é OWNER'S MANUAL HONDA MANUEL DU CONDUCTEUR FAHFIER-HANDBUCH CBFI 'l 1 OOXX Honda CBRl 100XX OWNER’S MANUAL MANUEL DU CONDUCTEUR FAHRER-HANDBUCH © Honda Motor Co.. Ltd. 2002 IMPORTANT INFORMATION 0 OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. Never exceed the maximum weight capacity as shown on the accessories and loading label. 0 ON-ROAD USE This motorcycle is designed to be used only on the road. O READ THIS OWNER‘S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual These messages are fully explained in the “A Few Words About Safety" section which appears before the Contents page. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold. Honda CBRl 100XX OWNER’S MANUAL All infomation in this publication is based on the latest production information available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the right to make changes at any time without notice and without inciu-ring any obligation. No part of this publication may be reproduced without written pennisgion. WEIXEOME The motorcycle presents you a challenge to master the machine, a challenge to adventure. You ride through the wind, linked to the road by a vehicle that responds to your commands as no other does. Unlike an automobile. there is no metal cage around you. Like an airplane, a preriide inspection and regular maintenance are essential to your safety. Your reward is free om. To meet the challenges safely, and to enjoy the adventure fully, you should become thoroughly familiar with this owner‘s manual BEFORE YOU RIDE THE MOTORCYCLE. As you read this manual, you will find inlormation that is preceded by a symbol. This inlormation is intended to help you avoid damage to your motorcycle, other property, or the environment. When service is required, remember that your Honda dealer knows your motorcycle best 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 ! 0 Following codes in this manual indicate each country E UK F France ED Europeandlrectsales Belgium Be um Finland U Australia Ho and Norway BR Brazil Spain Portugal Italy Germany Sweden Austria Denmark oThe specifications may vary with each locale. A FEW WORDS ABOUT SAFETY Your safety, and the safe of others. is very important. And operating this motorcycle safely is an important responsibi 'ty. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good judgment. You will find important safety information in a variety of forms, including: 0 Safety Labels — on the motorcycle. 0 Safety Messages — preceded by a safety alert symbol A and one of three signal words: DANGER, WARNING, or CAUTION. These signal words mean: m You WILL be KILLED or SERIOUSLY HURT iI you don't Iollow InstructlonsI N You CAN be KILLED or ssmousu Hum It you don't lollow Instructlons. A CAUTION Vou CAN be HURT il you don't follow Instructions. 0 Safety Headings — such as Important Salety Reminders or Important Salety Precautions. 0 Safety Section — such as Motorcycle Salary. 0 Instructions — how to use this motorcycle wrrectly and safely. This entire manual is filled with important safety intormation — please read it carelully. OPERATION Page 1 MOTORCYCLE SAFETY 1 Important Safety Information 2 Protective Apparel 4 Load Limits and Guidelines 8 PARTS LOCATION 11 Instruments and Indicators 24 MAJOR COMPONENTS (lntonnation you need to operate this motorcycle) 24 Suspension 26 Brakes 29 Clutch 3] Coolant 33 Fuel 36 Engine Oil 37 Tubeless Tyres Page 43 ESSENTIAL INDIVIDUAL COMPONENTS 43 Ignition Switch 44 Keys 46 Immobilizer System (HISS) < Except BR type} 49 Right Handlebar Controls 51 Left Handlebar Controls Page 52 FEATURES (Not required {or operation) 52 Steering Lock 53 Helmet Holder 54 Seat 55 Document Bag 56 Storage Compartment for U-Shaped Anti-then Lock 57 Rear Cowl 58 Lower Cowl 60 Upper Cowl Cover 61 Wind Guard 62 Inner Panel 63 Headllght Aim Vertical Adjustment Page 64 OPERATION 64 Pre-ride Inspection 66 Starting the Engine 69 Running-in 70 Riding 72 Braking 74 Parking 75 Anti-theft Tips MAINTENANCE Page 76 MAINTENANCE The Importance of Maintenance Maintenance Safety Safety Precautions Maintenance Schedule Tool Kit Serial Numbers Colour Label Engine Oil Spark Plugs Throttle Operation Idle Speed Coolant Drive Chain Drive Chain Slider Front and Rear Suspension Inspection Side Stand Wheel Removal Brake Pad Wear Brake System Inspection Battery Fuse Replacement page 122 Stoplight Switch Adjustment 123 Bulb Replacement 129 CLEANING 134 STORAGE GUIDE 134 Storage 136 Removal from Storage 137 SPECIFICATIONS 141 CATALYTIC CONVERTERS 142 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) MOTORCYCLE SAFETY IMPORTANT SAFETY INFORMATION Your motorcycle can provide many years of service and pleasure — if you take responsibility {or your own safety and understand the challenges that you can meet on the road. There is much that you can do to protect yourself when you ride. You'll find many helpful recommendations throughout this manual. Following are a tow that we consider most important. Always Wear a Helmet It’s a proven fact: helmets significantly reduce the number and severity of head injuries, So always wear an approved motorcycle helmet and make sure your passenger does the same, We also recommend that you wear eye protection. sturdy boots, gloves, and other protective gear (page 2 ). Make Yourself Easy to See Some drivers do not see motorcycles because they are not looking for them. To make yourself more visible. wear bright reflective clothing» position yourself so other drivers can see you, signal before turning or changing lanes. and use your horn when it will help others notice you, Ride Within Your Limits Pushing the limits is another major cause of motorcycle accidents Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue and inattention can significantly reduce your ability to make good judgements and ride safely Don’t Drink and Ride Alcohol and riding don't mix Even one drink can reduce your ability to respond to changing conditions. and your reaction time gets worse with every additional drink. So don’t drink and ride. and don’t let your friends drink and ride either. Keep Your Bike in Safe Condition For sate riding, it‘s important to inspect your motorcycle before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by Honda for this motorcycle. See page 4 for more details. PRUFECI‘WEAPPAREL For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride. Although complete protecn'on is not possible, wearing proper gear can reduce the chance of injury when you ride. Following are suggestions to help you choose proper gear. AWARNING Not weaving a helmet increases the chance at serious injury or death in a crash. Be sure you and your passenger always wear a helmet. eye protection and other protective apparel when you ride. Helmets and Eye Protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. A bi'ightvcoloured helmet can make you more noticeable in tralflc, as can reflective strips An open»face helmet offers some protection, but a full-lace helmet oliers more. Always wear a face shield or goggles to protect your eyes and help your vision. Additional Riding Gear In addition to a helmet and eye protection, we also recommend: 0 Sturdy boots with non—slip soles to help protect your feet and ankles. 0 Leather gloves to keep your hands warm and help prevent blisters, cuts, bums and bruises I A motorcycle riding suit or jacket for comlort as well as protection Bright- coloured and reflective clothing can help make you more noticeable in traffic Be sure to avoid loose clothes that could get caught on any part of your motorcycle. LOAD LIMITS AND GUIDELINES Your motorcycle has been designed to carry you and one passenger, When you carry a passenger, you may feel some difference during acceleration and braking. But so long as you keep your motorcycle well— maintained, with good tyres and brakes, you can safely carry loads within the given limits and guidelines. However, exceeding the weight limit or carrying an unbalanced load can seriously affect your motorcycles handling, braking and stability, Non-Honda accessories. improper modifications. and poor maintenance can also reduce your saiery margin. The following pages give more specific information on loading, accessories and modifications. Loading How much weight you put on your motorcycle» and how you load it, are impoflanl to your safety. Anytime you ride with a passenger or cargo you should be aware of the following inIormationl AWARNING 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. Load Limits Following are the load limits for your motorcycle: Maximum weight capacity: 185 kg (411 lbs) Includes the weight of the rider, passenger. all cargo and all accessories Mnxirnumcargoweight: 27 kg (60 lbs) The weight of added accessories will reduce the maximum cargo Weight you can CarTy. Loading Guidelines Your motorcycle is primarily intended for transporting you and a passenger. You may wish to secure a jacket or other small items to the seat when you are not riding with a passenger. It you wish to carry more cargo, check with your Honda dealer for advice. and be sure to read the information regarding accessories on page 6 . Improperly loading your motorcycle can affect its stability and handling Even if your motorcycle is properly loaded, you should ride at reduced speeds and never exceed 130 km/h (80 mph) when carrying cargol Follow these guidelines whenever you carry a passenger or cargo: 0 Check that both tyres are properly inflated. - Ii you change your normal load, you may need to adjust the rear suspension (page 24 ). 0 To prevent loose items from creating a hazard. make sure that all cargo is securely tied down before you ride away. I Place cargo weight as close to the center of the motorcycle as possible. 0 Balance cargo weight evenly on both sides. Accessories and Modifications Modifying your motorcycle or using non- Honda accessories can make your motorcycle unsare. Before you consider making any modifications or adding an accessory, be sure to read the following information. AWARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owners manual regarding accessories and modifications. Accessories We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle. Because Honda cannot test all other accessories, you must be personally responsible for proper selection. installation and use 01 non-Honda accessories. Check with your dealer [or assistance and always follow these guidelines: 0Make sure the accessory does not obscure any lights. reduce ground clearance and banking angle. limit suspension travel or steering travel, alter your riding position or interfere with operating any controls. 