This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. The vehicle pictured in this owner’s manual may not match your actual vehicle. © 2010 Honda Motor Co., Ltd. 32MFM630.indb 2 2010/12/14 15:43:47 Welcome Congratulations on your purchase of a new Honda motorcycle. Your selection of a Honda makes you part of a worldwide family of satisfied customers who appreciate Honda’s reputation for building quality into every product. To ensure your safety and riding pleasure: Read this owner’s manual carefully. ● Follow all recommendations and procedures contained in this manual. ● Pay close attention to safety messages contained in this manual and on the motorcycle. ● 32MFM630.indb 3 The following codes in this manual indicate each country. ● The illustrations here in are based on the CB400A type. Country Codes Code Country CB400 U, II U, V U, VI U Australia SI, II SI Singapore ● CB400A U, II U II SI Australia Singapore * The specifications may vary with each locale. 2010/12/14 15:43:47 A Few Words About Safety Your safety, and the safety of others, is very important. 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 safety 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 judgement. You will find important safety information in a variety of forms, including: ● Safety labels on the motorcycle. ● Safety Messages preceded by a safety alert symbol and one of three signal words: DANGER, WARNING, or CAUTION. These signal words mean: 32MFM630.indb 4 DANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. WARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. CAUTION You CAN be HURT if you don’t follow instructions. Other important information is provided under the following titles: NOTICE Information to help you avoid damage to your motorcycle, other property, or the environment. 2010/12/14 15:43:47 Contents 32MFM630.indb 1 Motorcycle Safety P. 2 Operation Guide P. 12 Maintenance P. 29 Troubleshooting P. 72 Information P. 94 Specifications P. 106 Index P. 109 2010/12/14 15:43:47 Motorcycle Safety This section contains important information for safe riding of your motorcycle. Please read this section carefully. Safety Guidelines ........................................................... P.3 Safety Precautions......................................................... P.6 Riding Precautions......................................................... P.7 Accessories & Modifications ................................ P.10 Loading................................................................................. P.11 32MFM630.indb 2 2010/12/14 15:43:48 Safety Guidelines Follow these guidelines to enhance your safety: ● Perform all routine and regular inspections specified in this manual. ● Stop the engine and keep sparks and flame away before filling the fuel tank. ● Do not run the engine in enclosed or partly enclosed areas. Carbon monoxide in exhaust gases is toxic and can kill you. Always Wear a Helmet It’s a proven fact: helmets and protective apparel significantly reduce the number and severity of head and other injuries. So always wear an approved motorcycle helmet and protective apparel. P.6 Before Riding Make sure that you are physically fit, mentally focused and free of alcohol and drugs. Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel. Instruct your passenger on holding onto the seat strap or your waist, leaning with you in turns, and keeping their feet on the footpegs, even when the motorcycle is stopped. Motorcycle Safety Safety Guidelines Take Time to Learn & Practice Even if you have ridden other motorcycles, practice riding in a safe area to become familiar with how this motorcycle works and handles, and to become accustomed to the motorcycle’s size and weight. Ride Defensively Always pay attention to other vehicles around you, and do not assume that other drivers see you. Be prepared to stop quickly or perform an evasive maneuver. 3 32MFM630.indb 3 2010/12/14 15:43:49 Safety Guidelines Motorcycle Safety Make Yourself Easy to See Make yourself more visible, especially at night, by wearing bright reflective clothing, positioning yourself so other drivers can see you, signaling before turning or changing lanes, and using your horn when necessary. Ride within Your Limits Never ride beyond your personal abilities or faster than conditions warrant. Fatigue and inattention can impair your ability to use good judgement and ride safely. Don’t Drink and Ride Alcohol and riding don’t mix. Even one alcoholic drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. Don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your motorcycle properly maintained and in safe riding condition. Inspect your motorcycle before every ride and perform all recommended maintenance. Never exceed load limits ( P.11), and do not modify your motorcycle or install accessories that would make your motorcycle unsafe ( P.10). If You are Involved in a Crash Personal safety is your first priority. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. Call for emergency assistance if needed. Also follow applicable laws and regulations if another person or vehicle is involved in the crash. If you decide to continue riding, first evaluate the condition of your motorcycle. If the engine is still running, turn it off. Inspect for fluid 4 32MFM630.indb 4 2010/12/14 15:43:49 Safety Guidelines Carbon Monoxide Hazard WARNING Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. Avoid any areas or activities that expose you to carbon monoxide. Motorcycle Safety leaks, check the tightness of critical nuts and bolts, and check the handlebar, control levers, brakes, and wheels. Ride slowly and cautiously. Your motorcycle may have suffered damage that is not immediately apparent. Have your motorcycle thoroughly checked at a qualified service facility as soon as possible. Exhaust contains poisonous carbon monoxide, a colourless, odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death. If you run the engine in a confined or even partly enclosed area, the air you breathe could contain a dangerous amount of carbon monoxide. Never run your motorcycle inside a garage or other enclosure. 5 32MFM630.indb 5 2010/12/14 15:43:49 Safety Precautions Motorcycle Safety Safety Precautions Ride cautiously and keep your hands on the handlebars and feet on the footpegs. ● Keep passenger’s hands onto the grab rail, passenger’s feet on the footpegs while riding. ● Always consider the safety of your passenger, as well as other drivers and riders. ● Face shield with unobstructed field of vision or other approved eye protection. ● Protective Apparel Make sure that you and any passenger are wearing an approved motorcycle helmet, eye protection, and high-visibility protective clothing. Ride defensively in response to weather and road conditions. ❙ Helmet Safety-standard certified, high-visibility, correct size for your head ● Must fit comfortably but securely, with the chin strap fastened. WARNING Not wearing a helmet increases the chance of serious injury or death in a crash. Make sure that you and any passenger always wear an approved helmet and protective apparel. ❙ Gloves Full-finger leather gloves with high abrasion resistance ❙ Boots or Riding Shoes Sturdy boots with non-slip soles and ankle protection ❙ Jacket and Pants Protective, highly visible, long-sleeved jacket and durable trousers for riding (or a protective suit). 6 32MFM630.indb 6 2010/12/14 15:43:49 Riding Precautions Running-in Period During the first 500 km (300 miles) of running, follow these guidelines to ensure your motorcycle’s future reliability and performance. ● Avoid full-throttle starts and rapid acceleration. ● Avoid hard braking. ● Ride conservatively. Brakes Observe the following guidelines: ● Avoid excessively hard braking and sudden shifting to a lower gear. a Sudden braking can reduce the motorcycle’s stability. a Where possible, reduce speed before turning; otherwise you risk wheel slippage. ● Exercise caution on low traction surfaces. a The wheels lock more easily on such surfaces, and braking distances are longer. ● Avoid continuous braking. a Repeated braking can overheat the brakes, reducing their effectiveness. Motorcycle Safety Riding Precautions 7 32MFM630.indb 7 2010/12/14 15:43:50 Riding Precautions Motorcycle Safety ❙ Combined ABS (CB400A) ❙ Engine Braking Your motorcycle is equipped with a brake system that distributes the braking force between the front and rear brakes. The distribution of the braking force applied to the front and rear brakes is different when operating the lever only and when operating the pedal only. For full braking effectiveness, operate both the lever and pedal together. Engine braking helps slow your motorcycle down when you release the throttle. For further slowing action, downshift to a lower gear. Use engine braking with intermittent use of the brakes to reduce speed when descending long, steep slopes. This model is also equipped with an Anti-lock Brake System (ABS) designed to help prevent the brakes from locking up during hard braking. Always use the recommended tyres to ensure correct ABS operation. ● ABS does not reduce braking distance. In certain circumstances, ABS may result in a longer stopping distance. ● ABS does not function at speeds below 10 km/h (6 mph). ● The brake lever and pedal may recoil slightly when applying the brakes. This is normal. ❙ Wet or Rainy Conditions Road surfaces are slippery when wet, and wet brakes further reduce braking efficiency. Exercise extra caution when braking in wet conditions. If the brakes get wet, apply the brakes while riding at low speed to help them dry. 8 32MFM630.indb 8 2010/12/14 15:43:50 Riding Precautions Park on a firm, level paved surface. If you must park on a slight incline or loose surface, park so that the motorcycle cannot move or fall over. ● Make sure that high-temperature parts cannot come into contact with flammable materials. ● Do not touch the engine, muffler, brakes and other high-temperature parts until they cool down. ● To reduce the likelihood of theft, always lock the handlebars and remove the key when leaving the motorcycle unattended. Use of an anti-theft device is also recommended. ● ● ❙ Parking with the Side Stand 4. Turn the handlebars fully to the left. a Turning the handlebars to the right reduces stability and may cause the motorcycle to fall. 5. Turn the ignition switch to the LOCK position and remove the key. P.21 Refuelling and Fuel Guidelines Motorcycle Safety Parking Follow these guidelines to protect the engine and catalytic converter: ● Use only unleaded petrol. ● Use recommended octane number. Using lower octane petrol will result in decreased engine performance. ● Do not use fuels containing a high concentration of alcohol. P.98 ● Do not use stale or contaminated petrol or an oil/petrol mixture. ● Avoid getting dirt or water in the fuel tank. 1. Stop the engine. 2. Push the side stand down. 3. Slowly lean the motorcycle to the left until its weight rests on the side stand. 9 32MFM630.indb 9 2010/12/14 15:43:50 Accessories & Modifications Motorcycle Safety Accessories & Modifications We strongly advise that you do not add any accessories that were not specifically designed for your motorcycle by Honda or make modifications to your motorcycle from its original design. Doing so can make it unsafe. Modifying your motorcycle may also void your warranty and make your motorcycle illegal to operate on public roads and highways. Before deciding to install accessories on your motorcycle be certain the modification is safe and legal. WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding accessories and modifications. Do not pull a trailer with, or attach a sidecar to, your motorcycle. Your motorcycle was not designed for these attachments, and their use can seriously impair your motorcycle’s handling. 