HONDA CB750F2 CB SevenFifty OWNER’S MANUAL I MANUEL DU CONDUCTEUR I I FAHRER-HANDBUCH © Honda Motor C0,, Ltd. 1996 IMPORTANT NUT ICE - OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. Never exceed the maximum weight capacity as shown on the tyre information label. 0 ON-ROAD USE This motorcycle is designed to be used only on the road. ' READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: AWARNING Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: _ Indicates a possibility of personal injury or equipment damage it instructions are not followedt NOTE: Gives helpful information. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold. HONDA CB750F2 CB SevenF if ty OWNER’S MANUAL All information in this publication is based on the latest production information available at the time of approval for printing. HONDA MOTOR C0.,LTD. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. WELCOME The motorcycle presents on a challenge to master the machine a challenge to adventure. You ride through the Win , linked to the road by a vehicle that responds to our commands as no other does. Unlike an automobile, there is no metal ane around you. Li e an airplane, a reside inspection and regular maintenance are essentia to your saiety. Your reward is ree om. To meet the challen es safely» and to en’o the adventure full . ou should become thoroughlyiamiliarwit thisowner‘smanual FOREYOU RIDET E OTORCYCLE. When service is required. remember that your Honda dealer knows your motorcycle best. If you have the required mechanical “know-how" and tools, your dealer can supply you with an official Honda Service Manual to help you perform many maintenance and repair tasks. Pleasant riding. and thank you for choosing a Honda ! o Following codes in this manual indicate each country. u rance G _ rmany ropean Finland sales Denmark Belgium Ital Ho and Portugal o The specifications may vary with each locale OPERATION Fig 1e 2 2 3 6 9 12 12 13 17 19 23 24 MOTORCYCLE SAFETY Safe Riding Rules Protective Apparel Modifications Loading and Accessories PARTS LOCATION Instruments and Indicators MAJOR COMPONENTS (Information you need to opetate this motorcycle) Suspension Brakes Clutch Fuel Engine Oil Tubeless Tyres page 27 27 28 29 30 30 31 32 32 33 34 35 39 42 ESSENTIAL INDIVIDUAL COMPONENTS Ignition Switch Right Handlebar Controls Left Handlebar Controls FEATURES (Not required for operation) Steering Lock Helmet Holder Seat Document Compartment Side Cover OPERATION Prende Inspection Starting the Engine Running-in Riding Braking Parking Anti-theft Tips MAINTENANCE page 44 45 48 49 50 51 52 55 56 58 59 60 61 66 67 68 75 77 80 82 MAINTENANCE Maintenance Schedule Tool Kit Serial Numbers Colour Label Maintenance Precautions Engine Oil Crankcase Breather Spark Plugs Throttle Operation Idle Speed Air Cleaner Drive Chain Drive Chain Slider Side Stand Wheel Removal Brake Pad Wear Battery Fuse Replacement Bulb Replacement page 88 90 90 92 93 ‘37 CLEANING STORAGE GUIDE Storage Removal from Storage SPECIFICATIONS NOISE CONTROL SYSTEM (AUSTRALIA ONLY) MUFORCYCLE SAFETY AWARNING 4tMotorcycle riding requires special efforts on your art to ensure your safety. Know I ese requirements before you ride: SAFE RIDING RULES LAlways make a pre-ride inspection (page 34) beiore you start the engine. You may prevent an accident or equipment damage. ‘ 2. Many accidents involve inexperienced riders. Most countries re uire a special motorcycle riding test or icense. Make sure ou are qualified before on ride. NEV R lend your motorcyc to an inexperienced rider. 3.Many automobile/motorcycle accidents happen because the automobile driver does not “see” the motorcyclist. _ Make yourseli conspicuous to help avord the accident that wasn’t your fault: 0 Wear bri ht or reflective clothing. 0 Don‘t ri e in another motorists “blind spot." 4. Obey all national and local laws and re lations. _ 4 I xcessive 5 ed is a factor in many accidents. 0 ey the speed limits. and NEVER travel faster than conditions warrant. 0 Signal before you make a turn or lane change. Your size and maneuverability can surprise other motorists. _ 5. Don't let other motorists surprise you. Use extra caution at intersections parking lot entrances and exits, and driveways. 6. Keep both hands on the handlehars and both feet on the footpegs while riding. A passenger should hold on ‘to the motortycle or the operator With both hands and keep both feet on the passenger footpegs. PROTECTIVE APPAREL 1.Most motorcycle accident fatalities are due to head injuries: ALWAYS wear a helmet. You should also wear a face shield or goggles as well as boots, gloves and protective clothing. A passenger needs the same protection. 2.The exhaust system becomes hot during operation, and it remains hot for a while alter stopping the engine. Be careful not to touch the exhaust system while it is Fat. Wear clothing that fully covers your egs. 3. Do not wear loose clothing which could catch on the control levers, iootpegs. drive chain or wheels. MODIFICATIONS “WARNING oModification of the motorcycle, or removal of original equipment, may render the vehicle unsafe or illegal. Obey all national and local equipment regulations. LOADING AND ACCESSORIES AWARNING tTo prevent an accident, use extreme care when adding and riding with accessories and cargo. Addition of accessories and cargo can reduce a motorcycle‘s stability, performance and safe operating speed. Never ride an accessory-equipped motorcycle at speeds above 130 km/h (80 mph). And remember that this 130 km/h (80mph) limit may be reduced by installation of nonvflonda accessories, improper loading, worn tyres and overall motorcycle condition, poor road or weather conditions. These general guidelines may help you decide whether or how to equip your motorcycle and how to load it safely. Loading The combined weight of the rider, passenger, cargo and additional accessories must not exceed the maximum weight capacity: 190 kg (419 lbs) Cargo weight alone should not exceed: 27 kg (60 lbs) 1. Keep cargo and accessory weight low and close to the center of the motorcycle. Load weight equally on both sides to minimize imbalance. As weight is located further (mm the motorcycles center of gravity, handling is proportionally affected. 2. Adjust tyre pressure (page 24) and rear suspension (page 12) to suit load weight and riding condiu’ons. 3.Vehicle handling and stability can be adversely affected by loose cargo. Recheck cargo security and accessory mounts frequently. 4. Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebars, fork. or fender. Unstable handling or slow steering response may result. Accessories Genuine Honda accessories have been specifically designed for and tested on this motorcycle. Because the factory cannot test all other accessories, you are personally responsible for proper selection, installation, and use of non-Honda accessories, Always follow the guidelines under Loading, and these: 1. Carefully inspect the accessory to make sure it does not obscure any lights, reduce ground clearance and banking angle, or limit suspension travel, steering travel or control operation. 2. Large fork-mounted iairings or Windshields, or poorly designed or improperly mounted fairings can produce aerodynamic forces that cause unstable handling. Do not insmll (airings that decrease cooling air flow to the engine. 3. Accessories which alter your riding position by moving hands or feet away from controls may increase reaction time in an emergency. 4. Do not add electrical equipment that will exceed the motorcycle’s electrical system capacity, A blown fuse could cause a dangerous loss of lights or engine power. 5. This motorcycle was not designed to pull a Sidecar or trailer. Handling may be seriously impaired if so equipped. PART S LOCATION Speedometer Tachometer Choke lever From brake fluid reservoir Rearview mirror Rearview mirror Clutch lever Left handlebar controls Fuel fill cap L l Document compartment Battery Passenger foolpeg Foalpeg Rear brake pedal Oil filler Cap/ dipstick Fuel valve Air cleaner Helmek hbiders Toolbox Gear shift peda! Side sland Footpeg Passenger foolpeg INSTRUMENTSAN'D INDICATORS The indicators are contained in the instrumem panel. Their functions are described in the tables on the [allowing pages. (1) Tripmeler (2) Speedometer (3) Odometer (4) Tachometer (5] Tachometer red zone (5) Side sland indicamr (7) Low oil pressure indicamr (8) Turn signal indicator (9) Neutral indicator (10) High beam indicator (11) Tn'pmeter reset knob (Ref.No.) Description Function (l) Tripmeter Shows mileage per trip (2) Speedometer Shows n'ding speed. (3) Odometer Shows accumulated mileage. (4) Tachometer Shows engine rpm. (5) Tachometer red zone Never allow the tachometer needle to enter the red zone, even after the engine has been broken in. CAUTIQN: . . Running the engine beyond recommended maxi- mum en e speed (tachometer red mne) can damage t e engine. (6) Side stand indicator Lights when the side stand is put down. Before parking, check that the side stand is fully down; the light 0an indicates the side stand ignition cut-off system (page 35) is activated. 