'Be sure electrical equipment does not exceed the motorcycle‘s electrical system capacity (page 144) ). A blown {use can cause a loss of lights or engine power. I Do not pull a trailer or sidecar with your motorcycle. This motorcycle was not designed for these attachments. and their use can seriously impair your motorcycles handling. Modifications We strongly advise you not to remove any original equipment or modify your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycles handlingv stability and braking. making it unsafe to ride. Removing or modifying your lights, mufflers, emission control system or other equipment can also make your motorcycle illegal. PARTS LOCATION Tachometer MullHunclion display Speedometer lndicalors Indicators am" ““1 ”58m" Front brake fluid reservoir Engine slop switch Passing light neutral switch Front brake lever Clutch lever \\ Headlight switth \ \BR type only) Headlight dimmer switch Tum signal switch Throttle gnp Horn button Smer button :\// Ignition switch Fuel fill cap Rearrebo dd ' (owe adju‘sllner “up” Helmetholder Too] kit ssenger foolpeg Gearshift pedal Center stand 5'“ 5'3““ Helme} holder Coolant reserve tank Rear brake Bane” fluid reservoir ' Document compartment . Passenger footpeg on filler cap Dipslick Rear bmke peda| 10 INSTRUMENTSAND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages (1) Neutral indicator (2) Low oil pressure indicator (3) Right turn signal indicator (4) Speedometer (5) H155 button (Except 13me) (6) Immobilizer system (HISS) indicator (7) MODE button (8) SET button (9) Multifunction display (10) Left turn signal indicator (11) High beam indicator (IZ) PGM-FI indicator (13) Tachometer (14) Tachometer red zone (12) (l3)(14) (l) 0 (9) (8) (6) (5) (4) 11 (Ref.No.) Description Function (1) Neutral indicator (green) Lights when the transmission is in neutral. Should also lights [or a few seconds and then go off when the ignition switch is turned ON. (2) Low oil pressure indicator (red) Lights when the engine oil pressure is below nomial operating range. Should light when ignition switch is ON and engine is not running. Should go out when the engine starts, except for occasional flickering at or near idling speed when engine is warm Running the engine with insufficient oil pressure may cause serious engine damage (3) Right turn signal indicator (green) Flashes when the right turn signal operates. Should lights for a few seconds and then go off when the ignition switch is turned 0N, (4) Speedometer Shows riding speed (page 21 ). 12 (Ref.No.) Description Function (5) H158 button Except BR type: This button is used to flash the immobilizer system (HISS) indicator when the ignition switch is OFF (page 47 )4 (6) Immobilizer system (H155) indicator (red) Except BRtype: This indicator lights for a few seconds when the ignition switch is turned 0N and the engine stop switch is at O (RUN). It will then go off i the properly-coded key has been inserted If an improperly-coded key has been inserted, the indicator will remain on and the engine will not start (page 46 ). (7) MODE button Select lripmeter A or B and resets the tripmeter to zero (0) (Page 20 ). This button is also used to change unit of speedometer (page 21 ). (8) SET button This button is used to adjust the time (page 22 ). This button is also used to change unit of speedometer (page 21 ). 13 (Ref.No.) Dmription Function (9) Multi-iuncfion display The display includes the following functions; This display shows the initial display (page 17 ). Coolant temperature Shows coolant tempemture (page 23 )l meter Fuel gauge Shows approximate fuel supply available (page 19 )l Digital clock Shows hour and minute (page 22 ). Odometer Shows accumulated mileage (page 20 )l ‘l‘ripmeter Shows mileage per trip (page 20 ). 14 (Ref.No.) Description Function (10) Left turn signal indicator (green) Flashes when the left turn signal operates, Should lights for a few seconds and then go off when the ignition switch is tumed ON. (1 1) High beam indicator (blue) Lights when the headlight is on high beam. Should also lights [or a few seconds and then go off when the ignition switch is turned ON. (12) PGM-FI indicator (red) Flashes when there is any abnormality in the PGM-FI (Programmed Fuel Injection) system. Should also light for a few seconds and then go off when the ignition switch is turned ON and engine stop switch is at O (RUN). If it comes on at any other time , reduce speed and lake the motorcycle to your Honda dealer as soon as possible. 15 (RetNm) Description Function (13) Tachometer Shows engine revolutions per minute. (14) Tachometer red zone Never allow the tachometer needle to enter the red ’ zone. even after the engine has been broken in. Runmng the engine beyond recommended maximum engine speed (the beginning of the tachometer red zone) can damage the engine. 16 Initial Display When the ignition switch is turned ON, the multi-iunction display (1) and speedometer (2) will temporarily Show all the modes and digital segments. Thereaiter. the speedometer (2) will show from 290 km/h to 0 km/h (E type only: From 180 mph to 0 mph in mph) and the coolant temperature meter (3) will show from 132°C to 35°C. In the View of that operation. you can make sure the liquid crystal display is functioning properly (Except digital clock) The unit “mph” and “mile“ will be displayed only for E type. Digital clock (4) and tripmeter (5) will reset it the battery is disconnected. (1) Multi-iunction display (2) Speedometer (3) Coolant temperature meter (4) Digital clock (5) 'l‘ripmeter (e) Fuelgauge 17 Multifunction Dis lay Multi-function displZy (1) includes the (l) following functions: Odometer Tripmeter Coolant temperature meter Fuel gauge Digital clock 13 (l) MulIi-funclion display (2) Odometer (3) Tripme'er (4) Coolant temperature meter (5) Fuelgauge (e) Digilal clock (7) MODE button (8) SET button Fuel Gauge The fuel gauge liquid crystal display (1) shows the approximate fuel supply available in a graduated display. When the segment F goes on. the fuel tank capacity including reserve is: 210 ll (6.08 US gal , 5‘06 Imp gal) When segment E (2) flashes, fuel will be low and you should refill the tank as soon as possible. The amount of fuel leit in the tank with the vehicle set upright is approximately: 3 0 B (0.79 US gal 0 66 Imp gal) (1) Fuel gauge display (2) SegmentE 19 Odometer Shows accumulated mileage. Tripmeter Shows mileage per trip. There are two tripmeters, tripmeter A (3) and tripmeter B (4 ). Switch between the A and B displays by pressing the MODE button (5) repeatedly, To reset the tripmeler, push and hold the MODE button (5) with the display in the tripmeter A or tripmeter B mode. 20 nu @ h’ ""m Wm (5) (l) Odometer (2) Tripmeter (3) Tripme‘er A (4) Tripmeter B (5) MODE button Speedometer Shows riding speed. Sgeed Unit Change ( We on”) Thehspeedometer displays both “km/h" and “m n Push and hold both the MODE (2) and SET (3 ) button to select “km/h" or “mph“. This function does not operate while set the clock in the adjust mode. (1) Speedometer (2) MODE button (3) SET button 21 Digital clock Shows hour and minute. To adjust the time, proceed as tollows: 1.Tum the ignition switch ON. 2. Press and hold the SET button (2) tor more than 2 seconds. The clock will be set in the adjust mode with the display flashing. \ ' x m —» n (2) (l) (1) Digitalclock (2) SET button 3, Push the button until the desired time is displayed. 0The time is advanced by one minute, each time the button is pushed. oThe time is advanced by ten minutes, when the button is pushed and held. .Hlsh the SET button after five seconds pass with not doing anything to enter the time. When the ignition switLh is turned OFF while set the clock in the adjust mode, the time will be fixed as just before the ignition OFF. a. Coolant'l‘emperature Meter Overheatin Messa e The coolant temperature meter (1) shows Wlien tfie coo ant temperature reaches coolant temperature digitally. 122°C, the display begins to flash and “red line" (2) appears on the display. TemErature Display If this occurs. stop the engine and check the reserve tank coolant level. Read pages Below 34°C “'7 7"is displayed. 31 7 32 and do not ride the motorcycle until the problem has been corrected Between 35°C Actual coolant tempera- and 132°C lure is indicated _ NOTICE Above 132°C The display will remain Exceeding maximum runn’ng temperature “132%". may cause serious engine damage. (l) Coolant temperature meter (2) Red line 23 MAJOR COMPONENTS (Information you need to operate this motorcycle) SUSPENSION Rear Suspension The rear suspension can provide the desired ride under various rider/passenger weight and riding conditions through adjustments of the rebound damping adjuster. Rebound Damging: e amping orce adjuster (l) is located behind the left step holder. To reduce (SOFI‘) : Turn the adjuster counterclockwise toward SOFI‘ for a light load and smooth road condition To increase (HARD) : Turn the adjuster clockwise toward HARD for a firmer ride and rough road condition. 24 To adjust the adjuster to the standard position, proceed as follows : 1. Turn the damping adjuster (1) clockwise until it will no longer turn (lightly seats). This is the full hard setting. 2. The adjuster is set in the standard position when the adjuster is turned counterclockwise approximately 1 turn so that its punch mark (2) aligns with the reference punch mark (3 ). Do not touch the exhaust pipe when adjusting the rebound damping adjuster. The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas. Do not, attempt to disassemble or service the damper; it cannot be rebuilt and must be replaced when worn out. Disposal should only be done by your Honda dealer. The instructions tound in this owner’s manual are limited to adjustment of the shock assembly only. (1) Damping adjuster (2) Punch mark (3) Reference punch mark 25 BRAKES Both the front 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 pads 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 114 ), there is probably air in the brake system and it must be bled. See your Honda dealer for this service. Front Brake Fluid Level: With the motorcycle in an upright position, check the fluid level. It should be above the LOWER level mark (1). It the level is at or below the LOWER level mark (1), check the brake pads for wear (page 114 ). 26 Wom pads should be replaced. It the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an equivalent. Front (l) LOWER level mark Front Brake Leven he Histance Between the tip of the brake lever (1) and the grip can be atfiusted by turning the adjuster (2) while pushing the lever forward. Align the arrow (3) on the brake lever with the index mark (4) on the acLiuster. Apply the brake several times and check for free wheel rotation after the brake lever is released. (3) (1) Bake lever (2) Adjuster (3) Arrow (4) lndexmark other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings 27 Rear Brake Fluid Level: ec e m e uid level from the inspection window (1) of the rear cowl with the motorcycle in an upright position. It should be between the UPPER (2) and LOWER (3) level marks. If the level is at or below the LOWER level mark (3), check the brake pads for wear (page 114 ). Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container. or an equivalent, Other Checks: MERe suremi—ere are no fluid leaks. Check {or deterioration or cracks in the hoses and fittings. 28 u) lnspeclion window (2) UPPER level mark (3) LOWER level mark CLUTCH This motorcycle has a hydraulically actuated clutch. There are no adjustments to perform but the clutch system must be inspected periodically for fluid level and leakage. If the control lever freeplay becomes excessive and the motorcycle creeps or stalls when shifted into gear, or ii the clutch slips. causing acceleration to lag behind engine speed. there is probably air in the clutch system and it must be bled out. See your Honda dealer [or this service Fluid Level: (fiecR tfiat the fluid level is above the LOWER level mark (1 ) with the motorcycle in an upright position. If the fluid level is near the lower level line. it indicates fluid leakage. See your Honda dealer. Other Checks: Make sure there are no fluid leaks Check {or deterioration or cracks in the hoses and fittings. (1) LOWER level mark Clutch Lever: lfie alstance between the lip of the clutch lever (l) and the grip can be adjusted by turning the adjuster (2) while pushing the lever forward. Align the arrow (3 ) on the clutch lever with the index mark (4) on the adjuster. (1) Clutch lever (3) Arrow (326 Adjuster (4) Index mark COOLANF Coolant Recommendation The owner must properly maintain the coolant to prevent freezing. overheating. and corrosion. Use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. (SEE ANTIFREEZE CONTAINER LABEL). Use only low-mineral drinking water or distilled water as a part of the antifreeze solution Water that is high in mineral content or salt may be harmlul to the aluminum engine. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. The factory provides a 50/50 solution oi antifreeze and distilled water in this motorcycle. This coolant solution is recommended for most operating temperatures and provides good corrosion protection. A higher concentration of antilreeze decreases the cooling system performance and is recommended only when additional protection against freezing is needed. A concentration of less than 40/ 60 (417%. antifreeze) will not provide proper corrosion protection. During treezing temperatures, check the cooling system frequently and add higher concentrations of antifreeze (up to a maximum of 60% antifreeze) it required. 31 Inspection 11 the reserve tank is empty, or if coolant The reserve tank is behind the frame. loss is excessive. check for leaks and see Check the coolant level in the reserve mnk your Honda dealer for repair. (1) while the engine is at the normal operating temperature with the motorcycle in an upright position. [i the coolant level is below the LOWER level mark (3), remove the seat (page 54 ) and reserve tank cap (4) and add coolant mixture until it reaches the UPPER level mark (2). Always add coolant to the reserve tank. Do not attempt t0 add coolant by removing the radiador Cap. (1) Reserve tank (4) Reserve tank can (1) Reserve tank (3) LOWER level mark (22) UPPER level mark 3 FUEL Fuel Tank The fuel tank capacity including the reserve supply is: 23.0 0 (6.08 US gal , 5.06 Imp gal) To open the fuel fill cap (1 ), insert the ignition key (2) and turn it clockwise. The fuel fill cap is hinged and will lit! up. Do not overfill the tank. There should be no fuel in the filler neck (3 ). After relueling, to close the fuel {ill cap, push the fuel fill cap into the filler neck until it snaps closed and locks, Remove the key. AWARNING Petrol is highly flammable and explosive. You can be bumed or seriously injured when handling luel. (l) Fuelfillcap (3) Fillerneck aStop the engine and keep heat, (2) Ignition key sparks, and llame away. 0 Refuel only outdoors. o Wipe up spills immediately. 33 Use unleaded petrol with a research octane number of 91 or higher. The use of leaded petrol will cause premature damage to the catalytic converters. 34 1f “spark knock“ or “pinking” occurs at a steady engine speed under normal leadv change brands of pelroL II spark knock or pinking persists. consult your Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda‘s Limited Warranty 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 5 oi “gasoho”: one containing ethano , and the other containing methanol. Do not use petrol that contains more than 10 96 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 96 methanol. even if it has cosolvents and corrosion inhibitors. Fuel system damage or engine perlormance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of iuels containing methanol since evidence of their suitability is as yet incomplete. Before buying fuel from an untam" station. try to find out if the fuel contains alcohol. If it does, confirm the type and percentage oi 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. 35 ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycles The level must be maintained between the upper (l) and lower (2) level marks on the dipstick (3 ), 1. Start the engine and let it idle for 3-5 minutes. Make sure the red low oil pressure indicator goes off. If the light remains on, stop the engine immediately, 2. Stop the engine and put the motorcycle on its center stand on level ground 3. Alter a few minutes. remove the dips ' k, 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, remove the oil filler cap (4) and add the specified oil (page 85) up to the upper level mark. Do not overiill. 5. Reinstall the dipstick and oil filler cap, 36Check for oil leaks. Running the engine with insufficient oil pressure may cause serious engine damage. (1) Upper level mark (2) Lower level mark (3) Dipslick (4) on filler cap TUBELESS TYRES To safely operate your motorcycle» your tyres must be the proper type and size, in good condition with adequate tread, and correctly inflated for the load you are carrying. The following pages give more detailed information on how and when to check your air pressure. how to inspect your tyres for damage, and what to do when your tyres need to be repaired or replaced. AWARNlNG Using tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owners manual regarding tyre inflation and maintenance. AirPressure Keeping your tyres properly inflated provides the best combination of handling. tread lite and riding comlort. Generally, underinflated tyres wear unevenly, adversely affect handling, and are more likely to fail [ram being overheated. Overinflated tyres make your motorcycle ride more harshly, are more prone to damage from road hazards. and wear unevenly We recommend that you visually check your tyres before every ride and use a gauge to measure air pressure at least once a month or any time you think the tyres mightbelow. Tubeless tyres have some sell-sealing ability if they are punctured. However. because leakage is often very slow, you should look closely for punctures whenever a tyre is not fully inflated, 37 Always check air pressure when your tyres are "cold" — when the motorcycle has been parked for at least three hours. If you check air pressure when your tyres are “warm" - when the motorcycle has been ridden for even a few miles — the readings will be higher than if the tyres were “cold“. This is normal, so do not let air out of the tyres to match the recommended cold air pressures given below. 1‘ you do, the tyres will be under-inflated. The recommended “col " tyre pressures are: Front 290 kPa (2.90 kqf/em“ 42 psi) Rear 290 kPa (2‘90 kgt/cm‘ 42 OS” 38 Inspection Whenever you check the tyre pressures, you should also examine the tyre treads and sidewalls for wear, damage, and foreign objects: Look for: O Bumps or bulges in the side of the tyre or the tread. Replace the tyre if you find any bumps or bulges. 0 Cuts, splits or cracks in the tyre. Replace the tyre if you can see fabric or Cord. - Exoessive tread wear. Also. it you hit a pothole or hard object, pull to the side of the road as soon as you safely can and carefully inspect the tyres for damage. TreadWear Replace tyres before tread depth at the lclenter of the tyre reaches the following 'mit: Mi imum tread depth Front: 15 mm (006 in) Rear. 2.0 mm (0.08 in) < For Genuany) German law prohibits use of tyres whose u'ead depth is less than 1.6 mm (1) Wear indicator (2) Wear indicator location mark (2) 39 Tyre Repair If a tyre is punctured or damaged, you should replace it, not repair it. As discussed below, a tyre that is rep red, either temporarily or permanently, w have lower speed and performance limits than a new tyre. A temporary repair, such as an external tubeless tyre plug, my not be safe [or normal speeds and riding conditions. It a temporary or emergency repair is made to a tyre, you should n'de slowly and cautiously to a dealer and have the tyre replaced If possible, you should not carry a passenger or cargo until a new tyre is installed. Even if a tyre is professionally repaired with a permanent internal patch plug, it will not be as good as a new tyre You should not exceed 80 km/ h (50 mph) for the first 24 hours, or 130 km/h (80 mph) at any time thereafter. In addition, you may not be able to safely carry as much weight as with a new tyre, Therefore. we strongly recommend that you replace a damaged tyre. If you choose to have a tyre repaired» bf] sure the wheel is balanced before you n e. Tyre Replacement The tyres that came on your motorcycle were designed to match the performance capabilities oi your motorcycle and provide the best combinafion of handling, braking. durability and comfort. AWARNING Installing improper tyres on your motorcycle can atlecl handling and stability. This can cause a crash in which you can be seriously hun or killed. Always use the size and type of tyres recommended in this owner‘s manual. The recommended tyres for your motorcycle are: Front: 120/70 ZR17 (58W) or 120/70 ZR17 M/C (58W) BRIDGESTONE BT57F RADIAL G DUNLOP D205F J MICHELIN MACADAM 90XS Rear: 180/55 ZR17 (73W) or 180/55 ZR17 M/C l73Wl BRIDGESTONE BT57R RADIAL G DUNLOP D205 G MICHELIN MACADAM SOXS Whenever you replace a tyre, use one that is equivalent to the original and be sure the wheel is balanced alter the new tyre is installed. 