é OWNER'S MANUAL HONDA uso E MANUTENZIONE MANUAL DEL PROPIETARIO CBRSOOFIFI Honda CBR600RR OWNER’S MANUAL USO E MANUTENZIONE MANUAL DEL PROPIETARIO © Honda Motor Co., Ltd. 2004 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 ' 0N»ROAD USE This motorcycle is designed to be used only on the road. 0 READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the salety messages that appear throughout the manual. These messages are fully explained in the “A Few Words About Saiety” section which appears beiore the Contents page. This manual should be considered a permanent part 01 the motorcycle and should remain with the motorcycle when resold, Honda CBRGOORR OWNER’S MANUAL All information in this publication is based on the latest production information available at the time of approval for printing. Honda Motor Co..Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without writien permission. WELCOME 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 pre-fiide inspection and regular maintenance are essential to your safety. Your reward is ree om. To meet the challenges salely, 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 information that is preceded by a symbol. This inlormation is intended to help you avoid damage to your motorcycle, othEF property. or the environment. When service is required. remember that your Honda dealer knows your motorcycle best. II 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 {or choosing a Honda ! oT‘ne following codes in this manual indicate each country. E UK ED European direct sales EK Ireland Austria Hun Portugal G Gennanv Belgium Israe Romania F France Belgium Bulgaria Iceland Russm‘ U Australia New ealand Croatia Italy‘ Slovakia Mexico Czech Latvia Slovenia BR Brazil Denmark Luxembourg Spain Finland Macedonia Sweden Greece Nomfiy Switzerland Holland Polan Ukraine oThe specifications may vary with each locale. A FEW WORDS ABOUT SAFETY Your safety, and the safety of others, is very important. And operating this motorcycle safely IS an important responsibility. To help you make informed decisions about safety, we have provided opemting procedures and other information on labels and in this manual. This iniormalion alerts you to potential hazards that could hurt you or others. 0! 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: ' Safely 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 Vou WILL be KILLED or SERIOUSLV HURT if you don’t follow lnstruciions. You CAN be KILLED or SERIOUSLY HURT ii ou don't follow “ WAR N I NG instructions. y A CAUTION Vou CAN be HURT If you don‘t follow Insirucflons. 0 Safety Headings — such as Important Safety Reminders or Important Safety Precautions. ‘ Safety Section — such as Motorcycle Safety. 0 Instructions — how to use this motorcycle correctly and safely. This entire manual is filled with important safety information -— please read it carefully. OPERATION page 1 1 Z 4 9 12 30 30 36 39 41 43 46 47 MOTORCYCLE SAFETY IMPORTANT SAFETY INFORMATION PROTECTIVE APPAREL LOAD LIMITS AND GUIDELINES PARIS LOCATION INSTRUMENTS AND INDICATORS MAJOR COMPONENI'S (Information you need to operate this motorcycle) SUSPENSION BRAKES CLUTCH COOLANT FUEL ENGINE OIL TUBELESS TYRES 53 54 56 59 61 page 53 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH KEYS I'MMOBILIZER SYSTEM (H155) (4) Neautral indicator (5) Tachometer (6) Tachometer red zone (7) Tachometer red zone indicator (8) Malfunction indicator (MIL) (9) High beam indicator (10) Right Turn signal indicator (11) Multifunction display (12) RESET button (13) AD] button 12 (1) (2) (4) (3) (5) (7) () (12) (8) (9) (10) (ll) (Ref.No.) Description Function (1) Fuel gauge and coolant temperature display Show approximate fuel supply available (Page 20 ) and coolant temperature (page 22 ), This display shows the initial display (page 18 ). (2) I/eft turn signal indicator (green) Flashes when the left turn signal operates. Should light for a iew seconds and then go off when the ignition switch is turned ON. (3) Immobilizer system (KISS) indicator (red) Except MX type: Th' indicator lights for a few sewnds when the ignition switch is turned 0N and the engine stop switch is at O (RUN). It will then go off it 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 56 )4 When the blinking function of this indicator is valid and the ignition switch is OFF, it keeps blinking for 24 hours (page 57 ), 13 (Ref.No.) Description Function (4) Neutral indicator (green) Lights when the transmission is in neutml. Should also light for a few seconds and then go off when the ignition switch is turned ON. (5) Tachometer Shows engine revolutions per minute. The tachometer needle will swing to the maximum scale on the dial once when the ignition switch is turned ON. (6) Tachometer red zone Never allow the tachometer needle to enter the red wne. even after the engine has been broken in. Running the engine