1D (Ref.No.) Description Function (7) Low oil pressure indicator (red) Lights when the engine oil ressure is below the normal 0 ratin range. Shou d light when ignition switch is N an engine is not running. Should 0 out when the engine starts. except [or occasional flic ering at or near idling speed when engine is warm. CAUTION: II Running the engine with insufficient oil pressure may cause serious engine damage. (8) Turn signal indicator Flashes when either turn signal is operated, (9) Neutral indicator (green) Lights when the transmission is in neutral. (10) High beam indicator (b ue) Lights when theheadlighi is on high beam. (11) Tripmeter reset knob Resets tripmeter to zero (0). Turn knob in direction shown. l1 MAJOR COMPONENTS (Information you need to operate this motorcycle) AWARMNG ' If the Pre-ride Inspecfion (page 34) is not performed, severe personal injury or vehicle damage may result. SUSPENSION Each shock absorber (1) has 5 adjustment positions for different load or riding conditions. Use a pin spanner (Z) to adjust the rear shocks. Position Us for light loads and smooth road conditions. Posirions 2 to 5 increase spring preload for a stiffer rear suspension, and can be used when the matorcycle is heaviiy loaded. Be certain to adjust both shock absorbers to the same position. Standard position: 2 12 (1) Shock absorber (2) Pin spanner BRAKES Both the from and rear brakes are the hydraulic disc types. As the brake pads wear, the brake fluid level drops, There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks. If the control lever or pedal free travel becomes excessive and the brake pads are not worn beyond the recommended limit (page 75), there is probably air in the brake system and it must be bled. See your authorized Honda dealer for this service. Front Brake Fluid Level: AWARNING tBrake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed. tKEEP 0UP 0F REACH OF CHJL DREN. CAUTION: ‘ Handle brake fluid with care because it can damage plastic and painted surfaces. * When adding brake fluid, be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out. t Use only DUI‘ 4 brake fluid from a sealed container. * Never allow contaminants such as dirt or water to enter the brake fluid reservoir. 13 Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark (1). Remove the screws (2), reservoir cover (3), diaphragm plate (4). and diaphragm (5), Fill the reservoir with DOT 4 BRAKE FLUID from a sealed conminer up to the upper level mark (6), Reinstall the diaphragm, diaphragm plate, and cover. Tighten the screws securely. (1) LOWER level mark (2) Screws (3) Reservoir cover 1 4 (4) Diaphragm nlale (5) Diaphragm (e) UPPER level mark Rear Brake Rear Brake Huiflevel: [AWARNINC ' Brake fluid may cause irritation Avoid Contact with skin or eyes. In case of Contact, flush thoroughly with water and call a doctor if your eyes were exposed. ‘KEEP OUI‘ OF REACH OF CHIL DREN. CAUTION: ' Handle brake fluid with care because it can danmge plastic and painted surfaces. ‘ When adding brake fluid, be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out. * Use only D01‘ 4 brake fluid from a sealed container. ' Never allow contaminants such as dirt or water to enter the brake fluid reservoir. Check the brake fluid level from the inspection window (1) of the right side cover with the motorcycle in an upright position, (1) Inspection window Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark (2). Remove the right side cover (page 33). Remove the reservoir cap (3). diaphragm plate (4), and ‘ diaphragm (5)» Fill the reservoir with DOT 4 BRAKE FLUID from a sealed container up to the UPPER level mark (6) Reinstall the diaphragmdiaphragm plate and cap (2) LOWER level mark (5) Diaphragm <3) Reservoir cap (6) UPPER level mark (4) Diaphragm plate 15 Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings 16 CLUTCH Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep; or it the clutch slips, causing acceleration to lag behind engine speed. Minor adjustments can be made with the clutch cable adjuster (4) at the lever (1) Normal clutch lever free play is: 10*20 mm (04,03 in) 1. Pull hack the mbber dust cover (2). Loosen the lock nut (3) and turn the adjuster (4), Tighten the lock nut (3) and check the adjustment. .If the adjuster is threaded out near its limit or if the correct free play cannot be obtained, loosen the lock nut (3) and turn in the cable adjuster (4) completely. Tighten the lock nut (3) and install the dust cover. to (1) Clutch lever (2) Dust cover (3) Lock nut (4) Clutch cable adjuster (A) lncreaselree play (8) Decrease tree play 17 3. Loosen the lock nut (6) at the lower end of the cable. Turn the adjusting nut (5) to obtain the specified free play. Tighten the lock nut (6) and check the adjustment. Scan the engine. pull in the clutch lever 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 The motorcycle should begin to move smoothly and accelerate gradually. NOTE: ‘ If proper adjustment cannot be obtained or the clutch does not work correctly. see your authorized Honda dealer. r" 18 Other Checks: 1 Heel? the clutch cable for kinks or signs of wear that could cause sticking or failure Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion. (5) Adjusting nut (6) Lock nut (A) Increase lree play (B) Decrease free play FUEL OFF With the fuel cock in the OFF position, fuel cannot flow from the tank to the carburetor. Turn the cock OFF whenever the motorcycle is not in use. ON With the fuel cock in the ON position. fuel will flow from the main fuel supply to the carburetor. RES With the fuel cock in the RES position, fuel will flow from the reserve tuel supply to the carburetor. Use the reserve fuel only when the main supply is gone. Refill the tank as soon as possible after switching to RES. The reserve fuel supply is: 30 ll (0.79 US gal , 0‘66 Imp gal) AWARNlNG a To avoid running out of fuel that may result in a sudden stop, learn how to operate the fuel cock when riding the motorcycle. NOTE: t Remember to check that the fuel cock is in the ON position each time you retuel. I! the cock is left in the RES position. you may run out of fuel with no reserve. (1) Fuel valve 19 Fuel Tank The fuel tank capacity including the reserve supply is: 20.0 a (5.23 us gal , 4.40 Imp gall To open the fuel fill cap (1), insert the ignitian key (2) and tum it clockwise. The fuel fill cap is hinged and will lift up (1» Fuel fill cap (2) Ignition key (3; Filler neck 20 After refueling, to close the fuel fill cap. push the fuel fill cap into the filler neck until it snaps closed and locks. Remove the key. Use unleaded or lowrlead petrol with a research octane number of 91 or higher. We recommend that you use unleaded petrol because it produces fewer engine and spark plug deposits and extends the life of exhaust system components. FOR AUSTRALIA ONLY: Use unleaded petrol with a research octane number of 91 or higher. CAUTION: ‘ If “spark knock” or “pinking” oocurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinking persists, consult your authorized Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda’s Limited Warranty. [AWARNlNG ' Petrol is extremely flammable and is explosive under certain conditions. Refuel in a well—ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where petrol is stored or where the fuel tank is refueled. 4' Do not overfill the tank (there should be no fuel in the filler hack (3)) After refueling, make sure the fuel fill cap is closed securely. ' Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may igaite. If any fuel is spilled, make sure the area is dry before starting the engine. tAvoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN. (3) Flller neck 21 Petrol Containing Alcohol if you decide to use a petrol containing alcohol (gasohol). be sure it‘s octane rating is at least as high as that recommended by Honda. There are two types at “gasohol”: one containing ethanol. and the other con- taining methanol. Do not use petrol that contains more than 10% ethanol. Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use petrol containing more than 5% methanol. even if it has cosolvents and corrosion inhibitors. NOTE: ' Fuel system damage or engine performa- nce problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete. *Before buying iuel from an unfamiliar station, try to find out if the fuel contains alcohol. if it does, confirm the type and percentage of alcohol used. if you notice any undesirable operating symptoms while using a petrol that contains alcohol, or one that you think contains alcohol. switch to a petrol that you know does not contain alcohol. ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be mainmined between the upper (l) and lower (2) level marks on the dipstick (3). 1. Start the engine and let it idle for a few minutes. Make sure the low oil pressure indicator goes off. If the light remains on. stop the engine immediately. 2. Stop the engine and hold the motnrcycle in an upright position on firm, level ground. 3‘ After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the dipstick without screwing it in. Remove the dipstick The oil level should be between the upper and lower marks on the dipstick. 4. If required, add the specified oil (see page 52) up to the upper level mark. Do not overiill. 5. Reinstall the oil filler cap/ dipstick. Check for oil leaks. CAUTION: ' Running the engine with insufficient oil pressure may cause serious engine damage. (3) (1) Upper level mark (2) Lower level mark (3) on filler cap/dipstick 23 TUBELESSTYRES This motorcycle is equipped with tubeless tyres, valves, and wheel rims. Use only tyres marked ‘TUBELESS" and tnbeless valves 0n rims marked “TUBELESS TYRE APPLICABLE," Proper air pressure will provide maximum stability, riding comfort and tyre life, Check tyre pressure frequently and adjust it neccessary. NOTE: * Tyre pressure should be checked before you ride while the tyres are "cold”. u Tubeless tyres have some degree of seifsealing ability it they are punctured, and leakage is often very slow. Inspect very closely (or punctures, especially if the tyre is not fully inflated. 24 Tyre size Front 120/70R17 58V DUNLOP 120/702R17 MICHELIN Rear 150/70R17 69V DUNLOP 150/702R17 MICHELIN Cold re pressures kPa /cm‘, psi) Driver Front 250 (2.50 l 36) only Rear 250 (2.50 , 36) Driver and Front 250 (2,50 , 36) one passenger Rear 290 (2.90 , 42> Tyre brand TUBELESS ONLY DUNLOP Front D202F Rear D202 MICHELIN Front ABQX Rear MBSX Check the tyres for cuts. embedded nails or other sharp objects. Check the rims for dents or deformation. it there is any damage, see your authorized Handa dealer for repair, replacement. and balancing. AWARNlNG 'Improper tyre inflation will cause abnormal tread wear and create a safety hazard. Undeflnflation may result in the tyre slipping on, or coming off of the rim causing tyre deflation that may result in a loss of vehicle control. ' Operation with excessively worn tyres is hazardous and will adversely affect traction and handling. Replace tyres before tread depth at the center of the tyre reaches the following limit: Minimum tread depth Front: 15 mm (0059 in) Rear: 20 mm (@079 in) NOTE: ' German law prohibits use of tyres whose tread depth is less than 1.6 mm. 25 Tyre Repair/ Replacement: See your authorized Honda Dealer. AWARNING - The use of tyres other than those listed on the tyre information label may adversely affect handling. I Do not install tube-type tyres on tubeless rims. The beads may not seat and the tyres could slip on the rims, causing tyre deflation that may result in a loss of vehicle control. ‘ Do not install a tube inside a tubeless tyret Excessive heat build—up may cause the tube to burst resulting in rapid tyre deflation that may result in a loss of vehicle controll ‘ Replace the tyre if the sidewall is punctured or damaged. Sidewall flexing may cause repair failure and tyre deflation that may result in a loss of vehicle control. 26 [AWARNING ' Proper wheel balance is necessary for safe, stable handling of the motorcycle. Do not remove or change any wheel balance weights. When wheel balancing is required, see your authorized Honda dealer. Wheel balancing is required after tyre repair or replacement. * To avoid possible repair failure and tyre deflation that may result in a loss of vehicle control, do not exceed 80 km/h (50 mph) for the first 24 hours, or 130 km/ h (80 mph) at any time, after tyre repair. CAUTION: ‘ Do not try to remove tubeless tyres without special tools and rim protectors. You may damage the rim sealing surface or disfigure the rim. ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (1) is below the indicator panel. (1) Ignition switch You should received a key number plate with your key. You will need this key number if you ever have to replace a lost key. Store this plate in a safe place. (2) (2) Key number plate Key Position Function l Key Removi— LOCK Sleen'ng is locked, Engine and lights cannot be Key can be (steering lock) operated. removed OFF Engine and lights cannot be operated. Key can be I- removed ON Engine and lights can be operated. Key cannot be removed 27 RIGHT HANDLEBAR CONTROLS Engine Stop Switch The engine stop switch (1) is next to the throttle grip. When the switch is in the O (RUN) position, the engine will operate. When the switch is in the 8 (OFF) position, the engine will not operate. This switch is intended primarily as a safety or e— mergency switch and should normally re main in the O (RUN) position. Headlight Switch < Except U type > The headlight switch (2) has three positions; #- , 5005 and OFF marked by a dot to the right of £305. W! :Headlight, taillight, position light and meter iights on. 5002 :Position light, taillight and meter lights on. OFF (dot): Headlight, taillight, position light and meter lights off. 28 StarterButton The starter button (3) is below the head light switch (2). When the starter button is pressed, the starter motor cranks the engine. If the engine stop switch is in the 1% (OFF) position, the starter motor will not operate. See page 36 for the starting procedure. (1) Engine stop switch (2) Headlight switch (3) Starter button LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch (1 Push the dimmer switch to (hint select high beam or to ED (L0) to select low beam Passing Light Control Switch (2) When this switch is pressed, ihe headlight flashes on to signal approaching cars or when passing. Turn Signal Switch (3) Move [0 ¢' (L) to signal a left turn, fl) (R) to signal a right turn. Press to turn signal off. Horn Button (4) Press the button to sound the horn (2) (I) (4) (1) Headlight dimmer switch (2) Passing light controlswitch (3) Turn signal switch (4) Hum buuon FEATURES (Not required for operation) STEERING LOCK To luck the steering, turn the handlebars all the way to Ihe left or right, turn the key (1) to LOCK while pushing in. Remove the key. AWARNING *Do not turn the key to P or LOCK while riding the motorcycle; loss of vehicle control will result. 30 (1) Ignition key (A) Push in (B) Turn to LOCK HELMET HOLDER The helmet holders are located below the seaL Remove the seat (see page 32). Hang oThe helmet holder is designed for the helmets on the holder hooks (1). Install helmet security while parked. Do not the seat and lock it securely, ride with a helmet attached to the holder; the helmet may interfere with safe operation and result in loss of control. (l) Holder hacks 31 SEAT To remove the seat (I), insert the ignition key into the seat lock (2) and turn it clockwise Pull the seat back and up. To install the seat. insert the prong into the recess under the frame cross member and then push down on the rear 01 the seat CAUTION: ' Be sure the seat is locked securely in position after installation. DOCUMENT COMPAR’I‘MENT The document bag is placed underneath the seat inside the tray beside the tool bag. To access the document, pull the tray out. This owner’s manual and other documents should be stored in this compartment. When washing your motorcycle, be careful not to flood this area with when (1) Seal (2) Seal lock 32 (1) Document oompanrnenl SIDE COVER The side cover (I) must be removed for the battery and air cleaner element maintenance. To remove the side cover: 1, Remove the seat. 2. Remove the screw (2). 3, Pull the retaining mbs (3) out from the rubber holes and remove the side cover (1). (1) (l) Sidecover (3) Retainingtabs (2) Screw NOTE: * Do not pull on the side cover with the screw (2) installed. 