41 Important Safety Reminders - Do 110‘ inslall a tube inside a tubeless tyre on this motorcycle Excessive heat build- up can cause the tube to burst. - Use only tubeless tyres on [his motorcycle. The rims are designed [or tubeless tyres, and during hard acceleration or braking, a lubetype tyre could slip on the rim and cause the tyre to rapidly deflate ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (1) is below the OFF indicator panel. (Except BR type) The headlight and taillights will come on whenever you turn the ignition switch 0N. If your motorcycle is stopped with the ignition switch 0N and the engine is not nmning, the headlight and taillights will still be on, resulting in battery discharge, (1) Ignition switch Key Position Function Key_Reln0val _ LOCK Steering is locked. Engine and lights cannot be Key can be (steerimz lock) operated, removed OFF Engine and lights cannot be operated. Key can be removed 0N Engine and lights can be operated. Key cannot be removed KEYS This motorcycle has two keys and a key number plate. @ @ | | l l (2) l l (1) (1) Keys (2) Key numberplate (For BR type) m\\\\\fl (2) (1) You will need the key number if you ever have to replace a key. Store the plate in a sale place. To reproduce keys, bring all keys, key number plate and motorcycle to your Honda dealer. Up to {our keys can be registered with the immobilizer system (HISS), including the ones in hand. Li all keys are lost. the PGM-Fl unit/ ignition control module must be replaced. To avoid this possibility we recommend that it only one key is left. you immediately have it reproduced to ensure that a back-up is available, These keys contain electronic circuits that are activated by the immobilizer system (HISS). They will not work to start the engine if the circuits are damaged. 0 Do not grind, drill or in any way alter the original shape of the keys. o Do not drop the keys or set heavy objects on them. a Keep the keys away irorn magnetic objects. IMMOBILIZER SYSTEM (HISS) < l‘kcept BR type> HISS is the abbreviation of Honda Ignition Security System. The immobilizer system (HISS) protects your motorcycle [rom theft. A properly- coded key must be used in the ignition switch for the engine to start. If an improperlycoded key (or other device) is used the engine‘s starting circuit is disabled. When the ignition switch is turned 0N and the engine stop switch is a “ O ” (RUN), the immobilizer system (HISS) indicator lights for a few seconds, then go off. I! the indicator remains on, it means the system does not recognize the coding of the key Turn the ignition switch to OFF, remove the key. reinsert and turn the switch 0N again. The immobilizer system (HISS) indicator can continues to flash every 2 seconds during 24 hours when the ignition switch is OFF. After this period, the indicator automatically switches off. To operate this iunction, proceed as follows: 1. Turn the ignition switch ON. 2. Push and hold the HISS button (2 ). The immobilizer system (HlSS) indicator (1 ) instantly flash, the function is enabled 3, Turn the ignition switch OFF and the key is pulled out, then the indicator start to flash. Whenever the ignition switch is turned ON, the light operation is canceled. : (Z) H'I'S'S (1) Immobilizer system (HISS) indimtor (2) HISSbutton 47 It the system repeatedly does not recognize die coding of your key, contact your Honda dealer. 0 The system may not recognize the key’s coding if any other immobilizer key is near the ignition switch. To make sure the system recognize the key code. keep each immobilizer key on a separate ring. t Do not attempt to alter the immobilizer system (HISS) or add other devices to it. Electrical problems could result. making it impossible to start your motorcycle I It all keys are lost. the PGM-FI unit/ ignition control module must be replaced. EC Directives This immobilizer system complies with the R & ’l'l‘E (Radio equipment and telecommw nications terminal equipment and the mutual recognition of their contormity) Directive. C6 0891© The declaration of conIormity 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 Honda dealer. RIGHT HANDLEBAR CONTROLS (For BR type only> 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 1% (OFF) position, the engine will not operate This switch IS intended primarily as a safety or emergency switch and should normally remainin the O (RUN) position Headlight Switch The headlight switch (2) has three positions; 1.5? , ; nd OFF marked by a dot to the right of EDCI “lit-z Headlight taillight position light and meter lights on EDGE: Position light. taillight and meter lights on. OFF (dot): Headlight, taillight, position light and meter lights 0“. Starter Button The starter button (3) is below the headlight switch (2). When the starter button is pressed, the starter motor cranks the engine. If the engine stop switch is in the 8 (OFF) position, the starter motor will not operate See page 67 for the stam'ng procedure. (1) Engine stop switch (2) Headlight switch (3) Starter button 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 emergency switch and should nonnally remain in the O (RUN) posin'on. ll your motorcycle is stopped with the ignition switch 0N and the engine stop switch Rt (OFF). the headlight and taillights will still be on, resulting in battery discharge. 50 Starter Button The starter button (2) is below the engine stop switch (1). The starter button is used [or starting the engine. Pushing the button in starts the engine. See Starting Procedure, page 67. When the smrter button is pushed, the starter motor will crank the engine; the headlight will automatically go out, but the taillights will stay on. (1) Engine stop switch (2) Starter button LEFT HANDLEBAR CONTROIS Headlight Dimmer Switch (1 ) Push the dimmer switch to ED (HI) to select high beam or t (L0) to select low beam. Passing Light Control Switch (2) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing. Tum Signal Switch (3) Move to ¢ (L) to signal a left turn, I¢> (R) to signal a right turn. Press to turn signal elf. Horn Button (4) Press the button to sound the horn. (4) (3) (l) Headlight dimmer switch (2) Passing light control switch (3) Turn signal switch (4) Hom button 51 FEATURES (Not required for operation) STEERING LOCK To lock the steering, tum the handlebars all the way to the left or right. turn the key (1) to LOCK while pushing in. Remove the key. To unlock the steering, tum the key to OFF while pushing in. Do not turn the key to LOCK while riding the motorcycle; loss of vehicle control will result. 52 To unlock (1) Ignition key (A) Push in (B) Tum to LOCK (C) Turn to OFF HELMET HOLDER The helmet holders are located below the seat. Remove the seat (page 54 ). Hang the helmets on the holder hooks (1 ). Install the seat and lock it securely. AWARNING 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 sen‘ously hurt or killed (1) Holder hooks Use the helmet holder only while parked. Do not ride with a helmet secured by the holder. 53 SEAT To remove the seat (1), insert the ign 'on key (2) into the seat lock (3) and turn it clockwise. Pull the seat back and up. To install the seat, insert the front prong (4) into the fuel tank stay (5) and the rear prongs (6) into the rear stay (7) on the frame and then push down on the rear of the seat. Be sure the seat is locked securely in position after installation (5) (7) (1) Seat (2) Ignition key (3) Seat lock (4) Front prong (5) Fuel tank stay (6) Rearprongs (7) Rear stay DOCUMENT BAG The document bag (1) is in the document compartment (2) on the reverse side of the seat (3 ). This owner‘s manual and other documents should be stored in the document bag. When washing your motorcycle, be careful not to flood this area with water, (3) (1) Document bag (2) Document compartment (3) Seal 55 STORAGE COMPAKI‘M'ENT FOR U- SHAPED ANT l-THEFI‘ DOCK The rear fender has a storage compartment to store a U-shaped anfi-meft lock under the seat. After storing, be sure to fasten the lock with the rubber band (1 ) securely. Some U-shaped locks may not be stored in the compartment due to their size or design. 56 (1) Rubber band REAR COWL Removal: 1. Remove the seat (page 54) 2. Remove the caps (l ), bolts (2) and washers (3). 3. Remove the rear grab rail (4 )l 4. Remove the bolts (5) and washers (6). 5‘ Carefully pry up on the front prongs (7) of the rear cowl (8) and remove the rear cowl (8) by sliding it toward the rear. Installation: 0 nsta Enon can be done in the reverse order of removal. (1) Caps (5) Bolts (2) Bolts (6) Washers (3) Washers (7) Prongs (4) Reargmb rail (8) Rearcowl 57 LOWER COWL Removal: 1. Remove the boltsA (1) and bolts B (2). 2. Remove the clip A (3). <1) BolLsA (7) BoltsD (10) BoltsE (2) 130le (9) RighIlowercowl (12) Lefllowercowl (3) CfipA 58 3. Remove the bolts C (4). 4. Remove the clips B (5) and clips C (6). 5. Remove the bolts D (7). 6. Release the prong (8) 01 the right lower cowl (9) from the grommet and remove the right lower cow]. 7. Remove the bolts E (10). 8. Release the prong (11) of the left lower cowl (12) from the grommet and remove the left lower cowl. 9. Remove the clips D (13). 10. Remove the inner hall cowl (14). Installation: Olnstallation can be done in the reverse order of removal. (4) Bolts c (5) Clips B (6) Clips c (14) (s) Prong (11) Prong (13) Clips D (14) Inner half cowl 59 UPPER COWL COVER The right and left upper cowl covers can be removed in the same manner, Removal: 1. Remove the nut (1) and long mount bolt (2 ). 2. Remove the short mount bolt (3 ). 3. Remove the clip (4 ). 4. Remove the upper cowl cover (5 ). Installation: ‘ Install on can be done in the reverse order of removal. 60 (1) Nut (2) Long mounlbolt (3) Shun mountbolt (4) Clip (5) Upper cowl cover WIND GUARD The right and left wind guards can be removed in the same manner. Removal: 1. Remove the upper cowl cover (page 60 ). 2. Remove the clips A (1 ). 3. Remove the clips B (2 )‘ 4. Remove the wind guards (3 )4 Installation: 'Installalion can be done in the reverse order 0f removal (1) ClipsA (2) Clips B (3) Wind guards 61 INNER PANEL The right and left inner panels can be removed in the same manner. Removal: 1. Remove the lower cowl (page 58 ) and upper cowl cover (page 60 )4 2. Remove the clip A (l ). 3. Remove the clip B (2). 4. Remove the inner panel (3) by releasing it from the frame boss (4 ). 5, Remove the inner panel (3) by releasing it from the grommets (5) on the fuel tank. Installation: Glns lion can be done in the reverse order of removal. (l) (3) (l) CliDA (4) Frame boss (2) ClipB (5) Grommet (3) Inner panel HEADLIGHT AIM VERTICAL ADJUSI‘MENT Vertical adjustment can be made by turning the knob (1 ) in or out as necessary. Remove the upper cowl cover (page 60 ) to adjust head-light aim. Obey local laws and regtdafions. (1) Knob (A) Up (B) Down OPERATION PRE-RIDE INSPEUI‘ION For your safety, it is very importanl to take a few moments before each ride to walk around your motorcycle and check its condition. If you detect any problem. be sure you take care of it, or have it corrected by your Honda dealer. AWARNING Improperly maintaining this moturcycle or tailing to correct a problem belore riding can cause a crash in which you can be seriously hurt or killed. Always perform a pre-ride inspection before every ride and correct any problems. 1. Engine oil level—add engine oil it required (page 36 ). Check for leaks. 2. Fuel levelifil] fuel tank when necessary (page 33 ). Check for leaks. 