10 32MFM630.indb 10 2010/12/14 15:43:50 Loading Carrying extra weight affects your motorcycle’s handling, braking and stability. Always ride at a safe speed for the load you are carrying. ● Avoid carrying an excessive load and keep within specified load limits. Maximum weight capacity P.106 ● Tie all luggage securely, evenly balanced and close to the centre of the motorcycle. ● Do not place objects near the lights or the muffler. ● WARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed. Follow all load limits and other loading guidelines in this manual. Motorcycle Safety Loading 11 32MFM630.indb 11 2010/12/14 15:43:50 Parts Location Operation Guide Rear suspension spring preload adjuster Coolant reserve tank P.70 P.53 Front brake fluid reservoir Front brake lever P.55 P.68 Front suspension spring preload adjuster P.69 Throttle grip P.66 Engine oil fill cap P.49 Engine oil filter P.51 Engine oil level inspection window P.49 Right side cover Rear brake fluid reservoir P.46 P.72 12 32MFM630.indb 12 2010/12/14 15:43:51 Front suspension spring preload adjuster P.63 Fuel fill cap Battery Seat Fuse box (CB400A) P.24 P.47 P.45 P.91 Operation Guide Clutch lever P.69 Left side cover P.46 Rear suspension spring preload adjuster P.70 Fuse box Main fuse FI fuse Drive chain Shift lever Side stand Engine oil drain bolt P.51 Crankcase breather P.90 P.92 P.73 P.59 P.23 P.58 P.67 13 32MFM630.indb 13 2010/12/14 15:43:52 Instruments Speedometer Operation Guide Tachometer NOTICE Do not operate the engine in the tachometer red zone. Excessive engine speed can adversely affect engine life. Tachometer red zone (excessive engine rpm range) A button B button 14 32MFM630.indb 14 2010/12/14 15:43:52 Operation Guide Odometer [ODO] & Tripmeter [TRIP 1/2] A button switches between odometer & tripmeters. • Odometer: Total distance ridden. • Tripmeter: Distance ridden since tripmeter was reset (press and hold A button to reset to 0.0 km). Display Check When the ignition switch is turned ON, all the mode and digital segments will show. If any part of these displays does not come on when it should, have your dealer check for problems. continued 15 32MFM630.indb 15 2010/12/14 15:43:53 Instruments (Continued) Clock (12-hour display) Operation Guide Fuel gauge Remaining fuel when the display lights as shown in the illustration: approximately 4.0 litres (1.06 US gal, 0.88 Imp gal) A button B button 16 32MFM630.indb 16 2010/12/14 15:43:54 To set the clock: 1 Turn the ignition switch ON. the hour digits start flashing. a The adjustment will be cancelled if no operation is performed for 30 seconds during the time adjustment mode. 3 Press A button until the desired hour and AM/PM are displayed. a Press and hold to advance the hour fast. Operation Guide 2 Press and hold A and B buttons until 5 Turn the ignition switch OFF. 4 Press B button until the desired minute is displayed. a Press and hold to advance the minute fast. 17 32MFM630.indb 17 2010/12/14 15:43:55 Indicators Operation Guide PGM-FI (Programmed Fuel Injection) malfunction indicator lamp (MIL) Comes on briefly when the ignition switch is turned ON with the engine stop switch in the RUN position. If it comes ON while engine is running: P.75 Low oil pressure indicator Comes on when the ignition switch is turned ON. Goes off when the engine starts. If it comes ON while engine is running: P.75 High coolant temperature indicator If it comes ON while engine is running: P.74 ABS (Anti-lock Brake System) indicator (CB400A only) Comes on when the ignition switch is turned ON. Goes off when your speed reaches approximately 10 km/h (6 mph). If it comes ON while riding: P.76 18 32MFM630.indb 18 2010/12/14 15:43:57 P.73 HISS indicator • Comes on briefly when the ignition switch is turned ON with the engine stop switch in the RUN position. Goes off if the ignition key has the correct coding. • Flashes every 2 seconds for 24 hours when the ignition switch is turned OFF. Operation Guide Neutral indicator Comes ON when the transmission is in Neutral. High beam indicator Right turn signal indicator Left turn signal indicator 19 32MFM630.indb 19 2010/12/14 15:43:59 Switches Operation Guide Engine stop switch Should normally remain in the RUN position. a In an emergency, switch to the OFF position to stop the engine. Horn button Turn signal switch Headlight dimmer switch • : High beam • : Low beam Passing light control switch Flashes the high beam headlight. Hazard switch Switchable when the ignition switch is ON. Start button Headlight turns off when operating the starter motor. 20 32MFM630.indb 20 2010/12/14 15:44:02 Ignition Switch Switches the electrical system on/off, locks the steering. Steering Lock Lock the steering when parking to help prevent theft. A U-shaped wheel lock or similar device is also recommended. Ignition key Push 2 Turns electrical system on for starting/riding. OFF Turns engine off. LOCK Locks steering. Operation Guide a Key can be removed when in the OFF or LOCK position. ON ❙ Locking 1 Turn the handlebars all the way to the left. 2 Push the key down, and turn the ignition switch to the LOCK position. a Jiggle the handlebars if the lock is difficult to engage. 3 Remove the key. Turn ❙ Unlocking Insert the key, push it in, and turn the ignition switch to the OFF position. 1 21 32MFM630.indb 21 2010/12/14 15:44:02 Starting the Engine Operation Guide Start your engine using the following procedure, regardless of whether the engine is cold or warm. 1 Make sure the engine stop switch is in the RUN 3 2 1 position. 2 Turn the ignition switch to the ON position. 3 Shift the transmission to Neutral ( N indicator comes ON). Alternatively, pull in the clutch lever to start your motorcycle with the transmission in gear so long as the side stand is raised. 4 Press the start button with the throttle completely closed. 4 NOTICE • If the engine does not start within 5 seconds, turn the ignition OFF and wait 10 seconds before trying to start the engine again to recover battery voltage. • Extended fast idling and revving the engine can damage the engine, and the exhaust system. • Snapping the throttle or fast idling for more than about 5 minutes may cause exhaust pipe discoloration. If the engine does not start: 1 Open the throttle fully and press the start button for 5 seconds. 2 Repeat the normal starting procedure. 3 If the engine starts, open the throttle slightly if idling is unstable. 4 If the engine does not start, wait 10 seconds before trying steps ❙ If Engine Will Not Start & again. P.73 22 32MFM630.indb 22 2010/12/14 15:44:03 Shifting Gears Operation Guide Your motorcycle transmission has six forward gears in a one-down, five-up shift pattern. If you put the motorcycle in gear with the side stand down, the engine will shut off. 23 32MFM630.indb 23 2010/12/14 15:44:04 Refuelling Fuel fill cap Filler neck plate Fuel level (max) Operation Guide Fuel filler opening Opening the Fuel Fill Cap Open the lock cover, insert the ignition key, and turn it clockwise to open the cap. Closing the Fuel Fill Cap 1 After refuelling, push the fuel fill cap Ignition key Lock cover Do not fill with fuel above the plate. Fuel type: Unleaded petrol only Fuel octane number: Your motorcycle is designed to use Research Octane Number (RON) 91 or higher. Tank capacity: 18.0 litres (4.76 US gal, 3.96 lmp gal) ❙ Refuelling and Fuel Guidelines P.9 closed until it locks. 2 Remove the key and close the cover. a The key cannot be removed if the cap is not locked. WARNING Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine, and keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. 24 32MFM630.indb 24 2010/12/14 15:44:04 Storage Compartment Helmet Holder Ignition key Holder hook ❙ Using the Helmet Holder 1 Insert the ignition key and turn it clockwise to unlock. 2 Hang your helmet on the holder hook. 3 Turn the key counterclockwise to lock the holder hook and then remove the key. WARNING Operation Guide The helmet holder is located on the left side below the seat. Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed. Turn Helmet holder a Use the helmet holder only when parked. a There is also another helmet holder located on under the seat. P.26 Use the helmet holder only while parked. Do not ride with a helmet secured by the holder. 25 32MFM630.indb 25 2010/12/14 15:44:05 Storage Compartment (Continued) Rear Compartment Operation Guide The helmet holder, tool kit and document bag are located under the seat. There is also space to store a U-shaped lock. Document bag Rubber band Helmet holder U-shaped lock Tool kit a The U-shaped lock is held in place above the rear fender by the rubber band. a Use the helmet holder only when parked. a Some U-shaped locks may not fit in the compartment due to their size or design. ❙ Removing the Seat P.45 WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed. Use the helmet holder only while parked. Do not ride with a helmet secured by the holder. 26 32MFM630.indb 26 2010/12/14 15:44:06 Centre Compartment (CB400) Centre compartment (CB400A) Operation Guide The centre compartment is located under the seat. Maximum Weight Limit: 3.0 kg (6.6 Ib) Centre compartment a The centre compartment may become heated by the engine. Do not store any items that are flammable or susceptible to heat damage. ❙ Removing the Seat P.45 27 32MFM630.indb 27 2010/12/14 15:44:06 Luggage Tie-down Hooks Operation Guide This motorcycle is equipped with the retractable luggage tie-down hooks below the seat of both sides. Luggage tie-down hook a Never use the tie-down hooks to tow or lift the motorcycle. 28 32MFM630.indb 28 2010/12/14 15:44:07 Maintenance Please read “Importance of Maintenance” and “Maintenance Fundamentals” carefully before attempting any maintenance. Refer to “Specifications” for service data. Importance of Maintenance ............................... P.30 Maintenance Schedule .............................................P.31 Maintenance Fundamentals ............................... P.34 Tool kit ................................................................................. P.44 Removing & Installing Body Components ................................................................... P.45 Seat ..................................................................................... P.45 Side Covers ..................................................................... P.46 Battery................................................................................P.47 Engine Oil .......................................................................... P.49 Coolant .................................................................................P.53 Brakes ....................................................................................P.55 32MFM630.indb 29 Side Stand ......................................................................... P.58 Drive Chain ........................................................................P.59 Clutch .................................................................................... P.63 Throttle................................................................................ P.66 Crankcase Breather ................................................... P.67 Other Adjustments..................................................... P.68 Brake Lever ..................................................................... P.68 Front Suspension......................................................... P.69 Rear Suspension ........................................................... P.70 Headlight Aim................................................................ P.71 Brakelight Switch ......................................................... P.71 2010/12/14 15:44:07 Importance of Maintenance Importance of Maintenance Maintenance Keeping your motorcycle well-maintained is absolutely essential to your safety and to protect your investment, obtain maximum performance, avoid breakdowns, and reduce air pollution. Maintenance is the owner’s responsibility. Be sure to inspect your motorcycle before each ride, and perform the periodic checks specified in the Maintenance Schedule. P.31 WARNING Improperly maintaining your 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. Maintenance Safety Always read the maintenance instructions before you begin each task, and make sure that you have the tools, parts, and skills required. 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. Follow these guidelines when performing maintenance. ● Stop the engine and remove the key. ● Park your motorcycle on a firm, level surface using the side stand or a maintenance stand to provide support. ● Allow the engine, muffler, brakes, and other high-temperature parts to cool before servicing as you can get burned. ● Run the engine only when instructed, and do so in a well-ventilated area. 30 32MFM630.indb 30 2010/12/14 15:44:08 Maintenance Schedule The maintenance schedule specifies the maintenance requirements necessary to ensure safe, dependable performance, and proper emission control. Honda recommends that your dealer should road test your motorcycle after each periodic maintenance is carried out. Maintenance Maintenance work should be performed in accordance with Honda’s standards and specifications by properly trained and equipped technicians. Your dealer meets all of these requirements. Keep an accurate record of maintenance to help ensure that your motorcycle is properly maintained. Make sure that whomever performs the maintenance completes this record. All scheduled maintenance is considered a normal owner operating cost and will be charged for by your dealer. Retain all receipts. If you sell the motorcycle, these receipts should be transferred with the motorcycle to the new owner. 31 32MFM630.indb 31 2010/12/14 15:44:08 Maintenance Schedule Frequency Items × 1,000 km × 1,000 mi Month 1 0.6 6 4 6 Odometer Reading *1 12 18 24 8 12 16 12 18 24 30 20 30 36 24 36 Refer to page Maintenance Fuel Line I I I – Throttle Operation I I I 66 Air Cleaner *2 R Crankcase Breather *3 C Spark Plug C I Valve Clearance C C R C R – C 67 I – 49 – I Engine Oil R R R R Engine Oil Filter R R R R 51 Radiator Coolant *4 I I R 53 Cooling System I I I – Secondary Air Supply System I I I – Maintenance Level : Intermediate. We recommend service by your dealer, unless you have the necessary tools and are mechanically skilled. Procedures are provided in an official Honda Shop Manual. Maintenance Legend I : Inspect (clean, adjust, lubricate, or replace, if necessary) C : Clean L : Lubricate R : Replace : Technical. In the interest of safety, have your motorcycle serviced by your dealer. 32 32MFM630.indb 32 2010/12/14 15:44:10 Maintenance Schedule Frequency 1 0.6 6 4 6 Odometer Reading *1 12 18 24 8 12 16 12 18 24 Items × 1,000 km × 1,000 mi Month Drive Chain Every 1,000 km (600 mi): I L 36 24 36 Refer to page I 62 59 I I Brake Fluid *4 I I R I I R 55 Brake Pads Wear I I I I I I 56 Brake System I I I 34 Brake Light Switch I I I 71 Headlight Aim I I I 71 I 63 Clutch System I I I I I I I Side Stand I I I 58 Suspension I I I 69, 70 I I I – I I I 41 I I I – Nuts, Bolts, Fasteners I Wheels/Tyres Steering Head Bearings I Maintenance Drive Chain Slider 30 20 30 Notes: *1 : At higher odometer readings, repeat at the frequency interval established here. *2 : Service more frequently when riding in unusually wet or dusty areas. *3 : Service more frequently when riding in rain or at full throttle. *4 : Replace every 2 years, or at indicated odometer intervals, whichever comes first. Replacement requires mechanical skill. 33 32MFM630.indb 33 2010/12/14 15:44:10 Maintenance Fundamentals Pre-ride Inspection Maintenance To ensure safety, it is your responsibility to perform a pre-ride inspection and make sure that any problem you find is corrected. A pre-ride inspection is a must, not only for safety, but because having a breakdown, or even a flat tyre, can be a major inconvenience. Check the following items before you get on your motorcycle: ● Tyre tread wear and air pressures are within limits. P.41 ● Lights, horn, and turn signals operate normally. ● Check the condition of the drive chain. Adjust slack and lubricate as needed. P.40, 59 Check the following items if you are carrying a passenger or cargo: ● Combined weight is within load limits. P.106 Cargo is secured properly. ● Suspension spring preload is adjusted to suit load. P.69, 70 ● Check the following items after you get on your motorcycle: ● Throttle action moves smoothly without binding. P.66 ● Brake lever and pedal operate normally ● Refuel when needed. P.9, 24 ● Engine stop switch functions properly. P.20 Check the following items at regular intervals: ● Oil level is between the upper and lower marks. P.49 ● Brake fluid level is Front: above the LOWER level mark. Rear: between the UPPER and LOWER level marks. P.55 34 32MFM630.indb 34 2010/12/14 15:44:11 Maintenance Fundamentals Engine coolant level is between the UPPER and LOWER level marks. P.53 ● Side stand functions properly. P.23, 58 ● Colour label Replacing Parts Maintenance Always use Honda Genuine Parts or their equivalents to ensure reliability and safety. When ordering coloured components, specify the model name, colour, and code mentioned on the colour label. The colour label is attached to the frame under the seat. P.45 WARNING Installing non-Honda parts may make your motorcycle unsafe and cause a crash in which you can be seriously hurt or killed. Always use Honda Genuine Parts or equivalents that have been designed and approved for your motorcycle. 35 32MFM630.indb 35 2010/12/14 15:44:11 Maintenance Fundamentals Battery Maintenance Your motorcycle has a maintenance-free type battery. You do not have to check the battery electrolyte level or add distilled water. Clean the battery terminals if they become dirty or corroded. Do not remove the battery cap seals. There is no need to remove the cap when charging. NOTICE Your battery is a maintenance-free type and can be permanently damaged if the cap strip is removed. This symbol on the battery means that this product must not be treated as household waste. NOTICE An improperly disposed of battery can be harmful to the environment and human health. Always confirm local regulations for battery disposal. WARNING The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery servicing. ❙ Cleaning the Battery Terminals 1. Remove the battery. P.47 2. If the terminals are starting to corrode and are coated with a white substance, wash with warm water and wipe clean. 36 32MFM630.indb 36 2010/12/14 15:44:12 Maintenance Fundamentals 3. If the terminals are heavily corroded, clean and polish the terminals with a wire brush or sandpaper. Wear safety glasses. Fuses ❙ Inspecting and Replacing Fuses 4. After cleaning, reinstall the battery. The battery has a limited life span. Consult your dealer about when you should replace the battery. Always replace the battery with another maintenance-free battery of the same type. NOTICE Installing non-Honda electrical accessories can overload the electrical system, discharging the battery and possibly damaging the system. Turn off the ignition switch to remove and inspect fuses. If a fuse is blown, replace with a fuse of the same rating. For fuse ratings, see “Specifications.” P.108 Maintenance Fuses protect the electrical circuits on your motorcycle. If something electrical on your motorcycle stops working, check for and replace any blown fuses. P.90 Blown fuse NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system. 37 32MFM630.indb 37 2010/12/14 15:44:12 Maintenance Fundamentals If a fuse fails repeatedly, you likely have an electrical fault. Have your motorcycle inspected by your dealer. Engine Oil Maintenance Engine oil consumption varies and oil quality deteriorates according to riding conditions and time elapsed. Check the engine oil level regularly, and add the recommended engine oil if necessary. Dirty oil or old oil should be changed as soon as possible. . The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. For example, the following label shows the MA classification. *1 Oil code Oil classification . The SAE standard grades oils by their viscosity. . The API classification specifies the quality and performance rating of engine oils. Use SG or higher oils, excluding oils marked as “Energy Conserving” on the circular API service symbol. *2 *3 ❙ Selecting the Engine Oil For recommended engine oil, see “Specifications.” P.107 If you use non-Honda engine oil, check the label to make sure that the oil satisfies all of the following standards: ● JASO T 903 standard*1: MA ● SAE standard*2: 10W-30 ● API classification*3: SG or higher Not recommended Recommended 38 32MFM630.indb 38 2010/12/14 15:44:13 Maintenance Fundamentals Brake Fluid NOTICE Brake fluid can damage plastic and painted surfaces. Wipe up spills immediately and wash thoroughly. Also inspect the engine sprocket and rear wheel sprocket. If either has worn or damaged teeth, have the sprocket replaced by your dealer. Maintenance Do not add or replace brake fluid, except in an emergency. Use only fresh brake fluid from a sealed container. If you do add fluid, have the brake system serviced by your dealer as soon as possible. If the chain does not move smoothly, makes strange noises, has damaged rollers or loose pins or missing O-rings, or kinks, have the chain inspected by your dealer. Recommended brake fluid: Honda DOT 4 Brake Fluid or equivalent Drive Chain The drive chain must be inspected and lubricated regularly. Inspect the chain more frequently if you often ride on bad roads, ride at high speed, or ride with repeated fast acceleration. Normal (GOOD) Worn (REPLACE) Damaged (REPLACE) NOTICE Use of a new chain with worn sprockets will cause rapid chain wear. 39 32MFM630.indb 39 2010/12/14 15:44:14 Maintenance Fundamentals ❙ Cleaning and Lubricating Maintenance After inspecting the slack, clean the chain and sprockets while rotating the rear wheel. Use dry cloth with chain cleaner designed specifically for O-ring chains, or neutral detergent. Use a soft brush if the chain is dirty. After cleaning, wipe dry and lubricate with the recommended lubricant. If not available, use SAE 80 or 90 gear oil. Recommended lubricant: Drive chain lubricant designed specifically for O-ring chains Do not use a steam cleaner, a high pressure cleaner, a wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner, chain cleaner or lubricant NOT designed specifically for O-ring chains as these can damage the rubber O-ring seals. Avoid getting lubricant on the brakes or tyres. Avoid applying excess chain lubricant to prevent spray onto your clothes and the motorcycle. Recommended Coolant Pro Honda HP is a pre-mixed solution of antifreeze and distilled water. Concentration: 50 % antifreeze and 50 % distilled water 40 32MFM630.indb 40 2010/12/14 15:44:14 Maintenance Fundamentals A concentration of antifreeze below 40 % will not provide proper corrosion and cold temperature protection. A concentration of up to 60 % will provide better protection in colder climates. Crankcase Breather Service more frequently when riding in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the transparent section of the drain tube. Tyres (Inspecting/Replacing) Inspect the tyres for cuts, slits, or cracks that exposes fabric or cords, or nails or other foreign objects embedded in the side of the tyre or the tread. Also inspect for the bumps or bulges in the side walls of the tyres. Maintenance NOTICE Using coolant not specified for aluminium engines or using ordinary tap water can cause corrosion. ❙ Inspecting for Damage ❙ Inspecting for Abnormal Wear Inspect the tyres for signs of abnormal wear on the contact surface. ❙ Checking the Air Pressure Visually inspect your tyres and use an air pressure gauge to measure the air pressure at least once a month or any time you think the tyres look low. Always check air pressure when your tyres are cold. 41 32MFM630.indb 41 2010/12/14 15:44:15 Maintenance Fundamentals ❙ Inspecting Tread Depth Inspect the tread wear indicators. If they become visible, replace the tyres immediately. For safe riding, you should replace the tyres when the minimum tread depth is reached. WARNING Maintenance Riding on 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. Wear indicator location mark 42 32MFM630.indb 42 2010/12/14 15:44:15 Maintenance Fundamentals Have your tyres replaced by your dealer. For recommended tyres, air pressure and minimum tread depth, see “Specifications.” P.107 Installing improper tyres on your motorcycle can adversely affect handling and stability, and can cause a crash in which you can be seriously hurt or killed. Maintenance Follow these guidelines whenever you replace tyres. ● Use the recommended tyres or equivalents of the same size, construction, speed rating, and load range. ● Have the wheel balanced with Honda Genuine balance weights or equivalents after the tyre is installed. ● Do not install a tube inside a tubeless tyre on this motorcycle. Excessive heat build-up can cause the tube to burst. ● Use only tubeless tyres on this motorcycle. The rims are designed for tubeless tyres, and during hard acceleration or braking, a tube-type tyre could slip on the rim and cause the tyre to rapidly deflate. WARNING Always use the size and type of tyres recommended in this owner’s manual. 