beyond recommended maximum engine speed (the beginning of the tachometer red zone) can damage the engine. (7) Tachometer red zone indicator (yellow) Flashes when the tachometer needle enters the red zone. Should light {or a few seconds and then go of! when the ignition switch is turned ON. 14 (Ref.No.) Description Function (8) Malfunction indicator (MIL) (red) Lights when coolant is over the specified temperature, and/or engine oil pressure is below normal operating range, and/or PGM—FI (Programmed Fuel Injection) system is abnormal. Should also light when ignition switch is ON and engine is not running. Should go out when engine starts, except [or occasional flickering at or near idling speed when engine is warm. See page 23 7 25 . (9) High beam indicator (blue) Lights when the headlight is on high beam, Should also light for a few seconds and then go off when the ignition switch is turned ON. (10) Right turn signal indicator (green) Flashes when the right turn signal opemtesi Should light for a few seconds and then go off When the ignition switch is turned 0N. 15 md.NoiDeudDfion Function (11) Multifunction display The display includes the following functions; This display shows the initial display (page 18 ). Low oil p r e s s u r e Lights the low oil pressure indicator and/ or coolant in d ica to r/ C 00 Ian t temperature indicator and/ or PGM-l-‘I indicator to temperature indicator/ notify that there is abnormality in engine oil pressure PGM-Fl indicator and/or coolant temperature and/or PGM-FI (Programmed Fuel Injection) system when the malfunction indicator (MIL) lights. See page 23 7 25 . Speedometer Shows riding speed (page 26 ). Odometer Shows accumulated mileage (page 26 )r Tripmeter Shows mileage per trip (page 26 ). Digital clock Shows hour and minute (page 28 ). 16 (Ref.No.) Description Function (12) RESET button Except E type: This button is used to reset the tripmeter or to adjust me u'me. For E type: This button is used to reset the tripmeter or to adjust the time or to change the speed and mileage units for the speedometer/odometer/tripmeter. (13) AD] button This button is used to select the tripmeter or to adjust the time. 17 Initial Display When the ignition switch is turned ON, the multifunction display (1) mid fuel gauge and coolant temperature display (2) will temporarily show all the modes and digital segments Thereafter. the speedometer (3) will show from 290 km/h to 0 km/h (E type only: From 180 mph to 0 mph in mph) so that you can make sure the liquid crystal display is functioning properly. The unit “mp “ (4) will be displayed only for E type. Digital clock (5) and tripmeter (6) will reset if the battery is disconnected. 18 (l) (3) (4) BBHmZ/ 88838 38888 III (2) (5) (6) (1) Multifunction display (2) Fuel gauge and coolant temperature meter (3) Speedometer (4) “mph" (5) Digital clock (5) Tripmewr Multifunction Display Mulli—function display (1) includes the followingfuncti s: Coolant temperature indicator Low oil pressure indicator PGM»FI indicator Speedometer Odometer Tripmeler Digital clock (1) (5) (8) (4) (3) (Z) (1) Muliiiunction display (2) Coolant temperature indicamr (3) Low oil pressure indicator (4) PGM-FI indicator (5) Speedometer (6) Odometer (7) Tripmeter (8) Digitalclock 19 Fuel Gauge and Coolant Temperature Display The fuel gauge and coolant temperature display (1) includes the fuel gauge liquid crystal display (2) and the coolant temperature meter (3 ). Fuel Gauge ‘ e ue gauge liquid crystal display shows the approximate fuel supply available in a graduated display. When the segment F (4) goes on, the fuel tank capacity including reserve is: 18.0 D (4.76 US gal, 3.96 Imp gal) When segment E (5) flashes, fuel will be low and you should refill the tank as soon as possible The amount of fuel left in the tank with the vehicle set upright is approximately: 3.8 “100 US gal, 0.84 Imp gal) 20 (1) (2) (3) (4) (5) r r 33 33 5 E \E, /I\ (1) Fuel gauge and coolant nempemure display (2) Fuel gauge liquid crystal display (3) Coolant temperature meter (4) SegmentF (5) Segment]; Fuel Ga gge Failure [1111' 'on t e ue system as an error, the fuel gauge indicators will be displayed as shown in the illustration. If this occurs, see your Honda dealer as soon as possible. :«::H:«]l 21 Coolant Tem rature Meter fie coda—n 1 temperature meter (1) shows coolant temperature digitally. Temperature Display: Below 34°C “ 7 7 ” is displayed. Between 35°C Actual coolant tempen» and 130°C lure is indicated Above 130°C The display will remain and flash “130°C”. 