33 OPERATION PRE-RIDE INSPECTION AWARNING ' If the Pre-ride Inspection is not performed, severe personal injury or vehicle damage may result. Inspect your motorcycle every day before you ride it. The items listed here will only take a few minutes to inspect, and in the long run they can save time, expense. and possibly your life. 1. Engine oil levelradd engine oil it required (page 23). Check for leaks . 2. Fuel levelrfill fuel tank when necessary (page 19). Check for leaks. 3. Front and rear brakesrcheck operation; make sure there is no brake fluid leakage (pages 13—16). 3‘ 4. Tyresi check condition and pressure (page 24). 5. Drive chain-check condition and slack (page 61). Adjust and lubricate if necessary. 6. Throttle—check for smooth opening and full closing in all steering positions . 7. Lights and hornrcheck that headlight, tail/brake light, turn signals, indicators and horn function properly. 8. Engine stop switchrcheck for proper function (page 28). 9. Side smnd ignition cut—oft systemrcheck for proper function (page 67). Correct any discrepancy before you ride. Contact your authorized Honda dealer for assistance it you cannot correct the problem. STARTING THE ENGINE Always follow the proper starting procedure described below This motorcycle is equipped with a side stand ignition cut—off system The engine cannot be started if the side stand is down. unless the transmission is in neutral. l! the side stand is up, the engine can be started in neutral or in gear with the clutch lever pulled in. After starting with the side stand down, the engine will shut off if the transmission is put in gear before raising the side stand. AWARNlNG ' Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and lead to death. NOTE: tDo not use the electric starter for more than 5 seconds at a time. Release the starter button for approximately 10 seconds belore pressing it again. Before starting, insert the key, turn the ignition switch ON and confirm the following. 'The transmission is in NEUTRAL (neutral indicator light 0N). OThe engine stop switch is at O (RUN). ' The red low oil pressure indicator is ON . 0 The fuel cock is ON. 35 StartingProcedure To restart a warm engine, follow the procedure for “High Air Temperature.” Normal Air Temperature 10° * 5°C 50° —95°E 1, Pull the choke lever (I) back all the way to Fully ON (A), if the engine is cold. 2‘ Start the engine, leaving the throttle closed. NOTE: ‘Do not open the throttle when starting the engine with the choke ON. This will lean the mixture. resulting in hard starting. (l) Choke lever (A) Fully ON (B) Fully OFF 36 3. Immediately after the engine starts, operate the choke lever ( 1) to keep fast idle at: 1000-1500 min"(rpm) 4. About a half minute after the engine starts, push the choke lever (1) forward all the way to Fully OFF (3) 5.11 idling is unstable. open the throttle slightly. CAUTION: ‘The red low oil pressure indicator should go off a few seconds after the engine starts. If the light stays on, stop the engine immediately and check engine oil level. Operating the engine with insufficient oil pressure can cause serious engine damage. fligh Air Temperature 35°C {95°F or above 1. Do not use the choke. 2. Open the flImttle slightly. 3. Start the engine. Low Air Temggrature 10°C 50°F) or below 1. Follow steps 1 v 2 under “Normal Air Temperature." 2 When engine speed begins to pick up. operate the choke lever to keep fast idle 3, 500 4 000 min"trpm) 3 Continue Warming up the engine until it runs smoothly and responds to the throttle when the choke lever (1) is at Fully OFF (B). 37 Flooded Engine It the engine fails to start after repeated anempts, it may be flooded with excess fuel. To clear a flooded engine, leave the engine stop switch on O (RUN) and push the choke lever forward to Fully OFF (B). Open the throttle fully and crank the engine for 5 seconds. If the engine starts. quickly close the throttle, then open it slightly if idling is unstable. If the engine does not stain. wait 10 seconds, then follow the Starting Procedure. 38 RUNNING-IN During initial running-in newly machined surfaces will be in Contact with each other and these surfaces will wear in quickly. Running In maintenance at 1,000km (600 m es) is designed to compensate for this initial minor wear Timely periormance oi the running-in maintenance will ensure optimum service life and perfon'nance irom the engine. The general rules are as follows: 1. Never labour the engine with lull throttle at low engine speeds. This rule is applicable not only during running-in but at all times. 2. Maximum continuous engine speed during the first 1,000 km ( 600 miles) must not exceed 5000 min“ (rpm). 3. Increase the maximum continuous engine speed by 2,000 min“ (rpm) between odometer readings of 1,000 km 600 miles) and 1,600 km (1,000 miles). Drive briskly vary speeds frequently and use full throtfle for short bursts only. Do not exceed 7,000 min“ (rpm). 4. Upon reaching an odometer reading of 1,600 km (1,000 miles). you can subject the motorcycle to full throttle operation. However, do not exceed 9.300 min" (rpm) vindicated by the beginning at the tachometer red zone. (Do not let the tachometer needle enter the red zone.) CAUTION: * Running the engine beyond recom- mended mnximum engine speed (the beginning of the tachometer red zone) can damage the engine. RIDING AWARNlNG tReview Motorc cle Safet a as 1 7 5)before}):ouride. y (p g NOTE: t Make sure you understand the function of the side stand mechanism. (See MAIN~ TENANCE SCHEDULE on a e 46 and eié91)anationfor SIDE STA on page LAfter the e ine has been warmed up, the motorcyc e is ready for ridin . 2.While the engine is idling, pul in the clutch lever and depress the gearshift edal to shilt into 1st (low? gear. 3, lowly release the clutch ever and at the same time gradually increase engine speed by 0 enin the throttle. Coordination o the t rattle and clutch lever will assure a smooth positive start. 4.When the motorcycle attains a modemte sfeed, close the throttle, pull in the outch lever and shift to 2nd gear by ra‘ 'ng the gearsth pedal. This sequence is repeated to progressive ly shift to 3rd, 4th and 5th (top) gears. 40 iCoordinate the throttle and brakes for smooth deceleration. 6.Both front and rear brakes should be used at the same time and should not be applied stronfily enough to lock the wheel, or bra ’ng effectiveness will be reduced and control of the motorcycle be difficult, AWAHNING ‘ Do not downth when traveling at a speed that would force the engine to overrev in the next lower gear; the rear wheel may lose traction, resulting in a possible loss of vehicle control. CAUTION: t Do not shift gears without disengag- ing the clutch and closing the throttle. The engine and drive train could be damaged by overspeed and shock. ' Do not tow the motorcycle or coast for long distances while the engine is off. The transmission will not be properly lubricated and damage may result. ‘Do not ride over a curb or rub the wheel against an obstacle, as wheel damage may result. NOTE: 'The battery will not charge while the engine speed is near idle speed. Avoid idling for prolonged periods. 41 BRAKING 1. For normal braking, gradually apply both the front and rear brakes while downshifting to suit your road speed. 2. For maximum deceleration. close the throttle and apply the front and rear brakes firmly. Pull in the clutch lever before coming to a complete stop to prevent stilling the engine. A‘AWAHNlNG t Independent use of only the front or rear brake reduces stopping performance. Extreme braking may cause either wheel to lock, reducing control of the motorcycle. . When possible, reduce speed or brake before entering a tum; closing the throttle or braking in midAturn may muse wheel slip. Wheel slip will reduce control of the motorcycle. ing in wet or rainy condi- tions, or on loose surfaces. the ability to maneuver and stop will be reduced. All of your actions should be smooth under these conditions. Rapid accel- eration, braking or turning may cause loss of control. For your safety, exer— cise extreme caution when braking, accelerating or turning. ’ When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness. ' Riding with your foot resting on the brake pedal or your hands on the brake lever may actuate the brakeligllt, giving a false indication to other drivers. It may also overheat the brake, reducing effectiveness. PARKING 1.A[|er stopping the motorcycle. shitt the transmission into neutral. turn the fuel cock OFF. turn the handlebar full to the leit, turn the ignition switch 0 F and remove the key 2‘ Use the side or center stand to support the motorcycle while parked. CAUTION: OPark the motorcycle on firm, level round to prevent it from falling over. s you must park on a slight incline aim the front or the motorcycle uphill to reduce the possibility of rolling off the side stand or overturning. 