3. Coolant leveliadd coolant l1 required. Check for leaks (pages 31 — 32 ). 4. Front and rear brakesflzheck operation; make sure there is no brake fluid leakage (pages 26 -‘ 28 ). 5.Tyres*check condition and pressure (pages 37 — 42 ). 6. Drive chain'check condition and slack (page 97 ). Adjust and lubricate it necessary. 7.Throttle—check [or smooth opening and full closing in all steering positions. 8. Lights and homicheck that headlight, tail/brake light, turn signals. indicators and horn function properly 9‘ Engine stop switchicheck for proper function (pages 49 — 50 ). 10. Side stand ignition cut-off system —check (or proper function (page 105 ). 65 STARTING THE ENGINE Always follow the proper starting procedure described below. This motorcycle is equipped with a side stand ignition cutoff system, The engine cannot be started if the side stand is down. unless the transmission is in neutral. If 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 it the transmission is put in gear before raising the side stand. To protect the catalytic converters in your motorcycle‘s exhaust system, avoid extending idling and the use of leaded petrol. Your motorc cle’s exhaust contains poisonous car on monoxide gas. High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. Do not run the engine with the garage door closed. Even with the door open. run the engine only long enough to move your motorcycle out of the garage. Do not use the electric starter for more than 5 seconds at a time. Release the starter button for approximately 10 seconds before pressing it again. Preparation Before starting, insert the key. turn the ignition switch 0N and confirm the following: o The transmission is in NEUTRAL (neutral indicator light ON). 0The engine stop switch is at O (RUN). 0 The red low oil pressure indicator is ON. 0 The immobilizer system (HISS) indicator is OFF. o The PGM»FI indicator is OFF. The low oil pressure indicator should go oft a few seconds after the engine starts. If the light stays flashing. stop the engine immediately and check the engine oil level. Oper g the engine with insufficient oil pressure can cause serious engine damage. Starting Procedure This motorcycle has a I'uel-iniected engine with an automatic fast idle. Follow the procedure indicated below. An! Air Temperature 0 Press the starter button with the throttle completely closed. The engine will not start if the throttle is fully open (because the electronic control module cuts off the fuel supply). Flooded Engine If the engine fails to start alter repeated attempts. it may be flooded engine. 1. Leave the engine stop switch set to O (RUN). 2. Open throttle fully. 3. Press the starter button for 5 seconds. 4. Then follow the normal starting procedure. 5. If the engine start, then open the throttle slightly if idling is unstable. If the engine does not start, wait for 10 seconds, then follow steps 1*4 again. Ignition Cut Off Your motorcycle is designed to automatically stop the engine and tuel pump if the motorcycle is over4umed (a banking sensor cuts off the ignition system). Before restarting the engine, you must turn the ignition switch to the OFF position and then back to ON. RUNNING-IN Help assure your motorcycle‘s future reliability and performance by paying extra attention lo how you ride during lhe firsl 500 km (300 miles). During this period. avoid full-throttle starts and rapid acceleration. RIDING Review Motorcycle Safety (pages 1 r 7) before you ride. Make sure you understand the lunction of the side stand mechanism. (See MAIN- TENANCE SCHEDULE on page 81 and explanation [or SIDE STAND on page 105), Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when riding, idling, or parking your motorcycle. 70 14 After the engine has been warmed up. the motorcycle is ready for riding, 2. While the engine is idling, pull in the clutch lever and depress the gearsth pedal to shift into 1st (low) gear. 3. Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start. 4. When the motorcycle attains a moderate speed, close the throttle, pull in the clutch lever and shilt to 2nd gear by raising the gearsth pedal. This sequence is repeated to progres sively shift to 3rd, 4th, 5th and 6th(top) geari 5. Coordinate the throttle and brakes for smooth deceleration. 6. Both (rent and rear brakes should be used at the same time and should not be applied strongly enough to lock the wheel. or braking effectiveness will be reduced and control of the motorcycle be difficult. 71 BRAKING This motorcycle is equipped with a Dual Combined Brake System. Operating the front brake lever applies the (ram brake and a portion of the rear brake. Operating the rear brake pedal applies the rear brake and a portion of the front brake. For full braking effectiveness, use both the lever and pedal simultaneously. as you would with a conventional motorcycle braking system. As with a conventional motorcycle braking system, excessively hard application at the brake controls may cause wheel lock, reducing control of the motorcycle. For normal braking. apply both the brake pedal and lever While down-shifting to match your road speed. For maximum braking, close the throttle and firmly apply the pedal and lever; pull in the clutch lever before coming to a complete stop to prevent stalling the engine. 72 Important Safety Reminders: 0When possible. reduce speed or brake before entering a turn; closing the throttle or braking in mid-tum may cause wheel slip. Wheel slip will reduce control of the motorcycle. 0 When riding in wet or rainy conditions. or on loose surfaces. the ability to maneuver and stop will be reduced. All oi your actions should be smooth under these conditions. Rapid acceleration, braking or turning may cause loss of control. For your saiety. exercise extreme caution when braking, accelerating or turning, OWhen descending a long, steep grade. use engine compression braking by down- shilting 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 hand on the brake lever may actuate the brakelight. giving a false indication to other drivers. It may also overheat the brakes. reducing effectiveness. 73 PARKING LAiter stopping the motorcycle, shift the transmission into neutral, turn the handlebar fully to the left, turn the ignition switch OFF and remove the key. 2, Use the side or center stand to support the motorcycle while parked. Park the motorcycle on firm, level ground to prevent it from falling over. II you must park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility of rolling off the side stand or overturning. 3. Lock the steering to help prevent theit (page 52 ). 74 Make sure flammable materials such as dry grass or leaves do not come in Contact with the exhaust system when parking your motorcycle. ANT I-THEFI‘ TIPS 1, Always lock the steering and never leave the key in the ignition switch, This sounds simple but people do lorget. 2. Be sure the registration information for your motorcycle is accurate and current. 3. Park your motorcycle in a locked garage whenever possible, 4. Use an additional anti-theft device of good quality. 5‘ Put your name. address. and phone number in this Owner‘s Manual and keep it on your motorcycles at all times. Many times stolen motorcycles are identified by inlormation in the Owner's Manuals that are still with them. NAME: ADDRESS: PHONE N0: MAINTENANCE THE IMPORTANCE OF MAINTENANCE A well~maintained motorcycle is essential for safe. economical and troublefree riding. It will also help reduce air pollution. To help you properly care for your motorcycle. the following pages include a Maintenance Schedule and a Maintenance Record for regularly scheduled maintenance. These ’ structions are based on the assum that the motorcycle will be used exclusively for its designed purpose, Sustained high speed operation or operation in unusually wet or dusty Conditions will require more irequent service than specified in the Maintenance Schedule. Consult your Honda dealer {or recommendations applicable to your individual needs and use. 76 If your motorcycle overtums or becomes involved in a crash be sure your Honda dealer inspects all major parts. even it you are able to make some repairs AWARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always tollow the inspection and maintenance recommendations and schedules in this owner's manual, MAINTENANCE SAFEI'Y This section includes instmctions on some important maintenance tasks. You can perform some of these tasks with the tools pail/Med > it you have basic mechanical S 5. Other tasks that are more dilflcult and require special tools are best performed by professionals. Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service. Some oi the most important safety precautions follow. However. we cannot warn you of every conceivable hazard that can arise in periorming maintenance. Only you can decide whether or not you should perlonn a given task. “WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner's manual. SAFEI‘Y PRECAUTIONS 0 Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: t (kirbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. . Burns from hot parts. Let the engine and exhaust system cool before touching. a Injury from moving parts. Do not run the engine unless instnicted to do so. 0 Read the instructions before you begin. and make sure you have the tools and skills required 0To help prevent the motorcycle from tailing over, park it on a firm, level surface, using the center stand or a maintenance stand to provide support. 