43 32MFM630.indb 43 2010/12/14 15:44:16 Tool kit The tool kit is stored under the seat. P.45 Maintenance You can perform some roadside repairs, minor adjustments and parts replacement with the tools contained in the kit. ● ● ● ● ● ● ● ● ● ● ● ● Pin spanner 8 mm Open end wrench 10 x 12 mm Open end wrench 14 x 17 mm Open end wrench Pliers Standard/Phillips screwdriver Screwdriver handle Extension bar 5 mm Hex wrench 17 mm Box end wrench 24 mm Box end wrench Spark plug wrench 44 32MFM630.indb 44 2010/12/14 15:44:16 Removing & Installing Body Components Seat ❙ Removal Front prong Rear prongs Seat lock Pull Ignition Lock key lever Front stay Rear stay ❙ Installation Maintenance Seat 1. Insert the ignition key into the seat lock and turn it clockwise. 2. Pull the seat lock lever downward to unlock the seat. 3. Pull the seat back and up. 1. Insert the front prong into the front stay and the rear prongs into the rear stays on the frame. 2. Push forward and then down on the rear of the seat. a Make sure that the seat is locked securely in position to pull it up lightly. a The seat locks automatically when closed. Take care not to lock your key under the seat. 45 32MFM630.indb 45 2010/12/14 15:44:16 Removing & Installing Body Components a Side Covers Side Covers Maintenance The right side cover must be removed to access the coolant reserve tank. The left side cover must be removed for fuse maintenance. Grommets Right Bolt The right and left side covers can be removed in the same manner. Prongs ❙ Removal 1. Remove the seat. P.45 2. Remove the bolt. 3. Remove the prongs from the grommets. Left ❙ Installation 1. Insert the prongs into the grommets. 2. Install the bolt. 3. Install the seat properly. Grommets Prongs Bolt 46 32MFM630.indb 46 2010/12/14 15:44:17 Removing & Installing Body Components a Battery Battery ❙ Removal (CB400) Battery cover Maintenance Bolt Make sure the ignition switch is OFF. 1. Remove the seat. P.45 2. Open the battery cover by removing the bolt. (CB400A) Bolt Battery cover 47 32MFM630.indb 47 2010/12/14 15:44:18 Removing & Installing Body Components a Battery (CB400) Negative terminal Maintenance 3. Disconnect the negative terminal from the battery. 4. Disconnect the positive terminal from the battery. 5. Remove the battery taking care not to drop the terminal nuts. ❙ Installation Battery Positive terminal (CB400A) Negative terminal Battery Positive terminal Install the parts in the reverse order of removal. Always connect the positive terminal first. Make sure that bolts and nuts are tight. The clock will be reset AM 1:00 if the battery is disconnected. To set the clock, see “Operation Guide.” P.17 For proper handling of the battery, see “Maintenance Fundamentals.“ P.36 Battery Goes Dead P.86 48 32MFM630.indb 48 2010/12/14 15:44:19 Engine Oil Checking the Engine Oil Oil level inspection window Upper level Oil fill cap Maintenance 1. If the engine is cold, idle the engine for 3 to 5 minutes. 2. Turn the ignition switch OFF, stop the engine and wait 2 to 3 minutes. 3. Place your motorcycle in an upright position on a firm, level surface. 4. Check that the oil level is between the upper and lower level marks in the oil inspection window. Lower level 49 32MFM630.indb 49 2010/12/14 15:44:19 Engine Oil a Adding Engine Oil Adding Engine Oil Maintenance If the engine oil is below or near the lower level mark, add the recommended engine oil. P.38 1. Remove the oil fill cap. Add the recommended oil until it reaches the upper level mark. a Place your motorcycle in an upright position on a firm, level surface when checking the oil level. a Do not overfill above the upper level mark. a Make sure no foreign objects enter the oil filler opening. a Wipe up any spills immediately. 2. Securely reinstall the oil fill cap. NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine. Do not mix different brands and grades of oil. They may affect lubrication and clutch operation. For the recommended oil and oil selection guidelines, see “Maintenance Fundamentals.” P.38 50 32MFM630.indb 50 2010/12/14 15:44:20 Engine Oil a Changing Engine Oil & Filter Changing Engine Oil & Filter Use a new Honda Genuine oil filter or equivalent specified for your model. NOTICE Using the wrong oil filter can result in serious damage to the engine. 1. If the engine is cold, idle the engine for 3 to 5 minutes. 2. Turn the ignition switch OFF, stop the engine and wait for 2 to 3 minutes. 3. Park on a firm, level surface and lower the side stand. 4. Place a drain pan under the drain bolt. Maintenance Changing the oil and filter requires special tools. We recommend that you have your motorcycle serviced by your dealer. 5. Remove the oil fill cap, drain bolt, and sealing washer to drain the oil. 6. Remove the oil filter with a filter wrench and let the remaining oil drain out. Make sure the prior seal is not stuck to the engine. a Discard the oil and oil filter at an approved recycling centre. Rubber seal Oil filter Drain bolt Sealing washer continued 51 32MFM630.indb 51 2010/12/14 15:44:20 Engine Oil a Changing Engine Oil & Filter 7. Apply a thin coat of engine oil to the rubber seal of a new oil filter. 8. Install a new oil filter and tighten. Torque: 26 N·m (2.7 kgf·m, 19 lbf·ft). Maintenance 9. Replace the sealing washer. Install the drain bolt and tighten. 11. Check the oil level. P.49 12.Check that there are no oil leaks. NOTICE Improper installation of the oil filter can result in serious damage to the engine. Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft). 10.Fill the crankcase with the recommended oil ( P.38) and install the oil fill cap. Required oil When changing oil & engine oil filter: 3.2 litres (3.4 US qt, 2.8 Imp qt) When changing oil only: 3.0 litres (3.2 US qt, 2.6 Imp qt) 52 32MFM630.indb 52 2010/12/14 15:44:20 Coolant Checking the Coolant Reserve tank cap Reserve tank Maintenance The reserve tank is behind the right side cover. 1. Place your motorcycle on a firm, level surface. 2. Hold your motorcycle in an upright position. 3. Check that the coolant level is between the UPPER and LOWER level marks in the reserve tank. If the coolant level is dropping noticeably or the reserve tank is empty, you likely have a serious leak. Have your motorcycle inspected by your dealer. UPPER level LOWER level 53 32MFM630.indb 53 2010/12/14 15:44:21 Coolant a Adding Coolant Adding Coolant Maintenance 1. If the coolant level is below the LOWER level, add the recommended coolant ( P.40) until the level reaches the UPPER level mark. Add fluid only from the reserve tank cap and do not remove the radiator cap. 2. Remove the right side cover. P.46 3. Remove the reserve tank cap and add fluid while monitoring the coolant level. a Do not overfill above the UPPER level mark. a Make sure no foreign objects enter the reserve tank opening. 4. Securely reinstall the cap. 5. Install the right side cover. WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out, potentially scalding you. Always let the engine and radiator cool down before removing the radiator cap. Changing Coolant Have your dealer change the coolant unless you have the proper tools and are mechanically qualified. 54 32MFM630.indb 54 2010/12/14 15:44:21 Brakes Checking Brake Fluid If the brake fluid level in either reservoir is below the lower level mark or the brake lever and pedal freeplay becomes excessive, inspect the brake pads for wear. If the brake pads are not worn, you most likely have a leak. Have your motorcycle inspected by your dealer. Front brake fluid reservoir LOWER level mark Maintenance 1. Place your motorcycle in an upright position on a firm, level surface. 2. Check that the brake fluid reservoir is horizontal and that the fluid level is: Front above the LOWER level mark. Rear between the LOWER level and UPPER level marks. Front Rear Rear brake fluid reservoir UPPER level mark LOWER level mark 55 32MFM630.indb 55 2010/12/14 15:44:22 Brakes a Inspecting the Brake Pads Inspecting the Brake Pads Maintenance Check the condition of the brake pad groove wear indicators. (CB400) Front The pads need to be replaced if a brake pad is worn to the bottom of the groove. Rear The pads need to be replaced if a brake pad is worn to the groove. Front 1. Front Inspect the brake pads from in front of the brake caliper. a Always inspect both left and right calipers. 2. Rear Inspect the brake pads from the rear right of the motorcycle. If necessary have the pads replaced by your dealer. Always replace both left and right brake pads at the same time. Rear Disc Brake pads Wear indicator Wear indicator Wear indicator Brake pads Wear indicator Disc Brake pads 56 32MFM630.indb 56 2010/12/14 15:44:22 Brakes a Inspecting the Brake Pads (CB400A) The pads need to be replaced if a brake pad is worn to the groove. Maintenance Front 1. Front Inspect the brake pads from below the brake caliper. a Always inspect both left and right calipers. 2. Rear Inspect the brake pads from the rear right of the motorcycle. If necessary have the pads replaced by your dealer. Always replace both left and right brake pads at the same time. Rear Brake pads Wear indicator Wear indicator Wear indicator Brake pads Disc Wear indicator Disc 57 32MFM630.indb 57 2010/12/14 15:44:23 Side Stand Maintenance 4. Start the engine, pull the clutch lever in, and shift the transmission into gear. 5. Lower the side stand all the way. The engine should stop as you lower the side stand. If the engine doesn’t stop, have your motorcycle inspected by your dealer. Side stand spring 1. Check that the side stand operates smoothly. If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with clean grease. 2. Check the spring for damage or loss of tension. 3. Sit on the motorcycle, put the transmission in Neutral, and raise the side stand. 58 32MFM630.indb 58 2010/12/14 15:44:23 Drive Chain Inspecting the Drive Chain Slack Drive chain slack: 25 to 35 mm (1.0 to 1.4 in) a Do not ride your motorcycle if the slack exceeds 50 mm (2.0 in). Maintenance Check the drive chain slack at several points along the chain. If the slack is not constant at all points, some links may be kinked and binding. Have the chain inspected by your dealer. 3. Check the slack in the lower half of the drive chain midway between the sprockets. 