3. Lock the steering to help prevent theft (page 30). ANTI-THEFI‘TIPS I.Alwa s lock the steering and never leave the ey in the ignition switch. This sounds simple but people do forget. 2. Be sure the registration information for Eur motorcycle is accurate and current. . rk your motorcycle in a locked garage whenever possible. 4. Use an additional anti-theft device of good quality, 5. it your name, address. and hone number in this Owner's Manual an keep it on your motorcycles at all times Many times stolen motorcycles are identified by information in the Owner's Manuals that are still with them. NAME : ADDRESS : PHONE NO : MAINTENANCE ' The Required Maintenance Schedule specifies how often you should have your motorcycle served, and what things need attention. It is essential that your motorcycle be served as scheduled to retain its high level ol safety, dependability, and emission control performance. ~ These insiructions are based on the assumption that [he motnrcycle will be used exclusively for its designed purpose, Suslained high speed operaiion, or operation in unusually wet or dusty conditions. will require more frequent service ihan specified in the MAINTENANCE SCHEDULE. Consult your authorized Honda dealer {or recommendations applicable to your individual needs and use, MAINTENANCE SCHEDULE The following Maintenance Schedule specifies all maimnnance requlrefl Io kt-ep your motorcycle m peak overhung condluon Maintenance work should be performed In accordance wiIh standards and spec“ aliens of Honda by properly Imned and equipped lechnicians. Your athorized Honda dealer meets all DI mesa requirement—s Perfarm the Pie-ride Inspection (page 31) at each scheduled malnlenance period I: INSPECT AND CLEAN, ADJUSr, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE FREQUENCY Evé‘flm ‘ onomnnz mums [NOTE (1)} Flksr x woolrm l 5 12_& 24 so 36 Reler L x l 000 mi 06 ¢ 8 12 2‘) 24 IO “M5 NOTE MOMH§_ 5 12 18 so 36 mes 0 FUEL UNE ;_ » _ 3 FUEL srRAINERSCREEN i c i t THROTTLE OPERATION A I 58 P CARBURETOR CHOKE I- - AIR CLEANER _ NOTE (2 R 60 CRANKCASE BREATHE]? N0”) (3) C 55 PARK YLUG R 56 ENGINEOIL _ _R i- ENGINE OIL FILTER R 53 ’I CARBURETOR SYNCHRONIZATION l > t ENGINE IDLE SPEED I 59 t SECONDARY AIR SUPPLY SYSTEM NO’I'EAU I r l5 ODOMETER READING [NOTE (1)1 6 12 18 24 ReIer 1 FREQUENCY 4 lo 6 1 13 24 1 G HEADLIGHT CLUTCH SYSTEM SIDE 51‘ N 0N STEERING HEAD BEARINGS l6 * SHOULD BE SERVICED BY YOUR AUIHORIZED HONDA DEALER, UNLESS THE OWNER HA5 PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLV QUALIFIED. REFER TO THE OFFICIAL HONDA SHOP MANUAL. “ IN THE INTEREST OF SAFEI'Y, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR AUTHORIZED HONDA DEALER. Honda recommends than your authorized Honda dealer should road test your momrcycle mer each veriodic maintenance IS carried DlIL NOTES m (2) (3) (u (5) AL nigner odometer readings, repeam the lrequency mlerval established here. Service more irequenlly when riding in unusually wei wr dusty mas. Service morefrequnnlly when riding in rain or ai inn Ihrolllev Swilmland and Austria was only. Replrne every 2 years. or 3! indicated odomeier interval, whicheveroomes insc. Replacement requires mechanical skin 47 TOOL KIT The (001 ki‘ (1) is in The tool box under the seat. Some roadside repairs, minor adjustments and parts replacement can be performed with the tools conuined in the kit. 0 10 X 12 mm open end wrench ' 14 X 17 mm open end wrench I 8 mm open end wrench 0 12 mm box end wrench 0 24 mm box end Wrench 0 Spark plug wrench 0 No.2 Phillips screwdriver ' N02 screwdriver I Screwdriver grip 0 Pin spanner 0 Feeler gauge 0 Fuse puller 0 Tool bag 48 (1) Tool kit SERIAL NUMBERS The frame and engine serial numbers are required when registering your motorcycle. They may also be required by your dealer when ordering replacemem parts. Record the numbers here (or your reference. FRAME NO, The fmme number (1) is stamped on the right side of the steering head. The engine number (2) is stamped on the right side of the crankcase ENGINE NO. (1) Frame number (2) Engine number 49 COLOUR LABEL The colour label (1) is attached to the left frame rail under the seat It is helpful when ordering replacement pans. Record the colour and code here for your reference. COLOUR CODE (l) Colnur label 50 MAINTENANCE PRECAUTIONS tIf your motorcycle is overturned or involved' In a collision, inspect control levers, cables, brake hoses calipers, accessories, and oth er vital partsf or damage. Do not ride the motorcycle if damage Impaixs safe operation. Have your authorized Honda dealer Ins ct Ehe major componeints, inclu ing rarne, suspensIon an steering parts, for misalignment and damage that on may not be able to detect se new lag‘e nuine Honda parts or their equIv em for maintenance and repair. Parts which are not of equivalent quality ma impair the safety of your motorcyc e. tStop the engine and sugport the motorcycle securely on a Irm, level surface before performing any maintenance. 51 ENGINE 0!]. (Refer to the maintenance precautions on page 51). Engine Oil Good engine oil has many desirable qualities. Use only high detergent. quality motor oil certified on the container to meet or exceed requirements for API Service Classification SE, SF or SO. Viscosity: Viscosity grade of engine oil should be based on average atmospheric temperature in your riding area. The following provides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures. 52 ® ill] 0 ll 2| SI In E ._._._._i In 4|! 5| III Ian (I) Singlegrade (2) Multimde Engine Oil and Filter Engine oil quality is the chief factor affecting engine service lite. Change the engine oil as specified in the maintenance schedule (page 45), Changing the oil filter requires a special oil filter tool and a torque Wrench. 1! you do not have these tools and the necessary skill, we recommend that you have your authorized Honda dealer perform this service. If a torque wrench is not used for this insmllation, see your authorized Honda dealer as soon as possible to verify proper assembly. (1) Oil drain plug (2) Sealing washer NOTE: ' Change the engine oil with the engine at normal operating temperature and the motorcycle on its side stand to assure complete and mpid draining. CAUTION: ' To prevent oil leaks and filter damage, never support the engine on the oil filter. 1. To drain the oil. remove the oil filler cap/ dipstick and crankcase drain plug (1) and sealing Washer (2) . AWARNING ' A warmed-up engine and the oil in it are hot; be careful not to burn yourself. 53 2. Remove the oil filter (3) with a filter wrench and let the remaining oil drain out. Discard the oil filter. 3. Apply a thin coat of engine oil to the new oil filter rubber seal (4) 4. Using a special tool and a torque wrench, install the new oil filter and tighten to a torque of: 10 N~m (1.0 kgf—m , 7 lbf-fl) Use only the Honda genuine oil filter or a filter of equivalent quality specified for your model. Using the wrung Honda filter or a non-Honda filter which is not of equivalent quality may cause engine damage (3) Oil filter 54 5. Check that the sealing washer on the drain plug is in good condition and install the plug. Replace the sealing washer every other time the oil is changed, or each time if necessary. Oil Drain Plug Torque: 34 Nm (3.5 kgI-m , 25 Ibf-f!) 6. Fill the crankcase with the recommended grade oil; approximately: 3,0 013.2 us qt , 2.6 Imp qtl 7. install the nil filler cap. 8. Start the engine and let it idle for 2—3 minutes. 9. Several minutes after stopping the engine, check that the oil level is at the upper level mark on the dipstick with the motorcycle upright on fin-m level ground. Make sure there are no oil leaks. (4) Oil filter rubber seal NOTE: ’ When running in very dusty conditions, all changes should be perfumed more frequently than specified in the maintenance schedule, 'Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the rubbish or pour it on the ground or down a drain. CAUTION: a Used engine oil may cause skin can- cer if repeatedly left in Contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as Solon as possible after handling used OI . CRANKCASE BREATHER (Refer to the maintenance precautions on page 51). 