78 O’l‘o reduce the possibility of a fire or explosion, be careful when working around petrol or batteries. Use only nonflammable solvent not petrol to clean parts Keep Cigarettes sparks and flames away Irom the battery and all [uel—related Darts. Remember that your Honda dealer knows your motorcycle best and is iully equipped to maintain and repair it. To ensure the best quality and reliability, use only new genuine Honda parts or their equivalents for repair and replacement MAINTENANCE SCHEDULE Perrorni ihe Preride Inspecrlon (page at ) at each scheduled maintainnee period, l: 114st AND CLEAN. ADJUST LUBRICATE OR REPLACE IF NECESSARY c: CLEAN R: REPLACE A; ADJUST L» LUBRICATE The following Maintenance Schedule spec. res all maintenance required to keep your motorcycle in peak operating Condition. Maintenance wortr should be perlonned in accordance with siandards and specifications at Honda by properly trained and equipped technicians. Your Honda dealer meets all ot these requirements. . Should be serviced by your Honda dealer, unless the owner has the proper lools and service data and is mechanically qualified Reter to the omcinl Honda Shop Manual, on [n the interest or satery, we recommend these items be serviced only by your Honda dealer. Honda recommends that your Honda dealer should road test your motorcycle atter each periodic maintenance is carried out, NOTE& (1) At higher odometer readings, repeat at the lrequency interval established here. (2) Service more [requendy it the motorvycle is ridden in unusually wet or dusty areas, (3) Replaoe every 2 years, or at indicated odometer interval, Whichever comes first. Replacement requires mechanical skill, 79 FREQUENCY ‘éfifgfivm ODOMETER READING 1mm; ml FIRST X Imkm l 6 12 13 24 30 35 REFER I X 101‘! mi 0.6 4 8 12 15 20 2‘ TO IT M NOTE MONTH 6 12 13 24 30 36 PAGE ' FUEL LINE I I I 7 c THROTTLE OPERATION 1 I I 94 . AIR CLEANER NOTE (2) R R 7 SPARK PLUGS EVERY 241”“ km [lfim I'll) I, 89’93 EVERY 48.030 km (32“ ‘7 R o VALVE CLEARANCE 1 ~ ENGINE O". R R R R 35* 38 ENGINE OIL FILTER R R R R 86*” ‘ ENGINE IDLE SPEED I I I I I I I 95 RADIATOR COOLANT NOTE (3) I I R 31* 32 * COOLING SYSTEM I I I 7 ‘ SECONDARY AIR SUPPLY SYb‘I-EM I I I — 80 FREQUENCY WHIcI-IEVER A COMES ODOME’I‘ERREADING [NOTE (1)] FIRST x 11mm 1 6 12 18 24 30 36 REFER 1 momma 0,5 4 a 12 16 20 24 10 mm NOTE MONTH s 12 18 2A 30 31; PAGE DRIVE CHAIN EVERY 1 1mm (600 m1 L 977102 DRIVE CHAIN SLIDER 1 1 I 103 BRAKE FLUID NOTE <3) 1 1 R 1 1 R 26* 23 BRAKE PAD WEAR 1 1 1 1 1 114 BRAKE SYSTEM 1 1 1 1 26*28 116 s BRAKE ucm‘swrmI 1 1 1 122 . HEADLIGHT AM 1 I 1 63 CLUTCH SYerM I I 1 29 CLUTCH FLUID NOTE (3) I I R I 1 R 29 SIDE STAND I 1 1 105 .1 SUSPENSION 1 1 1 104 : NUTS BOLmFAStENERs 1 1 I I , u WHEELS/TYRES 1 I 1 , «- STEERING HEAD BEARINGS I I 1 1 7 31 TOOL KIT The tool kit (1 ) is in the tool box under the seat. Some roadside repairs. minor atfluslments and pans replacement can be performed with the tools contained in the kit. - Spark plug wrench o 10 X 12 mm Box end wrench I 22 mm Box end wrench . 27 mm Box end wrench o 8 mm Open end Wrench 0 10 X 12 mm Open end wrench ¢ Fliers o 5 mm Hex Wrench 0 6 mm Hex Wrench 0 Screwdriver handle a Tool bag 0 Extension bar 0 0.7 mm F eeler gauge . Slandard/ Phillips screwdriver 0 8 mm Box wrench 82 (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 replacement parts, Record the numbers here [or your reference. FRAME NO. The frame number (1) is stamped on the right side of the steering head, The engine number (2) is stamped on top of the crankcase. ENGINE N0. (1) Frame number (2) Engine number 83 COLOUR ”BEL The colour label (1 ) is attached to the frame below the seat (page 54 ). It is helpful when ordering replacement pans, Record the colour and code here for your relerence. COLOUR CODE (1) Colour label 84 ENGINE OIL Refer to the Safety Precautions on page 78 r 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 56, Viscosity: Viscosity grade oi 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. (1) Single grade Sll u IllllT (2) Mulu' grade Engine Oil and Filter Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule (page 80 ). When running in very dusty conditions, oil changes should be periormed more frequently than specified in the maintenance schedule. Please dispose oi 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 [or reclamation. Do not throw it in the trash or pour it on the ground or down a drain. Used engine oil may cause skin cancer if repeatedly leit in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis. it is still advisable to thoroughly wash your hands with soap and water as soon as possi- ble after handling used oil, Changing the oil filter requires a special oil filter tool and a torque wrench. If you do not have these tools and the necessary skill, we recommend that you have your Honda dealer perform this service. If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly. Change the engine oil with the engine at normal operating temperature and the motorcycle on its center stand to assure complete and rapid draining. 1. Remove the lower cow] (page 58 ). 3 Remove the oil filter (3) with a filter 2. To dmin the oil, remove the oil filler cap wrench and let the remaining oil drain out 2;? oil drain plug (1) and sealing washer ( . (l) Oildmin plug (2) Sealingwasher (3) Oil finer 4‘ Apply a thin coat 0! engine oil to the new oil filter rubber seal (4 ). 5, Using a special tool and a torque wrench. install the new oil filter and tighten to a torque of: 93 Nrm (1.0 kgf‘m , 7 Ibfit) Use only the Honda genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong Honda filter or a non-Honda filter which is not of equivalent quality may cause engine damage. (4) Oil filter rubber seal 88 6. Check that the sealing msher 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: 29 N~m (3‘0 kgf‘m , 22 Ithl 7. Fill the crankcase with the recommended grade oil; approximately: 33 a (M US qt , 3,4 Imp qt) 8‘ Install the oil filler cap. 9, Install the lower cowl 10. Slart the engine and let it idle [or 3*5 minutes. 11. Several minutes alter stopping the engine, check that the oil level is at the upper level mark on the dipstick with the motorcycle on its center stand, level ground. Make sure there are no oil leaks. SPARK PLUGS Refer to the Safety Precautions on page 78 . Recommended plugs: IMRQCi9H (NGKl Never use a spark plug with an improper heat range. Severe engine damage could result. This mo rcycle uses the spark plugs that have a i dium coated center electrode Be sure to observe the following when servicing the spark plugs. 0 Do not clean the spark plug It the electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one. 0 Use only “wiretype feeler gauge“ to check the spark plug gap to prevent damaging the iridium coating of the center electrodes. Never use “leaf-type feeler gauge”. . Do not adjust the spark plug gap. If the gap is out 01 specification, replace the spark plug with a new one. 89 1. Remove the lower cowl (page 58 ), 2. Remove the upper cowl cover (page 60 ). 3. Remove the wind guard (page 61 )4 4. Remove the inner panel wage 62 ). 5. Remove the oil cooler upper mount bolts (1 ) and harness guide (2). 6, Remove the oil cooler lower mount bolts (3 ). 7‘ Move the oil cooler (4) forward. Damage 0 due oil cooler fins can reduce cooling or cause a system leak. Handle the oil cooler with care. (1) Upper mount bolts (3) Lower mount bolts (2) Hamessguide (4) Oilcmler 30 8. Remove the radiator mount bolt (5 ). 9‘ Move the radiator (6) out of the way and remove the grommets (7) from the radiator stays (8 )r 10. Pull the radiator toward the front. (8) ‘7’ <5) (7) (6) (5) Radiator mount bolt (5) Radiator (7) Grommets (8) Radiator stays Damage to the radiator fins can reduce cooling or cause a system leak. Handle the radiator with care 11.Remove the heat guard (9) from the radiator stay (8 ). (9) Heat guard 91 12. Disconnect the spark plug caps from the spar plugs. 13. glean any dirt from around the spark plug ases. Remove the spark plugs using the spark plug wrench (10) furnished in the tool kit. 14. Inspect the electrodes and center porcelain [or deposits, erosion or carbon fouling. If the erosion or deposit is heavy, replace the plug. (10) Spark plug Wrench 92 15. Make sure that the 1,0 mm wiretype feeler gauge does not insert between the spark plug gap (11). If the gauge is inserted into the gap, replace the plug with a new one. 16. Make sure the plug washer is in good condition. (11) fl (1!) Spark plug gap 17.Wilh the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 18.Tighten a new spark plug 1/2 turn with a spark plug wrench to compress the washer. If you are reusing a plug, it should only take 1/871/4 turn after the plug seats. The spark plug must be securely fightened. An improperly tightened plug can become very hot and possibly damage the engine. 19. Reinstall the spark plug caps, 20.1nstall the remaining parts in the reverse order of removal. To avoid possible costly damage to the radiator. do not install the upper (longer) mount bolts In the lower mounts. Also avoid crossthreading or overtightening the oil cooler lower mount bolts (3) (page 90 ). THRUIT LE OPERATION Refer to the Salety Precautions on page 78 . ,.i . Check [or smooth rotation of the throttle grip [mm the fully open to the fully closed position at both full steering positions. 2. Measure the throttle grip free play at the throttle grip flange. The standard free play should be approximately: 2*6mm(0.08*0,24in) To adjust the free play, loosen the lock nut (l) and turn the adjuster (2). (1) Lock nut (2) Adiuster IDLE SPEED Reler to the Safety Precautions on page 78 . The engine must be at normal operating temperature [or accurate idle speed adjustment. Ten minutes of slop-and-go riding is sufficient. 1. Warm up the engine. and shift to neutral. and place the motorcycle on its center stand. 2. Adjust idle speed with the throttle stop screw (1) ldle speed (In neutral): 1,100 i 100 min" (rpm) (1) Throttle stop screw (A) Increase (B) Decrease 95 COOIANI‘ Refer to the Saiety Precautions on page 78 . Coolant Replacement Coolant should be replaced by a Honda dealer. unless the owner has proper tools and service data and is mechanically qualified. Refer to an official Honda Shop Manual. Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. AWARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always lei the engine and radialor cool down beiore removing the radiator cap. DRIVE CHAIN Refer to the Saiety Precautions on page 78 . The service lile of the drive chain is dependent upon proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the dn‘ve chain and sprockets The drive chain should be checked and lubricated as part of the Preride Inspection (page 64 ). Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas. more frequent maintenance will be necessary Inspclion: . um I e engine oil, place the motorcycle on its center 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: 25—35 mm (li0*1.4 in) w .Rotate the rear wheel. Stop. Check the drive chain slack. Repeat this procedure several times. Drive chain slack should remain constant. If the chain Is slack only in certain sections, some links are kinked and binding. B ding and kinking can lrequently be eliminated by lubrication In In. 3 9 Aw .m.‘ c 3 '1‘“;le (1) (1) Drive chain 97 4. Rotate the rear wheel slowly and inspect the drive chain and sprockets [or any of the following conditions: DRIVE CHAIN 'Damaged Rollers 'Loose Pins ‘Dry or Rusted Links ’Kinked or Binding Links 'Excessive Wear 'Improper Adjustment "Damaged or Missing 0~rings SPROCKETS *Excessively Worn Teeth “Broken or Damaged Teeth A drive chain with damaged rollers, loose pins. or missing (kings must be replaced. A chain which appears dry, or shows signs of rust requires supplementary lubrication. Kinked or binding links should be thor- oughly lubricated and worked free it links cannot be freed» the chain must be replaced. Damaged sprocket Worn sprocket Teeth Teeth Replace Replace s...» Normal sprocket Teeth GOOD Ad'ustment: rive c am slack should be checked and adjusmd. 