1. Place your motorcycle on the side stand on a level surface. 2. Stop the engine place the gear in Neutral. 4. Roll the motorcycle forward and check that the chain moves smoothly. continued 59 32MFM630.indb 59 2010/12/14 15:44:24 Drive Chain a Adjusting the Drive Chain Slack 5. Inspect the sprockets. P.39 6. Clean and lubricate the drive chain. Index mark P.40 Maintenance Adjusting the Drive Chain Slack Adjusting the chain requires special tools. Have the drive chain slack adjusted by your dealer. (CB400A only) When adjusting the drive chain slack, be careful not to damage the wheel speed sensor and pulser ring. 1. Place your motorcycle on the side stand on a level surface. 2. Stop the engine. Place the transmission in Neutral. 3. Loosen the rear axle nut. Scales Adjusting bolt Rear axle nut 4. Turn both adjusting bolts an equal number of turns until the correct drive chain slack is obtained. Turn the adjusting bolts counterclockwise to tighten the chain. Turn the adjusting bolts clockwise to provide more slack. Adjust the slack at a point midway between the front sprocket and the rear wheel sprocket. Check the drive chain slack. P.59 60 32MFM630.indb 60 2010/12/14 15:44:24 Drive Chain a Adjusting the Drive Chain Slack 6. Tighten the rear axle nut. Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft). 7. Tighten the adjusting bolts lightly. 8. Recheck drive chain slack. If a torque wrench was not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. Maintenance 5. Check rear axle alignment by making sure the scales on the drive chain adjusters align with the index marks on both sides of the swingarm. Both scales should correspond. If the axle is misaligned, turn the right or left adjusting bolt until the scales are aligned and recheck chain slack. 61 32MFM630.indb 61 2010/12/14 15:44:24 Drive Chain a Checking the Drive Chain Slider ❙ Checking the Drive Chain Wear Maintenance Check the chain wear label when adjusting the drive chain. If the index mark on the swingarm enters the red zone on the label after the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced. Chain: RK 525SMOZ5 Checking the Drive Chain Slider Check the condition of the drive chain slider. The drive chain slider need to be replaced if it is worn to the wear limit line. If necessary have the drive chain slider replaced by your dealer. Wear limit line If necessary have the drive chain replaced by your dealer. Index mark Drive chain slider Red zone 62 32MFM630.indb 62 2010/12/14 15:44:25 Clutch Checking the Clutch ❙ Checking the Clutch Lever Freeplay Freeplay at the clutch lever: 10 to 20 mm (0.4 to 0.8 in) Freeplay Maintenance Check the clutch lever freeplay. Check the clutch cable for kinks or signs of wear. If necessary have it replaced by your dealer. Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion. Clutch lever 63 32MFM630.indb 63 2010/12/14 15:44:26 Clutch a Adjusting the Clutch Lever Freeplay Adjusting the Clutch Lever Freeplay Upper clutch cable adjuster Maintenance ❙ Upper Adjustment Attempt adjustment with the upper clutch cable adjuster first. 1. Loosen the upper lock nut. 2. Turn the upper clutch cable adjuster until the freeplay is 10 to 20 mm (0.4 to 0.8 in). 3. Tighten the upper lock nut and check the freeplay again. Upper lock nut ❙ Lower Adjustment If the upper clutch cable adjuster is threaded out near its limit, or the correct freeplay cannot be obtained, attempt adjustment with the lower adjusting nut. 64 32MFM630.indb 64 2010/12/14 15:44:26 Clutch a Adjusting the Clutch Lever Freeplay Lower adjusting nut Maintenance 1. Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in (to provide maximum freeplay). Tighten the upper lock nut. 2. Loosen the lower lock nut. 3. Turn the lower adjusting nut until the clutch lever freeplay is 10 to 20 mm (0.4 to 0.8 in). 4. Tighten the lower lock nut and check the clutch lever freeplay. 5. Start the engine, pull the clutch lever in, and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. Your motorcycle should move smoothly and accelerate gradually. Lower lock nut If proper adjustment cannot be obtained or the clutch does not work correctly, see your dealer. 65 32MFM630.indb 65 2010/12/14 15:44:27 Throttle Maintenance Checking the Throttle Adjusting the Throttle Freeplay With the engine off, check that the throttle rotates smoothly from fully closed to fully open in all steering positions and throttle freeplay is correct. If the throttle does not move smoothly, close automatically, or if the cable is damaged, have the motorcycle inspected by your dealer. 1. Loosen the lock nut. 2. Turn the adjuster until the freeplay is 2 to 6 mm (0.1 to 0.2 in). 3. Tighten the lock nut and inspect the throttle action again. Throttle grip Freeplay at the throttle grip flange: 2 to 6 mm (0.1 to 0.2 in). Freeplay Lock nut Adjuster 66 32MFM630.indb 66 2010/12/14 15:44:27 Crankcase Breather Cleaning the Crankcase Breather Maintenance 1. Remove the crankcase breather tube plug from the tube. 2. Drain deposits into a suitable container. 3. Install the crankcase breather tube plug. Crankcase breather tube plug 67 32MFM630.indb 67 2010/12/14 15:44:28 Other Adjustments Adjusting the Brake Lever You can adjust the distance between the tip of the brake lever and handle grip. After adjustment, check that the lever operates correctly before riding. NOTICE Do not turn the adjuster beyond its natural limit. ● Maintenance ❙ Adjustment method Turn the adjuster until the index mark aligns with the arrow while pushing the lever forward in the desired position. Index mark Brake lever Adjuster Arrow 68 32MFM630.indb 68 2010/12/14 15:44:28 Other Adjustments a Adjusting the Front Suspension Adjusting the Front Suspension ❙ Spring Preload Maintenance You can adjust the spring preload by the adjuster to suit the load or the road surface. Turn clockwise to increase spring preload (hard), or turn counterclockwise to decrease spring preload (soft). The standard position is the third groove from the top aligns with the top surface of the fork cap. NOTICE Do not turn the adjuster beyond its limits. Adjust both left and right forks to the same spring preload. Adjuster Standard position 69 32MFM630.indb 69 2010/12/14 15:44:29 Other Adjustments a Adjusting the Rear Suspension Adjusting the Rear Suspension ❙ Spring Preload Maintenance You can adjust the spring preload by the adjuster to suit the load or the road surface. Use the pin spanner and extension bar to turn the adjuster. Position 1 to 2 are for a decrease spring preload (soft), or turn the position 4 to 5 increase spring preload (hard). The standard position is 3. Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber. NOTICE Adjust both left and right shock absorbers to the same spring preload. NOTICE The rear shock absorber damper unit contains high pressure nitrogen gas. Do not attempt to disassemble, service, or improperly dispose of the damper. See your dealer. Pin spanner 54 3 21 Adjuster Extension bar 70 32MFM630.indb 70 2010/12/14 15:44:29 Other Adjustments a Adjusting the Headlight Aim Adjusting the Brakelight Switch You can adjust vertical aim of the headlight for proper alignment. To move the headlight case, loosen the bolts. Obey local laws and regulations. Check the operation of the brakelight switch. Turn the adjusting nut in the direction A if the switch operates too late, or turn the nut in the direction B if the switch operates too soon. Headlight case Maintenance Adjusting the Headlight Aim Up Bolts A B Down Adjusting nut Brakelight switch 71 32MFM630.indb 71 2010/12/14 15:44:30 Troubleshooting Engine Will Not Start (HISS indicator stays ON) .....................................P.73 Overheating (High coolant temperature indicator is ON) .......................................................... P.74 Warning Indicators ON or Flashing ................P.75 Low Oil Pressure Indicator ......................................P.75 PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)...................P.75 ABS Indicator (CB400A)........................................... P.76 32MFM630.indb 72 Other Warning Indications ...................................P.77 Fuel Gauge Failure Indication ...............................P.77 Tyre Puncture ...................................................................P.78 Electrical Trouble ......................................................... P.86 Battery Goes Dead ..................................................... P.86 Burned-out Light Bulb ............................................. P.86 Blown Fuse ..................................................................... P.90 2010/12/14 15:44:31 Engine Will Not Start (HISS indicator stays ON) Check if there are no any metallic seals or stickers on the key. If the HISS indicator still stays ON, have your motorcycle inspected by your dealer. ❙ Starter Motor Operates But Engine Does Not Start ❙ Starter Motor Does Not Operate Check the following items: Make sure engine stop switch is RUN position. P.20 ● Check for a blown fuse. P.90 ● Check for a loose battery connection or battery terminal corrosion. P.36 ● Check the condition of the battery. P.86 If the problem continues, have your motorcycle inspected by your dealer. ● Troubleshooting Check the following items: ● Check the correct engine starting sequence. P.22 ● Check that there is petrol in the fuel tank. ● Check if the PGM-FI malfunction indicator lamp (MIL) is ON. a If the indicator light is ON, contact your dealer as soon as possible. ● Check if the HISS indicator stays ON. a Turn the ignition switch to the OFF position and remove the key. Reinsert the key and turn the ignition switch to the ON position. If the indicator still stays ON, check the following: Check if there is no another HISS key (including spare key) close to the ignition switch. 73 32MFM630.indb 73 2010/12/14 15:44:32 Overheating (High coolant temperature indicator is ON) Troubleshooting The engine is overheating when the following occurs: ● High coolant temperature indicator comes ON. ● Acceleration becomes sluggish. ● If this occurs, pull safely to the side of the road and perform the following procedure. Extended fast idling may cause the high coolant temperature indicator comes ON. NOTICE Continuing to ride with an overheated engine can cause serious damage to the engine. 1. Stop the engine using the ignition switch, and then turn the ignition switch to the ON position. 2. Check that the radiator fan is operating, and then turn the ignition switch to the OFF position. If the fan is not operating: Suspect a fault. Do not start the engine. Transport your motorcycle to your dealer. If the fan is operating: Allow the engine to cool with the ignition switch in the OFF position. 3. After the engine has cooled, inspect the radiator hose and check if there is a leak. P.53 If there is a leak: Do not start the engine. Transport your motorcycle to your dealer. 4. Check the coolant level in the reserve tank, and add coolant as necessary. P.54 5. If 1-4 check normal, you may continue riding, but closely monitor the high coolant temperature indicator. 74 32MFM630.indb 74 2010/12/14 15:44:32 Warning Indicators ON or Flashing Low Oil Pressure Indicator If the low oil pressure indicator comes ON, pull safely to the side of the road and stop the engine. 1. Check the engine oil level, and add oil as necessary. P.50 2. Start the engine. a Only continue riding if the low oil pressure indicator goes OFF. Rapid acceleration may momentarily cause the low oil pressure indicator to come ON, especially if the oil is at or near the low level. If the low oil pressure indicator stays ON when the oil level is at the proper level, stop the engine and contact your dealer. PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL) If the indicator comes ON while riding, you may have a serious problem with the PGM-FI system. Reduce speed and have your motorcycle inspected by your dealer as soon as possible. Troubleshooting NOTICE Continuing to ride with low oil pressure can cause serious damage to the engine. If the engine oil level goes down rapidly, your motorcycle may have a leak or another serious problem. Have your motorcycle inspected by your dealer. 