22 (1) Coolant temperature meter Overheating Message: When the coolant temperature reaches 120°C, the display begins to flash, Al the same time, the red malfunction indicator (MIL) (2) and the coolant temperature indicator (3) light. If this occurs, stop the engine and check the reserve tank coolant level. Read pages 41 7 42 and do not ride the motorcycle until the problem has been corrected. Exceeding maximum running temperature may cause serious engine damage. ‘l » «s? =E x1000 r/ min (3) H l ~53 (2) Red Mallnnclion indiwtor (MIL) (3) Coolant tempemture indicator Law Oil Pressure Indicator and Malfunction Indicator (MIL) The low oil pressure indicator (1) and the red malfunction indicator (MIL) (2) light when engine oil pressure is below the normal operating range. The low oil pressure indicator and the red malfunction indicator (MIL) should light when the engine is not running with the ignition switch turned 0N. Both should go off when the engine starts, except for occasional flickering at or near idling speed when the engine is warm. Running the engine with insufficient oil pressure may cause serious engine damage. 24 (2) \ A I 7n; g x1flllfl r/ min _éa/ <1) (1) Low oil pressure indicator (2) Red Malfunction indicator (MIL) PGM-FI Indicator and Malfunction Indicator (MIL) The PGM-FI indicator (1) and the red malfunction indicator (MIL) (2) lights when there is any abnormality in the PGM- Fl (Programmed Fuel Injection) system. The PGM—FI indicator should also go on for a few seconds and then go oil when the ignition switch is turned ON and engine stop switch is at 0 (RUN). Ii the PGMvFI indicator and red malfunction indicator (MIL) lights at any other time, reduce speed and take the motorcycle to your Honda dealer as soon as possible. (2) 19' :— x1fllllJr/min (1) ‘V (1) POM-Fl indicator (2) Red Malfunction indicator (MIL) 25 Speedometer/Odometerfl‘ripmeter/ Speed and Mileage Unit Change Speedometer Shows riding speed. Odometer Shows accumulated mileage. This meter can be displayed to 0 to 99,999 kilometers (miles). If the display exceeds 99.999 kilometers (miles), it will return to 0 automatically. If you drive 1011000 kilometres (miles) or above and when the ignition switch is turned 0N, number of the 6th digit is shown in the right end place of the odometer for 0.75 seconds after the initial display on the odometer. (That is number indicating hundreds thousands kilometres) Then, the odometer returns to the ordinary display. 26 (1) [—35% (2) —.>5 175' '1 #85,... Example: the case of 123,000 km mn. (1) Speedometer (Z) Odometer (3) Tripmeter Tripmeter Shows mileage per trip. There are two tripmeters, tripmeter A (4) and tn’pmeter B (5). Switch between the A and B displays by pressing the AD] button (6) repeatedly. To reset the tripmeter, push and hold the RESET button (7) with the display in the tripmeter A or tripmeter B mode. Speed and Mileage Unit Change (E typeon n) The hspeedometer displays both‘ ‘km/h" and The odometer/tripmeter displays both “km" and “mile". Push the RESET button (7) to select “kmfl1"/“km" or “mph”/“mile" with the display in the tn'pmeter A mode. (4) TripmeterA (5) Tripmeter B (6) ADJ button (7) RESET button 27 Digital Clock Shows hour and minute, To adjust the time, proceed as follows: 1.Tum the ignition switch 0N. .Push and hold both the ADJ button (2) and RESET button (3) for more than 2 seconds. The clock will be set in the adjust mode with the hour display flashing, (1) m (1) Digital clock (2) AD] button (3) RESET button 28 3. To set the hour, push the RESET button until the desired hour is displayed. M» cw 4. Push the AD] button, The minute display will start flashing, 5.To set the minute. push the RESET button until the desired minute. The minute display will return to "00“ when “60" is reached without affecting the hour display. 0 The time advances by one minute, each time the button is pushed. OThe time advances fast when the button is pushed and held. I a _ am in 6‘ To end the adjustment, push the AD] button or turn the ignition switch OFF. The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed {or about 30 seconds. 29 MAJOR COMPONENTS (Information you need to operate this motorcycle) SUSPENSION FrontSus nsion ’ Pregead: t e sp ng preload by turning the preload adjuster (1 ) with the 22 mm wrench provided in the tool kit. Make sure that both fork legs are adjusted to die same position To reduce (SOFT) : Turn the adjuster counterclockwise toward SOFl‘ for a light load and smooth road condition. To increase (HARD) : Turn the adjuster clockwise toward HARD for a fumer ride and rough road condition. To adjust the adjuster to the standard position, proceed as follows : 1.Turn the preload adjuster (1) counterclockwise until it will no longer turn (lightly seats). This is the full soft setting. 