction, we suggest you take the following action:

*

Discuss your problem with a member of dealership management. Often complaints can be quickly resolved at that level. If the problem has already been reviewed with the Service

Manager, contact the owner of the dealership or the General Manager.

*

If your problem still has not been resolved to your satisfaction, contact the Motorcycle

Customer Service Department, AMERICAN HONDA MOTOR CO., INC. 100 West Alondra

Boulevard, Gardena, California 90247 (213) 327-8280, and provide them with:

Your name, address and telephone number

Vehicle frame number

Dealer's name and location

Vehicle delivery date and present mileage

Nature of problem

After reviewing all the facts involved, you will be advised of what action can be taken.

Please bear in mind that your problem will likely be resolved in the dealership, using the dealer's facilities, equipment and personnel. So it is very important that your initial contact be with the dealer.

Your purchase of a Honda product is greatly appreciated by both your dealer and American

Honda Motor Co., Inc. We want to assist you in every way possible to assure your complete satisfaction with your purchase.