75 32MFM630.indb 75 2010/12/14 15:44:32 Warning Indicators ON or Flashing a ABS (Anti-lock Brake System) Indicator (CB400A) ABS (Anti-lock Brake System) Indicator (CB400A) Troubleshooting If the indicator operates in one of the following ways, you may have a serious problem with the brake system. Reduce your speed and have your motorcycle inspected by your dealer as soon as possible. ● ● ● The ABS indicator may flash if you turn the rear wheel while your motorcycle is lifted off the ground. In this case, turn the ignition switch OFF and then ON again. The ABS indicator will go OFF after your speed reaches 30 km/h (19 mph). Indicator comes ON or starts flashing while riding. Indicator does not come ON when the ignition switch is in the ON position. Indicator does not go OFF at speeds above 10 km/h (6 mph). If the ABS indicator stays ON, your brakes will continue to work as a conventional system, but without the anti-locking function. 76 32MFM630.indb 76 2010/12/14 15:44:32 Other Warning Indications Fuel Gauge Failure Indication Troubleshooting If the fuel system has an error, the fuel gauge indicators will be displayed as shown in the illustration. If this occurs, see your dealer as soon as possible. 77 32MFM630.indb 77 2010/12/14 15:44:33 Tyre Puncture Repairing a puncture or removing a wheel requires special tools and technical expertise. We recommend you have this type of service performed by your dealer. After an emergency repair, always have the tyre inspected/replaced by your dealer. Troubleshooting Emergency Repair Using a Tyre Repair Kit If your tyre has a minor puncture, you can make an emergency repair using a tubeless tyre repair kit. Follow the instructions provided with the emergency tyre repair kit. Riding your motorcycle with a temporary tyre repair is very risky. Do not exceed 50 km/h (30 mph). Have the tyre replaced by your dealer as soon as possible. WARNING Riding your motorcycle with a temporary tyre repair can be risky. If the temporary repair fails, you can crash and be seriously injured or killed. If you must ride with a temporary tyre repair, ride slowly and carefully and do not exceed 50 km/h (30 mph) until the tyre is replaced. Removing Wheels Follow these procedures if you need to remove the wheel in order to repair a puncture. 78 32MFM630.indb 78 2010/12/14 15:44:33 Tyre Puncture a Removing Wheels (CB400A only) When removing and installing the wheel, be careful not to damage the wheel speed sensor and pulser ring. ❙ Front Wheel Troubleshooting Removal 1. Park on a firm, level surface. 2. Cover both sides of the front wheel and brake caliper with protective tape or cloth. 3. Remove the right and left caliper assemblies from the fork leg by removing the fixing bolts. a Support the brake caliper assembly so that it doesn’t hang from the brake hose. Do not twist the brake hose. a Avoid getting grease, oil, or dirt on the disc or pad surfaces. a Do not pull the brake lever while the brake caliper is removed. a Take care to prevent the brake caliper from scratching the wheel during removal. Brake caliper assembly Fixing bolts 79 32MFM630.indb 79 2010/12/14 15:44:33 Tyre Puncture a Removing Wheels 4. Loosen the right axle pinch bolts. 5. Remove the front axle bolt. 6. Support your motorcycle securely and raise the front wheel off the ground using a maintenance stand or a hoist. 7. Loosen the left axle pinch bolts. 8. On the left side, withdraw the front axle shaft, and remove the side collars and wheel. Troubleshooting Axle pinch bolts Front axle bolt Front axle shaft Axle pinch bolts 80 32MFM630.indb 80 2010/12/14 15:44:34 Tyre Puncture a Removing Wheels Index line 4. Tighten the left axle pinch bolts to hold the axle. 5. Tighten the front axle bolt. Torque: 59 N·m (6.0 kgf·m, 44 lbf·ft). 6. Loosen the left axle pinch bolts. 7. Tighten the right axle pinch bolts. Torque: 23 N·m (2.3 kgf·m, 17 lbf·ft). 8. Install the right and left brake calipers and tighten the fixing bolts. Troubleshooting Installation 1. Attach the side collars to the wheel. 2. On the left side, place the wheel between the fork legs and insert the front axle shaft, through the left fork leg and wheel hub. 3. Align the index line of the front axle shaft with the surface of the fork leg. Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft). a Take care to prevent the brake caliper from scratching the wheel during installation. Surface of the fork leg NOTICE When installing the brake calipers into position on the fork legs, carefully fit the brake disc between the pads to avoid scratching them. 81 32MFM630.indb 81 2010/12/14 15:44:35 Tyre Puncture a Removing Wheels 9. Lower the front wheel on the ground. 10.Apply the brake lever several times. Then, pump the fork several times. 11. Retighten the left axle pinch bolts. If a torque wrench was not used for installation, see your dealer as soon as possible to verify proper assembly. Clearance Torque: 23 N·m (2.3 kgf·m, 17 lbf·ft). Troubleshooting 12.Raise the front wheel off the ground again, and check that the wheel rotates freely after you release the brake. 13. Check the clearances between each surface of the brake disc and the brake caliper body (not the brake pads) are symmetrical. If the clearances are not symmetrical, loosen the left axle pinch bolts and pull the left fork outward or push inward to adjust the clearance. 14.Lower the front wheel on the ground. 15. Remove the protective tape or cloth. Brake caliper body Brake disc 82 32MFM630.indb 82 2010/12/14 15:44:35 Tyre Puncture a Removing Wheels ❙Rear Wheel Drive chain Troubleshooting Removal 1. Support your motorcycle securely and raise the rear wheel off the ground using a maintenance stand or a hoist. 2. Loosen the rear axle nut and turn the adjusting bolts so the rear wheel can be moved all the way forward for maximum drive chain slack. 3. Remove the rear axle nut/washer. 4. Remove the drive chain from the rear wheel sprocket by pushing the rear wheel forward. 5. Remove the rear axle shaft. Rear axle nut Adjusting bolt Adjusting bolt Rear axle nut continued 83 32MFM630.indb 83 2010/12/14 15:44:36 Tyre Puncture a Removing Wheels Troubleshooting 6. Remove the rear axle shaft, side collars and rear wheel. a Support the brake caliper assembly so that it doesn’t hang from the brake hose. Do not twist the brake hose. a Avoid getting grease, oil, or dirt on the disc or pad surfaces. a Do not push the brake pedal while the brake caliper is removed. Installation 1. To install the rear wheel, reverse the removal procedure. a Take care to prevent the brake caliper from scratching the wheel during installation. NOTICE When installing the brake caliper into position, carefully fit the brake disc between the pads to avoid scratching them. 2. Make sure that the lug on the brake caliper bracket is positioned in the slot on the swingarm. Swingarm Lug Slot Brake caliper bracket 84 32MFM630.indb 84 2010/12/14 15:44:37 Tyre Puncture a Removing Wheels 3. Adjust the drive chain. P.60 4. Install and tighten the rear axle nut. Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft). Troubleshooting 5. After installing the wheel, apply the brake pedal several times, then recheck the disc for caliper holder to disc clearance. Do not operate the motorcycle without adequate clearance. If a torque wrench was not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. 85 32MFM630.indb 85 2010/12/14 15:44:37 Electrical Trouble Troubleshooting Battery Goes Dead Burned-out Light Bulb Charge the battery using a motorcycle battery charger. Remove the battery from the motorcycle while charging. Do not use an automobile-type battery charger, as these can overheat a motorcycle battery and cause permanent damage. If the battery does not recover after recharging, contact your dealer. Follow the procedure below to replace a burned-out light bulb. Turn the ignition switch to the OFF or LOCK position. Allow the bulb to cool before replacing it. Do not use bulbs other than those specified. Check the replacement bulb for correct operation before riding. NOTICE Jump starting using an automobile battery is not recommended, as this can damage your motorcycle’s electrical system. For the light bulb wattage, see “Specifications.“ P.108 86 32MFM630.indb 86 2010/12/14 15:44:37 Electrical Trouble a Burned-out Light Bulb ❙ Headlight Bulb Screw Connector Troubleshooting 1. Remove the screws from the headlight case. 2. Gently pull the lower end of the headlight forward and remove the headlight. 3. Disconnect the connector by pressing tabs. 4. Remove the dust cover. 5. Unhook the pin and remove the bulb. 6. Install a new bulb in the reverse order of removal. a Install the dust cover with its“TOP” mark facing up. Do not touch the glass surface of a new headlight bulb with your fingers. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol. “TOP”mark Dust cover Tabs Bulb Pin Headlight Screw 87 32MFM630.indb 87 2010/12/14 15:44:38 Electrical Trouble a Burned-out Light Bulb ❙ Front/Rear Turn Signal Bulb Troubleshooting 1. Remove the screw. 2. Remove the turn signal lens and lens packing. 3. Slightly press the bulb and turn it counterclockwise. ❙ Brake/Tail light Brake/Tail light Screw Turn signal lens Lens packing Bulb The brake and tail light uses several LEDs. If there is a LED which is not turned on, see your dealer for this service. 4. Install a new bulb in the reverse order of removal. 88 32MFM630.indb 88 2010/12/14 15:44:39 Electrical Trouble a Burned-out Light Bulb ❙ License Plate Light 1. Remove the screws. 2. Remove the license light cover. 3. Pull out the bulb without turning. Troubleshooting License light cover Screws Bulb 4. Install a new bulb in the reverse order of removal. 89 32MFM630.indb 89 2010/12/14 15:44:39 Electrical Trouble a Blown Fuse Blown Fuse Before handling fuses, see “Inspecting and Replacing Fuses.” P.37 ❙ Fuse Box Fuses Troubleshooting (CB400) 1. Remove the left side cover. P.46 2. Open the fuse box cover. 3. Pull out the fuses one by one to check for a blown fuse. Always replace a blown fuse with a spare of the same rating. 4. Close the fuse box cover. 5. Install the left side cover. Fuse box cover Spare fuses 90 32MFM630.indb 90 2010/12/14 15:44:40 Electrical Trouble a Blown Fuse (CB400A) Beside left rear suspension Under seat Beside left rear suspension Under seat Fuse box cover Spare fuse Troubleshooting 1. Remove the seat. P.45 2. Open the fuse box cover. 3. Pull out the fuses one by one to check for a blown fuse. Always replace a blown fuse with a spare of the same rating. 4. Close the fuse box cover. 5. Install the seat. 1. Remove the left side cover. P.46 2. Open the fuse box covers. 3. Pull out the fuses one by one to check for a blown fuse. Always replace a blown fuse with a spare of the same rating. 4. Close the fuse box covers. 5. Install the left side cover. Fuse box cover Spare fuse 91 32MFM630.indb 91 2010/12/14 15:44:41 Electrical Trouble a Blown Fuse ❙ Main Fuse Troubleshooting 1. Remove the left side cover. P.46 2. Disconnect the wire connector of the starter magnetic switch. 3. Pull out the main fuse and check for a blown fuse. Always replace a blown fuse with a spare of the same rating. a Spare main fuse is provided under the starter magnetic switch. (CB400) Wire connector Main fuse 4. Connect the wire connector of the starter magnetic switch. 5. Install the left side cover. NOTICE If a fuse fails repeatedly, you likely have an electrical problem. Have your motorcycle inspected by your dealer. (CB400A) Wire connector Starter magnetic switch Spare main fuse Spare main fuse Starter magnetic switch Main fuse 92 32MFM630.indb 92 2010/12/14 15:44:42 Electrical Trouble a Blown Fuse ❙ FI Fuse P.90 4. Close the fuse holder. 