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. (1) Axle nut (2) Adjusting bolt (3) Scale (4) Index mark If the drive chain requires adjustment, the procedure is as follows: 1, Place the motorcycle on its center stand with the transmission in neutral and the ignition switch OH. 2. Loosen the axle nut (1). 3.Tum both adjusting bolts (2) an equal number of turns until the correct drive chain slack is obtained. Turn the adjustin bolts counterclockwise to tighten e chain, or clockwise 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: 25-35 mm (1.0—1l4in) 4‘ Check the rear axle alignment by confirming the scale (3) on the drive chain adjusters against the index marks (4) on the swim. Both left and right scales should correspond lfthe axle is misaligned turn the left or right adjusting bolt until the scales correspond on both side of swingarm and recheck chain shck, 5. Tighten the axle nut to specified torque. Axle nut torque: 93 N-m (9,5 kgf‘rn , 69 |bf~fl) It a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly 6. Tighten the adjusting bolts lightly, 100 Wear Insgction: ec t e c ain wear label when adjusting the chain. ll the red zone (6) on the label aligns with the index mark (5) on the swingarm alter the chain has been adjusted to the proper slack, the chain is excessively Wom and must be replaced. The proper slack is: 25*35 mm (10*1‘4 in) Damage to the bottom part of the frame may be caused by excessive drive chain slack of more than: 50 mm (2.0 in) Replacement chain: DiL D50sz or RK50LFO‘Zi This motorcycle has a staked master link drive chain which requires a special tool for cutting and staking Do not use an ordinary giasiter link with this chain. See your Honda ea CL (5) Index mark (6) Red zone 101 Lubrication and Cleanin : u ncate every , (600 miles) or sooner if chain appears dry 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. The ()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 Orings. Brushing will damage them. Wipe dry and lubricave only with SAE 80 or 90 gear oil. Commercial chain lubri- cants may contain solvents which could damage the rubber O-rings. 102 DRIVE CHAIN SLIDER Refer to the Safety Precautions on page 78 . Check rhe chain slider (1) for wear. The chain slider must be replaced it it is worn to the wear limit line (2). For replacement, see your Honda dealer, (1) Chain slider (2) Wearlimit line 1 03 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page 78 . Check the fork assembly by locking the front bmke and pumping the fork up and down vigorously. Suspension action should be smooth and there must be no oil leakage. Swingann bearings should be checked by pushing hard against the side of the rear wheel while the motorcycle is on the center stand. Free play indicates wom bea ‘ . Carefully inspect all front and rear suspension fasteners [or tightness. 5° 5" 104 SIDE STAND Refer to the Safety Precautions on page 78 , Perform the following maintenance in accordance with the maintenance schedule. Functional Check: 01 FieclE the spring (1) [or damage or loss of tension and the side stand assembly for freedom 01 movement. D Check the side stand ignition cut-off 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 Honda dealer (or semce. (1) Side stand spring 105 WHEEL REMOVAL Refer to the Safety Precautions on page 78 . 3. Remove the two A socket bolts (2) and the B socket bolt (3 ). Front Wheel Removal 1 Raise the from wheel off the ground by placing a support block under the engine 2 Cover both sides of the from. wheel with a protective tape (1 ) or equivalent. (1) Protective tape (2) Socket boltsA (3) SockelboltB 106 4, Remove the left caliper assembly (4 ). 5. Remove the right caliper assembly (5) from the fork leg by removing the fixing bolts (6). 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. Do not depress the brake lever and brake pedal 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 Honda dealer for this service. (4) Left caliper assembly (5) Right caliper assembly (6) Fixing bolts 10': 6. Loosen the right and left axle pinch bolts (7 ). and remove the axle bolt (8 )l 7. Withdraw the front ande (9) and remove the from wheel. (7) Axle pinch bolts (8) Axle bolt (9) Front axle 108 Installation: 1. Posttlon the front wheel between the fork legs and insert the front axle from the left side through the left fork leg and wheel 2 Tighten the axle bolt to the specified torque: 59 N-m (6.0 kgf-m , 43 Ibf‘ftl 3. Tighten the axle pinch bolts on the right fork leg to specified torque: 22 N‘m (22 kgf-m ,16lbf‘fll 4. Install the right and left caliper assembly to the fork legs, tighten the fixing bolts and socket bolts to the specified torque: 31 N-m (3.2 kgf~m , 23 lbfrft) To avoid damaging the brake pads while installing the caliper assemblies. carefully fit both brake discs between the pads. 5. Temporarily tighten the axle pinch bolts on the left fork leg until lightly seat. 6. Operate the front brake and pump the fork several times. 109 7‘ Measure the clearance (10) between each surface of the left brake disc (11) and the left brake caliper holder (12) (not brake pads) with a 0.7 mm (0.028 in) Ieeler gauge (13) (see illustration). (12) ‘jL‘:_(10) (11) (10) Clearance (12) Caliper holder (11) Brake disc 1 1 0 (13) Feeler gauge 8. It the Iecler gauge inserts easily. tighten the left axle pinch bolts (7) to the specified torque: 22 N-m (2.2 kgf-m ,16lbf‘ftl If the feeler gauge cannot be inserted easily, pull the left fork outward or push inward to adjust the clearance, Then tighten the left axle pinch bolts to the specified torque. 9. After installing the wheel, apply the brake lever AND brake pedal several times, then recheck both discs {or caliper holder to disc clearance. Do not operate the motorcycle without adequate clearance. ' Check for free wheel rotation after the brake lever and brake pedal are released. Recheck the wheel i! the brake drags or if the wheel does not rotate freely. 'Aiter installing the wheel, operate the brake lever AND brake pedal several times until you feel pressure. You must restore pressure from BOTH the lever AND the pedal because this motorcycle is equipped with a Dual Combined Brake System. 0 Verify proper brake operation before riding. 10. Remove the protective tapes from the front wheel. Failure to provide adequate disc to caliper holder (not brake pads) clearance may damage the brake discs and impair braking efficiency. If the torque wrench was not used for insmllation, see your Honda dealer as soon as possible to Verify proper assembly. Improper assembly may lead to loss of braking capacity. Rear Wheel Removal 6. Remove the axle shaft (3 ), side collar and 1. Place the motorcycle on its center stand. rear wheel from the swingarm, 2. Loosen the rear axle nut (4 ). 3. Loosen the drive chain adjusting bolts Do not depress the brake lever and brake (1). pedal when the wheel is of! the motorcycle. 4. Remove the rear axle nul (4 ). The caliper piston will be forced out of the 5. Remove the drive Chain (2) from the cylinder with subsequent loss oi brake fluid. driven sprocket by pushing the rear If this occurs, servicing of the brake system wheel forward. will be necessary. See your Honda dealer for this service. (l) Adjusting bolt (3) Axle shalt (4) Rear axle nut (2) Drive chain 1 12 Installation Notes: 0 0 Install the rear wheel, reverse the removal procedure. I Make sure that the slot (5) on the brake caliper is located in the lug (6) in the swingarm (7). 0 Tighten the axle nut to: 93 Mm (935 kgf-m , 69 lbf-fl) 0 Adjust the drive chain (page 97 ). 0 Apply the brake several times and check for free wheel rotation after the brake lever and brake pedal are released. - Brake system inspection (page 116 ), When insmlling the wheel. carefully fit the brake disc between the brake pads to avoid damaging the pads. After installation, operate the brake lever and brake pedal and check the brake operation, If a torque wrench Was not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of brakingcapacity. (5) Slot (6) Lug (7) Swingarm 113 BRAKE PAD WEAR Refer to the Safety Precautions on page 73 i Brake pad wear depends upon the sevevity of usage, the type 0! riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval (page 81 ). Front Blake Always inspect each pad in both right and left brake calipers. Check the cutout (1 ) in each pad. If either pad is worn to the cutout» replace both pads as a set. See your Honda dealer {or this service. 114 < FRONT BRAKE > Illustration shows left side. right side similar. (l) i 1) Cutouts Rear Brake Check the Cutout (2) in each pad. If either pad is worn to the cutout, replace both pads as a set. See your Honda dealer for this service. < REAR BRAKE > (2) Cutouts (2) 115 BRAKESYSI‘EMINSPECI‘ION 2. Move the left caliper assembly (1) Referto the Safety Precautions on page 78 . upward while slowly rotating the rear wheel. The brake system is normal if the Check the brake system as follows: rear wheel stops. I! the rear wheel does 1. Place the motorcycle on its center smnd, not stop, see your Honda dealer. stop the engine. and place the transmission in neutral (1) (1) 1m caliper assembly 1 16 BATTERY Refer to the Safety Precautions on page 78 . It is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenancefree (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), Contact your Honda dealer. ttery is a maintenance-free type and can be permanently damaged ii the cap strip is removed “WARNING The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough lorce to kill or seriously hurt you. Wear protective clothing and a lace shield, or have a skilled mechanic do the battery maintenance. 117 Battery Removal 1, Remove the seat (page 54 ), 2. Release the rings and remove the rubber band (1 ). 3, Disconnect the negative (7) terminal lead (2) from the battery first. then disconnect the positive (+) terminal lead (3 ). 4. all out the battery (4) from the battery X4 118 (4) (1) Rubberband (2) Negative (A) leminal lead (3) Positive (+) terminal lead (4) Battery FUSE REPLACEMENT Reier to the Safety Precauiions on page 78 . When (requem (use failure occurs it usually indicates a short circuit or an overload in the electrical system See your Honda dealer for repair. Never use a [use with a different rating from that specified. Serious damage to the electrical system or a fire may result, causing a dangerous loss of lights or engine power. Blown {use 119 Fuse Box: fie luse box is located under the seaL The specified fuses are: 10A 20A L Remove the seat (page 54 ). 2, Open the fuse box cover (1 ). 3. Pull out the old [use and install a new fuse. The spare Inses (2) are located in the fuse box. 4. Close the fuse box cover and install the seal. (1} Fuse box cover (2) Spare (uses 120 Main Fuse A: fie mam fuse A (1) is located behind the rear cowl. The specified fuse is: 30A 1. Remove the rear cowl (page 57 ). 2. Disconnect the wire connector (2 ) of the starter magnetic switch. 