1. Remove the crankcase breather tube plug (1) from the tube and drain deposits into a suitable container. 2. Reinsmll the crankcase breather tube plug. NOTE: ' Service more trequently when riding in min or at lull throttle m L,’,/ \: \§H/ Afl // /’ (1) Crankcase breather tube plug 55 SPARK PLUGS (Refer to the maintenance precautions on page 51). Recommended plugs: Standard: DPRSEA—SlNGK) or X24EPR - U9(N|PPONDENSO) For extended high speed riding: DPRSEA— 9(NGK) or X27EPR - U9(NIPPONDENSO) 1. Disconnect the spark plug caps from the spark plugs. 2. Clean any dirt from around the spark plug ases. Remove the spark plugs using the spark plug wrench (1) furnished in the tool kit. (1) Spark plug wrench 3. Inspect the electrodes and center porcelain for deposits, erosion or cabon fouling. I! the erosion or deposit is heavy, replace the plug. Clean a carbon or wet fouled plug with a plug cleaner, otherwise use a wire brush. .Check the spark plug gap (2) using a wire—type feeler gauge. If adjustment is necessary. bend the side electrode (3) carefully. The gap should be: 0.8#0.9 mm (0.03%0134 in) p (2) Spark plug gap (3) Side elettrode 5. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 6, Tighten the spark plug 1/2 turn with a spark plug wrench to compress the washer. 7. Reinsmll the spark plug caps CAUTION: 'The spark plug must be securely tightened. An improperly tightened plug can become very hot and possibly damage the engine. tNever use a spark plug with all im- proper heat range. Severe engine damage could result. 57 THRCYITLE OPERATION (Refer to the maintenance precautians on page 51). 1. Check for smooth romtion of the throttle grip from the fully open to the [ully Closed position at both full steering positions. 2. Measure the throttle grip free play at the throttle gfip flange. The standard tree play should be approx: Z.0*6.0 mm (008*024 in) To adjust the free play, loosen the lock nut ( l) and turn the adjuster (2 ). 58 (1) Lock mu (2) l2) Adjuster IDLE SPEED (Refer to the maintenance precautions on page 51). The engine must be at normal operating temperature for accurate idle speed adjustment Ten minutes of stop-and-go riding is sufficient. NOTE: ' Do not attempt to compensate for faults in other systems by adjusting idle speed. See your authorized Honda dealer for regularly scheduled carburetor adjustments, including individual carburetor adjustment and synchronization . Warm up the engine. shift to neutral and , place the motorcycle on its center stand. 2‘ Adjust idle speed with the throttle stop screw (1). Idle speed (In neutral): 1,200: 100 min"(rpm) 1,200i50 min"(rpm) < SW Type > (1) Throttle stopscrew (A) Increase (B) Decrease AIR CLEANER (Refer to the maintenance precautions an page 51). The air cleaner should be serviced at regular intervals (page 45). Service more frequently when riding in unusually wet or dusty areas. 1. Remove the left side cover. 2. Remave the attaching screws (1) and air cleaner housing cover (2). <1) Atmching screws (2) Air cleaner housing cover so 3. Pull the set spring (3) out. . Remove and disaard the air cleaner (4). Install a new air cleaner. Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model. Using the wrong Honda air cleaner or a non»Honda air cleaner which ls not of equivalent quality may cause premature engine wear or perfonnance problems. 6. Install the removed pans in reverse order of removal. pup (3) Set spring (4) Air cleaner DRIVE CHAIN (Refer to the maintenance precautions on page 51). The service Life of the drive chain is dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprockets. The drive chain should be checked and lubricated as part of the Pre-n'de Inspection (page 34). Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary. Ins ection; 1. l urn the engine off, place the motorcycle on its side stand and shift the transmission into neutral. 2. Check slack in the lower drive chain run midway between the sprockets. Drive chain slack should be adjusted to allow the following vertical movement by hand: 30*40 mm (1.2r1.6 in) Rotate the rear wheel. Stop. Check the drive chain slack. Repeat this procedure several times. Drive chain slack should remain constant. Li the chain is slack only in certain sections, some links are kinked and binding. Binding and kinking can frequently be eliminated by lubrication. 5” {1) Drive chain 61 4. Rotate the rear wheel slowly and inspect the drive chain and sprockets (or any of the iollowing conditions: DRIVE CHAIN ‘Damagcd Rollers ‘Loose Pins ‘Dry or Rusted Links *Kinked or Binding Links *Excessive Wear ’ Improper Adjustment *Missing O-rings SPROCKEI‘S *Exoessively Worn Teeth ‘Broken or Damaged Teeth A drive chain with damaged rollers, loose pins. or missing O-rings must be replaced A chain which appears dry, or shows signs of mst, requires supplementary lubrication, Kinked or binding links should be thor- oughly lubricated and worked free. If links cannot be freed, the chain must be replaced. 62 Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket GOOD Ad'ustment: rive c ain slack should be checked and adjusted, if necessary, every 1,000 km (600 miles). When operated at sustained high speeds or under conditions of frequent rapid acceleration, the chain may require more frequent adjustment. (2) (5) (l) Axle nut (4) index mark (2} Lock nuts (5) Rear edge of (3) Adjusting nuts adjusting slot If the drive chain requires adjustment. the procedure is as tollows: 1. Place the motorcycle on its center stand with the transmission in neutral and the ignition switch off. 2. Loosen the axle nut (1). 3, Loosen the lock nuts (2) on both right and left swingarm. 4. Turn both adjusting nuts (3) an equal number of turns until the correct drive chain slack is obtained. Turn the adjusting nuts clockwise to tighten the chain, or counterclockwise to provide more slack. Adjust the chain slack at a point midway between the drive sprocket and the rear wheel sprocket. Rotate the rear wheel and recheck slack at other sections of the chain Chain slack should be: 30440 mm (1.2s1.6 in) 5. Check rear axle alignment by making sure the chain adjuster index marks (4) align with the rear edge (5) 01 the adjusting slots. Both left and right marks should correspond. If the axle is misaligned, turn the left or right adjusting nut until the marks correspond on the rear edge of the adjusting slots and recheck chain slack. 6. Tighten the axle nut to specified torque. Axle nut torque: 88 N-m19.0 kgf-m I 65 int) EWARNING ‘ If a torque wrench is not used for this installation, see your authorized Honda dealer as soon as possible to verify proper assembly. 7. Tighten the adjusting nuts lightly. then tighten the lock nuts by holding the adjusting nuts with a spanner. Wear ins tion: Check [fie chain wear label when adjusting the chain. It the red zone (6) on the label aligns with the arrow mark (7) on the Chain adjuster plates alter the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced. The proper slack is: 30~40 mm t1.2*1.6 in) (5) Red zone {7) Arrow mark Lubrication and cleanin : L—F—Tu ncate every Mn (600 miles) or sooner if chain appears dry. The O-rings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents. Clean the side surfaces of the chain with a dry cloth. Do not brush the rubber O-rings. Brushing will damage them. Wipe dry and lubricate only with SAE 80 or 90 gear oil. Commercial chain lubri- cants may contain solvents which could damage the rubber O-rings. RK525$M5 or DIDSZSVS CAUTION: *The drive chain on this motorcycle is equipped with small O-rings between the link plates. These O-rings retain grease inside the chain to improve its service life. However, special precautions must be taken when adjusting, lubricating, washing, and replacing the chain. 65 DRIVE CHAIN SLIDER (Refer to the maimenance precautions on page 51 ). Check the chain slider (l) for wear. The Chain slider must be repiaced if it is worn to the wear Ximit fine (2). For replacement. see your authorized Honda dealer. 66 (1) Chain slider (2) Wear limit line SIDE STAND (Refer to the maintenance precautions on page 51). Perform the following maintenance in accordance with the maintenance schedule. Functional Check: 0 Checl? the spring (1) for damage or loss of tension and the side shand assembly tor freedom of movement. ' Check the side stand ignition cutoff system: 1. Sit astride the motorcycle; put the side stand up and the transmission in neutral. 