5. Install the left side cover. (CB400A) Fuse box cover Troubleshooting (CB400) 1. Remove the left side cover. P.46 2. Open the fuse holder. 3. Pull out the FI fuse and check for a blown fuse. Always replace a blown fuse with a spare of the same rating. a Spare fuse is provided in the fuse box. (CB400A) 1. Remove the left side cover. P.46 2. Open the fuse box cover located beside the left rear suspension. 3. Pull out the fuse and check for a blown fuse. Always replace a blown fuse with a spare of the same rating. 4. Close the fuse box cover. 5. Install the left side cover. (CB400) FI fuse Fuse holder FI fuse Spare fuse NOTICE If a fuse fails repeatedly, you likely have an electrical problem. Have your motorcycle inspected by your dealer. 93 32MFM630.indb 93 2010/12/14 15:44:43 Information Keys .........................................................................................P.95 Instruments, Controls, & Other Features ............................................................ P.96 Fuels Containing Alcohol ...................................... P.98 Catalytic Converter .................................................... P.99 Caring for Your Motorcycle ............................... P.100 Storing Your Motorcycle ...................................... P.102 Transporting Your Motorcycle ........................ P.103 You & the Environment ........................................ P.104 Serial Numbers ............................................................ P.105 32MFM630.indb 94 2010/12/14 15:44:43 Keys Keys Ignition key A metal key holder may cause damage to the area surrounding the ignition switch. Information The ignition key contains a special coded chip that is recognized by the immobilizer system (HISS) in order to start the engine. Handle the key carefully to prevent damaging the HISS components. ● Do not bend keys or subject them to undue stress. ● Avoid prolonged exposure to sunlight or high temperatures. ● Do not grind, drill or in any way alter their shape. ● Do not expose to strong magnetic objects. To make a duplicate key and register it with your HISS system, take the spare key, the key number plate, and the motorcycle to your dealer. If you lose all keys and the key number plate, the PGM-FI unit/ignition control module must be replaced by your dealer. To avoid this, keep a duplicate key. If you lose a key, make another duplicate key immediately. 95 32MFM630.indb 95 2010/12/14 15:44:43 Instruments, Controls, & Other Features Instruments, Controls, & Other Features Ignition Switch The headlight is always ON when the ignition switch is ON. Leaving the ignition switch ON with the engine stopped will drain the battery. Information Do not turn the key while riding. Engine Stop Switch Do not use the engine stop switch except in an emergency. Doing so when riding will cause the engine to suddenly turn off, making riding unsafe. If you stop the engine using the engine stop switch, turn the ignition switch OFF. Failing to do so will drain the battery. Odometer The display locks at 999,999 when the readout exceeds 999,999. Tripmeter The tripmeter returns to 0.0 when the readout exceeds 999.9. HISS The Honda Ignition Security System (HISS) immobilizes the engine’s ignition system if an improperly-coded key is used to try and start the engine. When the ignition switch is turned OFF, the HISS immobilizer system is always alert, even if the HISS indicator is not flashing. If the ignition switch is turned ON with the engine stop switch in the RUN position, the HISS indicator turns ON and goes off after a few seconds to indicate it is OK to start the engine. HISS Indicator Does Not Turn OFF P.73 The HISS indicator starts flashing every 2 seconds for 24 hours after the ignition switch is turned OFF. To prevent or to restore the HISS indicator flashing: 96 32MFM630.indb 96 2010/12/14 15:44:44 Instruments, Controls, & Other Features 1. With the ignition switch ON, press and hold the A button ( P.14) for 1 second or more when the display function mode is odometer. a The HISS indicator flashes once. 2. Turn the ignition switch OFF. Ignition Cut-off System A banking (lean angle) sensor automatically stops the engine and fuel pump if the motorcycle falls over. To reset the sensor, you must turn the ignition switch to OFF and back to the ON position before the engine can be restarted. Information EC Directive This immobilizer system complies with R & TTE (Radio and Telecommunications Terminal Equipment and the mutual recognition of their conformity) Directive. Document Bag The owner’s manual, registration, and insurance information can be stored in the plastic document bag located under the seat. The declaration of conformity to R & TTE Directive is provided to the owner at the time of purchase. The declaration of conformity should be kept at a safe place. When the declaration of conformity is lost or is not provided, contact your dealer. 97 32MFM630.indb 97 2010/12/14 15:44:44 Fuels Containing Alcohol Fuels Containing Alcohol Some conventional fuels blended with alcohol are available in some locales to help reduce emissions to meet clean air standards. If you plan to use blended fuel, check that it is unleaded and meets the minimum octane rating requirement. Information The following fuel blends can be used in your motorcycle: ● Ethanol (ethyl alcohol) 10 % by volume (max). ● Petrol containing ethanol may be marketed under the name Gasohol. ● Methanol (methyl alcohol) 5 % by volume (max) that contain cosolvents and corrosion inhibitors to protect the fuel system. Never use a blend containing more than 5 %. The use of petrol containing more than 10 % ethanol (or more than 5 % methanol) may: ● Damage the painting of the fuel tank. ● Damage the rubber tubes of the fuel line. ● Cause corrosion of the fuel tank. ● Cause poor drivability. NOTICE Use of blended fuels containing higher than approved percentages can damage metal, rubber, plastic parts of your fuel system. If you notice any undesirable operating symptoms or performance problems, try a different brand of petrol. 98 32MFM630.indb 98 2010/12/14 15:44:44 Catalytic Converter Catalytic Converter A defective catalytic converter contributes to air pollution and can impair your engine’s performance. A replacement unit must be an original Honda part or equivalent. Information This motorcycle is equipped with an oxidation catalytic converter. The catalytic converter contains precious metals that serve as catalysts in high temperature chemical reactions that convert hydrocarbons (HC) and carbon monoxide (CO) in the exhaust gasses into safe compounds. Follow these guidelines to protect your motorcycle’s catalytic converter. ● Always use unleaded petrol. Leaded petrol will damage the catalytic converter. ● Keep the engine in good running condition. ● Have your motorcycle serviced if your engine is misfiring, backfiring, stalling, or otherwise not running properly, stop riding and turn off the engine. 99 32MFM630.indb 99 2010/12/14 15:44:44 Caring for Your Motorcycle Caring for Your Motorcycle Information Frequent cleaning and polishing is important to ensure the life of your Honda. A clean motorcycle makes it easier to spot potential problems. In particular, seawater and salts used to prevent ice on roads promote the formation of corrosion. Always wash your motorcycle thoroughly after riding on coastal or treated roads. Washing Allow the engine, muffler, brakes, and other high-temperature parts to cool before washing. 1. Rinse your motorcycle thoroughly using a garden hose to remove loose dirt. 2. If necessary, use a sponge or a soft towel with mild cleaner to remove road grime. a Clean the headlight lens and other plastic components with extra care to avoid scratching them. Avoid directing water into the air cleaner, muffler, and electrical parts. 3. Thoroughly rinse your motorcycle with plenty of clean water. 4. After the motorcycle dries, lubricate any moving parts. a Make sure that no lubricant spills onto the brakes or tyres. Brake discs or pads contaminated with oil will suffer greatly reduced braking effectiveness and can lead to a crash. 5. Lubricate the drive chain immediately after washing and drying the motorcycle. 6. Apply a coat of wax to prevent corrosion. a Avoid products that contain harsh detergents or chemical solvents. These can damage the metal, paint, and plastic on your motorcycle. Keep the wax clear of the tyres and brakes. a If your motorcycle has any matte painted parts, do not apply a coat of wax to the matte painted surface. 100 32MFM630.indb 100 2010/12/14 15:44:44 Caring for Your Motorcycle ❙ Washing Precautions Do not direct water at the air cleaner: a Water in the air cleaner can prevent the engine from starting. ● Do not direct water near the headlight: a Any condensation inside the headlight should dissipate after a few minutes of running the engine. ● Aluminium Components Aluminium will corrode from contact with dirt, mud, or road salt. Clean aluminium parts regularly and follow these guidelines to avoid scratches: ● Do not use stiff brushes, steel wool, or cleaners containing abrasives. ● Avoid riding over or scraping against curbs. Information Follow these guidelines when washing: ● Do not use high-pressure washers: a High-pressure water cleaners can damage moving parts and electrical parts, rendering them inoperable. ● Do not direct water at the muffler: a Water in the muffler can prevent starting and causes rust in the muffler. ● Dry the brakes: a Water adversely affects braking effectiveness. After washing, apply the brakes intermittently at low speed to help dry them. ● Do not direct water under the seat: a Water in the underseat compartment can damage your documents and other belongings. 101 32MFM630.indb 101 2010/12/14 15:44:44 Storing Your Motorcycle Exhaust Pipe and Muffler Information The exhaust is made of stainless steel, which can become tarnished with burn marks if splattered with oil or other substances when hot. To remove burn marks, use a mild abrasive compound. To remove dirt and mud, use a kitchen cleaning solution for stainless steel and wash with a soft sponge. Rinse with plenty of water to remove all residue. NOTICE Even though the exhaust is made of stainless steel, it can become stained. Remove all marks and blemishes as soon as they are noticed. Storing Your Motorcycle If you store your motorcycle outdoors, you should consider using a full-body motorcycle cover. If you won’t be riding for an extended period, follow these guidelines: ● Wash your motorcycle and wax all painted surfaces (except matte painted surfaces). Coat chrome pieces with rust-inhibiting oil. ● Lubricate the drive chain. P.40 ● Place your motorcycle on a maintenance stand and position a block so that both tyres are off the ground. ● After rain, remove the body cover and allow the motorcycle to dry. ● Remove the battery ( P.47) to prevent discharge. Charge the battery in a shaded, well-ventilated area. a If you leave the battery in place, disconnect the negative terminal to prevent discharge. 102 32MFM630.indb 102 2010/12/14 15:44:45 Transporting Your Motorcycle After removing your motorcycle from storage, inspect all maintenance items required by the Maintenance Schedule. Transporting Your Motorcycle NOTICE Towing your motorcycle can cause serious damage to the transmission. Information If your motorcycle needs to be transported, it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform, and motorcycle tie-down straps. Never try to tow your motorcycle with a wheel or wheels on the ground. 