3. Pull out the old fuse and install a new fusel The spare [use (3) is located under the starter magnetic switch. 4, Reconnect the connector and install the rear cowl. FI Fuse: fie Fl fuse (4) is located under the seat. The specified fuse is: 30A 1. Remove the seat (page 54 ). 2. Open the FI fuse box cover (5 ). 3. Pull out the old fuse and install a new fuse. The spare fuse (3 ) is located under the starter magnetic switch. 4, Close the FI fuse box cover and install the seat. (3) (1) Main fuseA (2) Wire connector (3) Spare main fuse (4) FIfuse (5) Fl fuse box cover 121 S’I‘OPLIGHT SWITCH ADJUSTMENT Refer to the Satety Precautions on page 78 . Check the operation of the stoplight switch (1) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut (2). Turn the nut in the direction (A) if the swimh operates too late and in direction (B) if the swimh operates too soon. (l) Stoplight switch (2) Adjusting nut 122 BULB REPLACEMENT Refer to the Salety Precautions on page 78 . The light bulb becomes very hot while the light is ON, and remain hot for a while after it is turned OFFl Be sure to let it cool down before servicing. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break. Wear clean gloves While replacing the bulb, If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. 0 Be sure to turn the ignition switch OFF when replacing the bulb. 0 Do not use bulbs other than that specified. 0 After installing a new bulb, check that the light operates properly. 123 Headlight Bulb 1, Remove the upper cowl cover (page 60 )l 2. Pull out the socket (1) without turning. 3. Remove the dust cover (2 ). 4. Remove the bull) (4) while pressing down on the pin (3). 5. Pull out the bulb (4) without turning. 6. Install a new bulb in the reverse order of removal 0 Install the dust cover with its ”TOP“ mark facing up, (1) Socket (3) Pin (2) Dustcover (4) Bulb 124 Position Light Bulb 1, Remove the position light cover (1 )r 2‘ Pull the position light reflector (2) and remove it. 3. Pull out the bulb (3) without turning. 4. Install a new bulb in the reverse order of removed. (1) (1) Position lighlcover (2) Position light reflector (3) Bulb 125 Stop/1‘ aillight Bulb 1. Remove the seal (page 54 )4 2‘ Turn the socket (1 ) 90° counter- clockwise, lhen pull it out toward you. 3. Pullout the bulb (2) without turning. 4.1nstall a new bulb in the reverse order of removal. (1) Socket (2) Bulb 126 Front Turn Signal Bulb 1. Turn over the rearview mirror boot (1 ). 2. Remove the two mounting bolts (2) and the rearview mirror (3). 3. Turn the socket (4) 90° counterclock- wise, and remove I 4 Slightly press the bulb (5) and turn it counterclockwise. 5. Install a new bulb in the reverse order of removal. (l) Bool (3) Rearview mirror (4) Socket (2) Balls (5) Bulb 127 Rear Turn Signal Bulb 1. Remove the rear turn signal lens (1) and the lens packing (4) by removing the screw (2). 2. Slightly press the bulb (3) and turn it counterclockwise, (2) 3. Install a new bulb in the reverse order of removal. (1) Lens (3) Bulb (2) Screw <4) Lenspacking 128 CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect for damage, wear, and oil, coolant or brake fluid leakage. Avoid cleaning products that are not specifically designed [or motorcycle or automobile surfaces They may contain harsh detergents or chemical solvents that could damage the metal. paint and plastic on your motorcycle, If your motorcycle is still warm [rom recent operation, give the engine and exhaust system time to cool oft We recommend avoiding the use of high pressure water spray (typical in wine operated car washes). Hig pressure water (or air) can damage certain parts of the motorcycle. Do not apply the pressured water directly to the air intake, The water can be drawn into the throttle body and/ or enter the air cleaner. (1) Air intake 129 Washing the motorcycle 1. Rinse the motorcycle thoroughly with cool water to remove loose dirt. 2. Clean the motorcycle with a sponge or soft cloth using cool water. Avoid directing water to muffler outlets and elem-ion] parts. 3. Clean the fairing. headlight lens and other 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. The rear grab rail is also a plastic part and can be cleaned in the same manner as described above. Take care to keep brake fluid or chemical solvents oil the motorcycle. They will damage the plastic and painted surfaces. 130 The inside of the headlight lens may be clouded immediately after washing the motorcycle. Moisture condensation inside the headlight lens will disappear gradually by lighting the headlight in high beam. Run the engine while keeping the headlight on. 4.After cleaning, rinse the motorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. 5. Dryy the motorcycle start the engine and let it run for several minutes 6.Test the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking performance. [Lubricate the drive chain immediately after washing and drying the motorcycle. Braking efficiency may be temporan'ly impaired immediately after washing the motorcycle Anticipate longer stopping distance to avoid a possible aocident. 13I Finishing'l‘ouches After washing your motorcycle, consider using a commercially-available spray cleaner/ polish or quality liquid or paste wax to finish the jobr Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instnictions on the container, If a surface on your motorcycle is chipped or scratched. your Honda dealer has touch- up paint to match your motorcycles colour. Be sure to use your motorcycle‘s colour code (page 84 ) when you buy touch‘up paint. 132 Removing Road Salt The salt contained in the road surface freezing prevention medicine which a road was Sprayed with in winter, and the seawater becomes the cause which rust occurs in. Wash your motorcycle by the following point after it mns through such a place. 1. Clean the motorcycle using cool water (page 129 ). Do not use warm waterr This worsens the effect of the salt. 2. Dry the motorcycle and the surface of the metal is protected with the wax. Painted Aluminum Wheel Maintenance Aluminum may corrode from contact with dirt. mud, or road salt. Clean the wheels after riding through any 01 these substanoes, Use a wet sponge and mild detergent. Avoid stiff brushes. steel wool, or cleaners containing 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. 133 STORAGE GUIDE Extended storage. such as {or 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. Make sure the cooling system is filled with a 50/ 50 % antifreeze solution. 3. Empty the fuel tank into an approved petrol container 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. 134 AWARNING Petrol is highly flammable and explosive. You can be burned or seriously injured when handling tuel. 0 Stop the engine and keep heat, sparks, and flame away. 0 Retuel only outdoors. o wipe up spills immediately. 4. To prevent rusting in the cylinders, perform 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 the are positioned away from the spark p ugs. 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 ems) oi 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. 0 Reinstall the spark plugs and spark plug caps. 5. Remove the battery Store in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month. 6. Wash and dry the motomycle. Wax all painted surtacesi Coat chrome with rustinhibitjng oil. 7. Lubricate the drive chain (page 102 ). 8.1nflate the tyres to their recommended pressures. Place the motorcycle on blocks to raise both tyres off the ground. 9. Cover the motorcycle (don't use plastic or other coated materials) and store in an unheated area, free of dampness with a minimum of daily temperature variation Do not store the motorcycle in direct sunlight. 135 REMOVAL FROM STORAGE 1. Uncover and clean the motorcycle. Change the engine oil it more than 4 months have passed since the start of storage. 2‘ Charge the battery as required. Install the battery. 3. Drain any excess aerosol rust-inhibiting oil from the fuel tank Fill the fuel tank with fresh petrol. 4. Perform all Pre-ride Inspection cheeks (W354 ). Test nde the motorcycle at low speeds in a safe riding area away from traffic. 136 SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase WEIGHT Dry weight CAPACITIES Engine all After dmining After draining and oil filter change Atter disassembly Fuel tank Cooling system capacity Passenger capacity Maximum weight capacity 2,160 mm (85.0 in) 720 mm (28.3 in) 1,200 mm (47.2 in) 1,490 mm (58.7 in) 224 kg (494 lbs) 3.3 a (4.0 us qt , 3.3 Imp qt) 3,9 41 (4.1 U5 qt , 3.4 Imp q!) 46 ll (4.9 US qt . 4.0 Imp qt) 23.0 R (6‘08 US gal, 5‘06 Imp gal) 3.2 a (3.4 us qt , 2.8 Imp qt) Operator and one passenger 185 kg (411 Ibst 137 ENGINE Bore and stroke Compression ratio Displacement Spark plug Idle speed Valve clearance (Cold) 138 79.0 X 580 mm (3.11 X 2.28 in) 110 :1 1,1 37 cm3 (69.4 curin) IMRSC—BH (NGK) 1,100 i 100 min" (rpm) Intake 0.16 mm (0.006 in) Exhaus1 0.22 mm (0309 in) CHASSIS AND SUSPENSION Caster Trail Tyre size, lront Tyre size» rear POWER TRANSMISSION Primary reduction Gear ratio, lst 2nd 3rd 41h 51h Gth Final reduction 25° 99 mm (309 in) 120/70 ZR17 (58W) or 120/70 ZR17 M/C (58W) 180/55 ZR17 (73W) or 180/55 ZR17 M/C (73W) 1571 20769 20000 1.579 L333 L167 10042 2.588 139 ELECTRICAL Battery Generator LIGHTS Headlight Tail/ brake light Turn signal light Front Rear Instmment lights Position light FUSE Main fuse A FI {use Other fuses 140 1ZV~ 10 AH 0.46kW/5,000 min" (rpm) 12V—55W X 2 1ZV*5/21W X 2 12Vi21W X 2 1ZVi21W X 2 14Vi1.4W X 2 12v—5w... Except Utype 30A 30A 10A, 20A CATALYTIC CONVERTERS < Except BR type> This motorcycle is equipped with catalytic converters. Each catalytic converter contains precious metals that serve as catalysts, promoting chemical reactions to convert the exhaust gasses without aifecting the metals. The catalytic converters act on HC, C0, and N0x. Replacement parts must be original Honda parts or equivalents. The catalytic converters must operate at a high temperature for the chemical reactions to take place. They can set on fire any combustible materials that come near them. Park your motorcycle away from high grasses, dry leaves, or other flammables. Defective catalytic converters contributes to air pollution. and can impair your engine’s performance. Follow these guidelines to protect your motorcycle’s catalytic converters. 0 Always use unleaded petrol. Even a small amount 01 leaded petrol can contaminate the catalyst metals, making the catalytic converters inefiectiveo 0 Keep the engine tuned-up. 0 Have your motorcycle diagnosed and replaced if it is misfiring, backfiring. stalling or otherwise not running properly, 141 NOISE CONl‘ROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH THE NOISE CONTROL SYSTEM 18 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 [or 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 person. 142 Sums—