2. Start the engine and with the clutch lever pulled in. shift the transmission into gear. 3. Lower the side stand. The engine should stop as you put the side stand down. If the side stand system does not operate as described, see your authorized Honda dealer for service. (1) Side stand spring 67 WHEEL REMOVAL Front Wheel Removal (Refer to the maintenance precautions on 1. Raise the front wheel off the ground by page 51 )4 placing a support block under the engine. 2. Remove the left caliper assembly (1) [mm the fork leg by removing the fixing bolts (2). CAUTION: *To avoid damage to the brake hose, support the caliper assembly so that it doesn’t hang from the hose. Do not twist the brake hose. (1) Bmke caliper assembly (3) Speedometer cable (2) Fixing bolts (4) Cable set screw 68 3. Disconnect the speedometer cable (3) 4. Loosen the right and left axle pinch bolts from the speedometer gear box by (5). and remove the axle bolt (7), removing the cable set screw (4). 5. Withdraw the front axle (6) and remove NOTE' the front wheel. * Do not depress the brake lever when the wheel is off the motorcycle. The caliper piston will be forced out of the cylinder with subsequent loss of brake fluid. If this occurs, servicing of the brake system will be necessary. See your authorized Honda dealer for this service. (5) Axle pinch bolts (7) Axle bolt (6) Front axle Installation Notes: Posuon the front wheel between the fork legs and insert the axle from the left side. through the left fork leg and wheel hub. CAUTION: ‘ When installing the wheel, carefully {it the left brake disc between the brake pads to avoid damaging the pa 5. (8) (8) Lugs 70 Position the lug on the speedometer gear box against the lug (8) on the left fork leg. Tighten the mde bolt to the specified torque r Front axle torque : 59 N-m (6.0 kgf‘m , 43 let) Fit the caliper over the disc. taking care not to damage the brake pads. Install the caliper fixing bolts, and tighten to a torque at : 30 NA"! (3‘1 kgl‘m , 221mm Measure the clearance (9) between each surlace of the left brake disc (10) and the left caliper holder (11) with a 0.7 mm (0.028 ‘ If a torque wrench was not used for in) [eeler gauge (12) (see illustration). installation, see your authorized If the gauge inserts easily. tighten lhe right Honda dealer as soon as possible to and left axle pinch bolts (5) to the specified verify proper assembly. Improper torque assembly may lead to loss of braking Axle pinch bolt torque: capacity. 22 N-m (2‘2 kgf—m ,16Ibl-fl) (9) Clearance (11) Caliper holder (12) Feeler gauge (10) Brake disc 71 If the feeler gauge cannot be inserted easily, pull the left fork outward or push inward until the gauge can be inserted and tighten the axle Dinch balls with the gauge inserted. Alter tightening, remove the gauge. After instaihng the wheel. apply the brakes several times. then recheck both discs for caliper holder to disc clearance. Do not operate the motorcycle without adequate ciearance. AWARNING *Failure to provide adequate disc to caliper holder clearance may damage the brake discs and impair braking efficiency. 72 Rearwheel Removal 5. Remove the axle shalt (4), side collar 1. Place the motorcycle on its center stand. and rear wheel from the swing arm. 2. Loosen the drive chain adjustng nut lock NOTE: nuts (I) and adjusting nuts (2). ’ Do not depress the brake pedal while the 3. Remove the rear axle nut. wheel is off the motorcycle. The caliper 4. Remove the drive chain (3) 1mm the pistons will be forced out of the cylinders driven sprocket by pushing the rear with subsequent loss of brake fluid. If this wheel forward. occuis, servicing oi the brake system will be necessary. See your authorized Honda dealer for this service. (1) Lock nuts (4) Axle shaft (2) Adjusting nuts l (3) Drive chain l 73 Installation To install the rear wheel, reverse the removal procedure, Torque the axle nut to the specified torque. Axle nut torque: 88 N>m (9.0 kgf-m 4 65 letl CAUTION: ‘When installing the wheel, carefully {it the brake disc between the brake pads to avoid damaging the pads. After installing the wheel, apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely. 74 AWARIUNG ' If a torque wrench was nut used for installation, see your authorized Honda dealer as soon as possible to verily proper assembly. Improper assembly may lead to loss of braking capacity. BRAKE PAD WEAR (Refer to the maintenance precautions on page 51). Brake pad wear depends upon the severity of usage, the type of riding. and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval (page 46). Front Brake Check the wear indicator mark (1) on each pa . If either pad is worn to the wear indicator mark, replace both pads as a set. See your authorized Honda dealer for this service, < FRONT BRAKE) (1) Wear indicator mark (1) 75 Rear Brake Check the cutout (2) in each pad. If either pad is worn to the cutout. replace bmh pads as a set. See your authorized Honda dealer [or this service. 76 < REAR BRAKE> (2) Cutout BATTERY (Refer to the maintenance precautions on page 51). if the motorcycle is operated with insufficient battery electrolyte. sultation and battery plate damage will occur. If rapid loss of electrolyte is experienced, or it your battery seems to be weak, causing slow starting or other electrical problems. see your authorized Honda dealer. [AWARNlNG 'The battery gives of! explosive gases; keep sparks, flames. and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space. [AWARNING ‘T‘IE battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a {ace shield. rlf electrolyte gets on your skin. flush with water. *If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. ' Electrolyte is poisonous. vlf swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. *KEEP OUI‘ 0F REACH OF CHIL— DREN. 71 Battegy electrolyg e attery 1 Is behind the right side cover. Remove the right side cover(page 33 . Check the electrolyte level with the motorcycle in an upright position on level ground. The electrolyte level must be maintained between the UPPER (2) and LOWER (3) level marks on the side of the battery. 11 the electrolyte level is low, remove the tiller caps. Carefully add distilled water to upper level mark, using a small syringe or plastic funnel. (1) Battery <3) LOWER level 78 (2) UPPER level (4) Battery breather tube CAUTION: t When checking the battery electrolyte level or adding distilled water, make sure the breather tube is connected to the battery breather outlet. ' Use only distilled water in the battery. Tap water will shorten the service life of the battery. ' Filling the battery above the UPPER LEVEL line may cause the electrolyte to overflow, resulting in corrosion to engine or frame parts. Immediately wash off any spilled electrolyte. ‘ The battery breather tube must be routed as shown on the label. Do not bend or twist the breather tube. A bent or kinked breather tube may pressurize the battery and damage its case. CAUTION: 'When the motorcycle is to be stored for an extended period of time, remove the battery from the motorcycle and charge it fully. Then store it in a cool, dry place. If the battery is to be left in the motorcycle, disconnect the negan‘ve cable from the battery terminal. Batte Removal; L Remove the nght side cover (page 33). 2. Disconnect the negative (—) terminal lead (1) from the battery first, then Elizsconnect the positive (+) terminal lead 3. Disconnect the battery breatherlube (3), 4. Remove the battery holder ( 4 ) by removing the three bolts (5). 5. Pull out the battery box( 6) and remove the battery, (1) Negative (,) terminal lead (2) Positive (+) tEI‘minal lead (3) Battery breather tube (4) Battery holder (5) Bolts (6) Battery box 79 FUSE REPLACEMENT (Refer to the maintenance precautions on page 51). The main {use ( 1 ). located on the starter [magnetic switch (2 ) below the seal . is 30 The spare main fuse (6) is located near the [use box. The fuse box (4) is also located below the seat. (1) Main [use (3) Wire coupler so (2) Starter magnetic switch When irequent luse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your authorized Honda dealer for repair. CAUTION: ‘ Turn the ignition switch OFF before checking or reglacing fuses to prevent accidental short—circuitjng. To replace the main fuse (1). remove the right side cover (page33). disconnect the wire coupler (3 ) and remove the old (use. install a new fuse and reconnect the wire coupler. (6) (4} Fuse box (5) Sparefuses (6) Spare main fuse To replace {uses in the fuse box (4), remove the the fuse box cover, The spare [uses(5) are located in the fuse 'Never use a fuse with a diflerent box. rating from (hm specified. Serious Pull the old {use out of the clips Push a new damage to the electrical system or a {use into the clips and install the fuse box fire may result, causing a dangerous cover. loss of lights or engine power. (7) (7) Blown (use 81 BULB REPIACEMENT (Refer to the maintenance precautions on page 51), Headlight/Position Light Bulb AWARNING . The light bulb becomes Very hm while the light is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing. CAUTION: ‘ gin clean gloves while replacing the 11. 'Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break t [f you touch the bulb with your bare hands. clean it with a cloth moistened with alcohol to prevent its early failure. NOTE: ‘ ‘ Be sure to turn the ignition switch OFF when replacing the bulb. 82 L Remove the screws (1) from the headlight case. 2. Gently pull the headlight forward and disconnect the connectors (2). u) Screws (2) Connectors 3. Remove the seat rubber (3). 