103 32MFM630.indb 103 2010/12/14 15:44:45 You & the Environment You & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect the environment. it down a drain or on the ground. Used oil, petrol, coolant, and cleaning solvents contain poisons that can hurt refuse workers and contaminate drinking water, lakes, rivers, and oceans. Choose Sensible Cleaners Information Use a biodegradable detergent when you wash your motorcycle. Avoid aerosol spray cleaners that contain chlorofluorocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Recycle Wastes Put oil and other toxic wastes in approved containers and take them to a recycling centre. Call your local or state office of public works or environmental services to find a recycling centre in your area, and to get instructions on how to dispose of non-recyclable wastes. Do not place used engine oil in the trash, or pour 104 32MFM630.indb 104 2010/12/14 15:44:45 Serial Numbers Serial Numbers Information The frame and engine serial numbers uniquely identify your motorcycle and are required in order to register your motorcycle. They may also be required when ordering replacement parts. The frame number is stamped on the right side of the steering head. The engine number is stamped on the right side of the crankcase. You should record these numbers and keep them in a safe place. Frame number Engine number 105 32MFM630.indb 105 2010/12/14 15:44:45 Specifications ■ Main Components Type Overall length Overall width Overall height Wheelbase Minimum ground clearance Caster angle Trail Curb weight Specifications Maximum weight capacity*1 Passenger capacity Minimum turning radius Displacement Bore x stroke Compression ratio NC42 2,040 mm (80.3 in) 725 mm (28.5 in) 1,070 mm (42.1 in) 1,410 mm (55.5 in) Fuel Tank capacity Battery 130 mm (5.1 in) 25º 05´ 90 mm (3.5 in) CB400 CB400A 195 kg (430 lb) 200 kg (441 lb) Gear ratios 179 kg (395 lb) Rider and 1 passenger Reduction ratios (primary / final) 399 cm3 (24.3 cu-in) 55.0 x 42.0 mm (2.17 x 1.65 in) 11.3:1 Unleaded petrol Recommended: 91 RON or higher 18.0 litres (4.76 US gal, 3.96 Imp gal) 12V-8.6Ah (10 HR) / 9.1Ah (20 HR) 1st 3.307 2nd 2.294 3rd 1.750 4th 1.421 5th 1.240 6th 1.130 2.171 / 2.933 2.6 m (8.53 ft) *1 Including rider, passenger, all luggage, and accessories 106 32MFM630.indb 106 2010/12/14 15:44:45 Specifications ■ Service Data Front Rear Front Rear Front Rear 290 kPa (2.90 kgf/cm2, 42 psi) Front Rear Spark plugs (standard) 1.5 mm (0.06 in) 2.0 mm (0.08 in) CR8EH-9 (NGK) or U24FER9 (DENSO) 0.80 to 0.90 mm (0.031 to 0.035 in) 1,400 ± 100 rpm Tyre type Recommended Tyres Spark plug gap Idle speed Front Rear Honda 4-stroke motorcycle oil API Service Classification SG or higher, Recommended excluding oils marked as engine oil “Energy Conserving,” SAE 10W-30, JASO T 903 standard MA 3.0 litres (3.2 US qt, After draining 2.6 Imp qt) After draining & 3.2 litres (3.4 US qt, Engine oil engine oil filter 2.8 Imp qt) capacity change 3.8 litres (4.0 US qt, After disassembly 3.3 Imp qt) Recommended Honda DOT 4 Brake Fluid brake fluid Cooling system 2.2 litres (2.3 US qt, 1.9 Imp qt) capacity Recommended Pro Honda HP Coolant coolant Specifications Tyre air pressure (Driver only) Tyre air pressure (Driver and passenger) Minimum tread depth 120/60ZR17M/C (55W) 160/60ZR17M/C (69W) Radial, tubeless DUNLOP D204FL BRIDGESTONE BT-50F DUNLOP D204J BRIDGESTONE BT-50R 225 kPa (2.25 kgf/cm2, 33 psi) 250 kPa (2.50 kgf/cm2, 36 psi) 250 kPa (2.50 kgf/cm2, 36 psi) Tyre size 107 32MFM630.indb 107 2010/12/14 15:44:45 Specifications Recommended drive chain lubricant Drive chain slack Standard drive chain Standard sprocket sizes Drive chain lubricant designed specifically for O-ring chains 25 to 35 mm (1.0 to 1.4 in) RK 525SMOZ5 No. of links Engine sprocket Rear wheel sprocket Specifications Front turn signal lights Rear turn signal lights License plate light 12V-60/55W LED SI type U type 12V-21W x 2 12V-5W Main fuse FI fuse Other fuses 108 15T 44T ■ Bulbs Headlight Brake/Tail light ■ Fuses 12V-21/5W x 2 12V-21W x 2 30A 20A CB400 CB400A 20A, 10A 30A, 20A, 10A ■ Torque Specifications Engine oil drain bolt Oil filter Front axle bolt Front brake caliper fixing bolts Front axle pinch bolts Rear axle nut 30 N·m (3.1 kgf·m, 22 lbf·ft) 26 N·m (2.7 kgf·m, 19 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 108 32MFM630.indb 108 2010/12/14 15:44:45 Index A ABS Indicator.............................................18 Accessories.................................................10 B C Caring for Your Motorcycle .................. 100 Clutch System ........................................... 63 Colour Label ..............................................35 Combined ABS ............................................8 Compartment Centre ......................................................27 Luggage tie-down hooks .........................28 Owner’s Manual.................................26, 97 Rear .........................................................26 Tool Kit ............................................. 26, 44 Coolant ............................................... 40, 53 Crankcase Breather .................................. 67 D Digital Clock Adjustment .........................17 Drive Chain ................................................59 E Electrical Trouble ..................................... 86 Engine Number..................................................105 Oil ..................................................... 38, 49 Oil Filter ...................................................51 Overheats.................................................74 Starting ....................................................22 Stop Switch ....................................... 20, 96 Stopping ................................................. 96 Environment ........................................... 104 Index Battery ................................................ 36, 47 Brakelight Switch ......................................71 Brakes Fluid ...................................................39, 55 Pad Wear ................................................ 56 Braking ........................................................7 Bulb Brake/Tail Light........................................ 88 Front/Rear Turn Signal ............................. 88 Headlight .................................................87 License Plate Light ................................... 89 a A to E 109 32MFM630.indb 109 2010/12/14 15:44:45 Index a F to L F Flooded Engine ........................................ 22 Frame Number ........................................105 Front Brake Lever Adjustment ................ 68 Front Suspension ......................................69 Fuel Gauge ......................................................16 Recommended .........................................24 Remaining ................................................16 Tank Capacity...........................................24 Fuels Containing Alcohol ........................ 98 Fuses.....................................................37, 90 High Coolant Temperature Indicator.............................................18, 74 HISS Indicator ......................................19, 73 Horn Button ............................................. 20 I Index Ignition Cut-off System Banking Sensor ........................................97 Side Stand ............................................... 58 Ignition Key .............................................. 95 Ignition Switch ....................................21, 96 Indicators ...................................................18 Instruments ...............................................14 G Gasohol ..................................................... 98 H Hazard Switch .......................................... 20 Headlight Aim ...........................................71 Headlight Dimmer Switch ....................... 20 Helmet Holder.................................... 25, 26 High Beam Indicator .................................19 L Load Limits ................................................11 Loading Guidelines ...................................11 Low Oil Pressure Indicator .................18, 75 Luggage tie-down hooks ........................ 28 110 32MFM630.indb 110 2010/12/14 15:44:46 Index a M to R M Maintenance Fundamentals.......................................... 34 Importance ............................................. 30 Safety...................................................... 30 Schedule ..................................................31 Maximum Weight Limit............................11 Modifications ............................................10 N Neutral Indicator ......................................19 R Recommended Coolant ................................................... 40 Fuel ..........................................................24 Oil ........................................................... 38 Refuelling ..................................................24 Removal Battery .....................................................47 Seat .........................................................45 Side Covers ............................................. 46 Repair Kit ...................................................78 Riding Precautions ......................................7 Index O Odometer ........................................... 15, 96 Oil Engine ............................................... 38, 49 Other Warning Indications ..................... 77 Overheating ..............................................74 Petrol .................................................. 24, 98 PGM-FI (Programmed Fuel Injection) malfunction indicator lamp (MIL)....18, 75 Protective Apparel ......................................8 P Parking.........................................................9 Parts Location ...........................................12 Passing light control switch .................... 20 111 32MFM630.indb 111 2010/12/14 15:44:46 Index a S to W S Index Safety Precautions ......................................6 Seat ........................................................... 45 Serial Numbers ........................................105 Shifting Gears .......................................... 23 Side Covers ............................................... 46 Side Stand ................................................. 58 Side Stand Ignition Cut-off System ........ 58 Specifications ......................................... 106 Speedometer.............................................14 Start Button ............................................. 20 Starting the Engine ................................. 22 Steering Lock .............................................21 Stopping Engine ...................................... 96 Storage Compartment ..........................................25 Owner’s Manual.................................25, 97 Storing Your Motorcycle ........................102 Switches .................................................... 20 Tool Kit ..................................................... 44 Transporting Your Motorcycle ...............103 Tripmeter ............................................ 15, 96 Troubleshooting .......................................72 Turn signal indicators ...............................19 Tyres Air Pressure ..............................................41 Puncture ..................................................78 Replacing ........................................... 41, 78 W Warning Indicators ON .............................75 Washing Your Motorcycle ..................... 100 Weight Limit..............................................11 Wheels Front removal ...........................................79 Rear removal ........................................... 83 T Tachometer ...............................................14 Throttle..................................................... 66 112 32MFM630.indb 112 2010/12/14 15:44:46