4. Remove the bulb (4) while pressing down on the pin (5). 5. Install a new bull) in the reverse order of removal. N 0T E: ‘ Do not use bulbs other than that specified. ' After installing a new bulb, check that the light operates properly, (3) (3) Seal mbber (4) Bulb (5) Pin 83 Stop/1‘ aillight Bulb AWARNVNG ' The light bulb becomes very hot while the light is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing. CAUTION: ¢ Wear clean gloves while replacing the bulb. 3 If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. NOTE: t sure to turn the ignition switch OFF when replacing the bulb. 8‘ 1. Remove the two screws (1). 2. Remove the millight lens (2). (1) Screws (2) Taillight lens 3, Slightly press down on the bulb and turn it counterclockwise. 4. Install a new bulb in the reverse order of removal. NOT E: c Do not use bulbs other than that specified. a After installing a new bulb, check that the light operates properly. 85 Frant/ Rear Tum Sigial Bulb AWARHH‘IG * The light bulb becomes very hot while the light is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing. CAUTION: ' Wear clean gloves while replacing the bul . NOTE: t Be sure to turn the ignition switch OFF when replacing the bulb. 86 1. Remove the three screws (Dr 2. Remove the turn signal lens (2). (l) Screws (2) Turn signal lens 3. Remove the bulb (3) by pressing in and turning counterclockwise. 4. Install a new bulb and check that the light operates properly. NOT E: ' Do not use bulbs other Ihan that specified, 0 After installing a new bulb, check that the light operates properly. (3) Bulb 87 CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect {or damage. wear, and oil or brake fluid leakage. CAUTION: ' High pressure water (or air) can damage certain parts of the motorcycle. Avoid spraying high pressure water (typical in coin~operated car washes) at the following areas: Ignition Switch Instruments Carburetors Wheel Hubs Drive Chain Muffler Outlets Under Seat Under Fuel Tank Handlebar Switches Brake Master Cylinder .Mter cleaning. rinse the motorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. NOTE: ' Clean the plastic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing it frequently with fresh water. 5" Dry the motorcycle. start the engine, and let it run for several minutes 3.Test the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking performance. .Lubricate the drive chain immediately after washing and drying the motorcycle. AWARNIN 1 Braking elficiency may be tempora- rily impaired immediately after washing the motorcycle. Anticipate longer stopping distance to avoid a possible accident. .s Painted Aluminum Wheel Maintenance Aluminum may corrode from contact with dirt, mud, or road salt. Clean the wheels after riding through any of these substances. Use a wet sponge and mild detergent. Avoid stlfl brushes, steel wool, or cleaners conmlning abrasives or chemical compounds. After washing, rinse with plenty of water and dry with a clean cloth. Apply touch-up paint to the wheels where damage has resulted. 89 STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non-use of the motorcycle. In addition. necessary repairs should be made BEFORE storing the motorcycle; otherwise, these repairs may be forgotten by the time the motorcycle is removed from storage. STORAGE 1. Change the engine oil and filter‘ 2‘ Empty the fuel tank into an approved petrol conuiner using a commercially available hand siphon or an equivalent method. Spray the inside of the tank with an aerosol rust-inhibiting oil. Reinstall the fuel fill cap on the tank N0 ' IfT storage will last more than one month carburetor draining IS very important to assure proper performance after storage 90 AWA llNG ' Petrol is ememely flammable and is explosive under certain conditions. Perfonn this opemfion in a well- ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where petrol is drained or stored and where the fuel tank is refueled. 3/11) prevent rusting in the cylinders DCrform the following: 0 Remove the spark plug caps from the spark plugs. Using tape or string, secure the caps to any convenient plastic body part so that they are positioned away from the spark plugs. 0 Remove the spark plugs from the engine and store them in a safe place. Do not connect the spark plugs to the spark plug caps. 0 Pour a tablespoon (15*20 cc) 0! clean engine oil into each cylinder and cover the spark plug holes with a piece of cloth. 0 Crank the engine several times to distribute the oil. 'Reinstall the spark plugs and spark plug caps. 4. Remove the battery. Store in an area protected from freezing temperatures and direct sunlight. Check the electrolyte level and slow charge the battery once a month. 5. Wash and dry the motorcycle. Wax all painted surfaces. Coat chrome with rustinhibiting oil. 6. Lubricate the drive chain (page 65). 7.1nflate the tyres to their recommended pressures. Place the motorcycle on blocks to raise both tyres off the ground. 8. Cover the motorcycle (don‘t use plastic or other coated materials) and store in an unheated area free oi dampness with a minimum oi daily temperature varia n. Do not store the motorcycle in direct sunlight. 91 REMOVAL FROM STORAGE l. Uncover and clean the motorcycle. 2. Change the engine oil it more than 4 months have passed since the start of storage. 3. Check the battery electrolyte level and charge the battery as required. Install the battery, .Drain any excess aerosol rust-inhibiting oil from the fuel tank, Fill the fuel tank with fresh petrol, Perform all Pre-ride Inspection checks (page 34 ). Test ride the motorcycle at low speeds in a safe n'ding area away from traific. .5 5'" 92 SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase WEIGHT Dry weight CAPACITIES Engine all After draining After draining and oil filter change After disassembly Fuel tank Fuel reserve Passenger capacity Maximum weight capacity 2,220 mm (87A in) 2,155 mm (84.8 in) 780 mm (30.7 in) 1,100 mm (43.3 in) 1,495 mm (58.9 in) 215.0 kg (474.0 lbs) MAR, G. IIG, SD. SW ...E, ED. F, SP, U,IIPO 2.3 B (3.0 US q! , 2.5 Imp qt) 3.0 B (3.2 US ql , 2.6 Imp qt) 3.8 a (4.0 US qt , 3.3 Imp qt) 20.0 (1 (5.28 US gal , 4.40 Imp gal) 30 a (0.79 US gal , 0.66 |mp gall Operator and one passenger 190 kg (419 lbs) 93 ENGINE Bore and stroke Compression ratio Displacement Spark plug Standard For exiended high speed riding Spark plug gap Idle speed 94 67 x 53 mm (2.64 x 2.09 in) 9.3: 1 747 cm“ (45.5 cu-in) DPRBEA‘ 91NGK) or XZAEPR > U9(NIPPONDENSO) DPRSEA 9(NGK)0 X27EPH USINIPPONDENSOi 0.8 0..-9mm(003 004m) 1,200+100 min"(rpm)..S E F G "G, SD, ED, U AR 1,200i 50 min"(rpm). CHASSIS AND SUSPENSION Caster 26° Trail 91 mm (36 in) Tyre size, from 120/70R17 58V (DUNLOP) 120/7OZR17 (MICHELIN) Tyre size, rear 150/70R17 69V (DUNLOP) 150/702R17 (MICHELIN) POWER TRANSMISSION Primary reduction 1.780 Gear ratio. lst 3000 2nd 2.056 3rd 1 .545 401 ‘l .240 5th 1074 Final reduction 2.667 ELECTRICAL Battery Generator LIGHTS Headlight Brake/tail light T urn signal light From Rear Instrument lights Neutml indicator light Turn signal indicator light High beam indicator light Low oil pressure indicator light Side stand indicator FUSE 12Vi 14Ah 0,24 kW/5,000 min"(rprn) 12Vi60/55W 12Vi21/5W x 2 12V—21W 12Vi21W 12Vi3,4Wx 2 12Vi1‘7W 12V—1.7W 12V71.7W 12V—1.7W 12Vi1.7W 30A(Main fuse) 10A,15A NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners are warned that the law may prohibit : (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement. of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any peison. 97 8.32"» As :33. a. 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