2.The adjuster is set in the standard position when the adjuster is turned clockwise 5 tumsi 30 3. Make sure that both liork legs are adjusted to the same position. (1) Preload adjusler Rebound Dam : I 0 reduce (Elli: I Turn the adjuster counterclockwise toward SOFT 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. To adjust the adjuster to the standard position, proceed as follows : 1.’l‘urn the damping adjuster (1) clockwise until it will no longer tum (lightly seats). This is the full hard setting, 2. The adjuster is set in the standard position when the adjuster is turned counterclockwise approximately 21/2tums so that its punch mark (2) aligns with the reference mark (3 ), 3. Make sure that both fork legs are adjusted to the same position. (3) Reference mark (1) Damping adjuster (2) Punch mark 31 Compression Dam : 0 reduce 1'51 W I Turn the adjuster counterclockwise toward $0” for a light load and smooth road condition. To increase (HARD) : Tum the adjuster clockwise toward HARD for a firmer ride and rough road condition. 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 2 1/2 turns so that its punch mark (2) aligns with the reference punch mark (3). 3. Make sure that both [ork legs are adjusted to the same position. 32 (1) Damping adjuster (2) Punch mark (3) Reference punch mark Rear Suspension Rebound Dam : 0 re uce . Turn the adjuster counterclockwise toward SOFI‘ for a light load and smooth road condition. To increase (HARD) : Turn the adjuster clockwise toward HARD [or a firmer ride and rough road condition. To adjust the adjuster to the standard position. proceed as follows : 1. Turn the damping adjuster (l) 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 adjust/er is turned counterclockwise approximately 2 1/2 turns so that its punch mark (2) aligns with the reference punch mark (3). (1) Damping adjuster (2) Punch mark (3) Reference punch mark 33 Com ression Dam : lo re%uce 50F Turn the adjuster counterclockwise toward SOFT for a light load and smooth road condition, To increase (HARD) : Turn the adjuster clockwise toward HARD [or a firmer ride and rough road condition. 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 12clicks so that its punch mark (2) aligns with the reference punch mark (3). 34 (1) Damping atfiuster (2) Punch mark (3} Reference punch mark Sgriugl’reload: T e sp ng preload adjuster (1) has 10 spring preload positions for different load or riding conditions. Use the pin spanner (2) and extension bar (3) to acfiust the rear shock Positions 1 to 3 are {or a light load and smooth road conditions. Position 4 is the standard position. Positions 5 to 10 increase spring preload for a stiffer rear suspension and can be used when the motorcycle is more heavily loaded. 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 found in this owner’s manual are limited to adjustment of the shock assembly onlyl (1) Spring preload adjuster (2) Pin spanner (3) Extension bar 35 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 pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks. If the brake lever or pedal free travel becomes excessive and the brake pads are not worn beyond the recommended limit (page 124 ). there is probably air in the bmke system and it must be bled. See your Honda dealer [or 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) If the level is at or below the LOWER level mark, check the brake pads {or wear (page 124 ). 36 Worn pads should be replaced. I! the pads are not worn, have your brake system inspected for leaks The recommended brake fluid is Honda DCfl‘ 4 brake fluid from a sealed conminer, or an equivalent. Front (1) LOWER level mark Front Brake Lever: The dismme between the tip of the brake lever (1) and the grip can be atfiusted by turning the atfiuster dial (2) while pushing the lever forward. Align the numbers (3) on the adjuster dial with the index mark (4). Apply the brake several times and check tor free wheel rotation after the brake pedal is released. (1) Brake lever (2) Adjuster dial (3) Numbers (4) Index mark Other Checks: Make sure there are no fluid leaks. Check {or deterioration or cracks in the hoses and fittings. 37 Rear Brake Fluid Level: With the motorcycle in an upright positionv check the fluid level. It should be between the UPPER (l) and LOWER (2) level marks. If the level is at or below the LOWER level mark. check the rear brake pads for wear (page 125 ). Wom 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. (1) UPPER level mark (2) LOWER level mark CLUI‘CH 1. Loosen the lock nut (2) and turn the Clutch adjustment may be required if the clutch cable adjuster. Tighten the lock motorcycle stalls when shifting into gear or nut and check the adjustment. tends to Creep; orifthe clutch slips. causing 2.“ the adjuster is threaded out near its acceleration to lag behind engine speed. limit or il the correct free play cannot be Minor adjustments can be made with the obtained, loosen the lock nut and turn in clutch cable adjuster (3) at the clutch lever the clutch cable adjuster completely. (1 Tighten the lock nut. Normal clutch lever free play is: 10720 mm (0,470.3 in) (1) Clutch lever (2) Lock nut (A) Increase free play (3) Clutch cable adjuster (B) Decrease free play 39 3. Loosen the lock nut (4) at the lower end of the cable. Turn the adjusting nut (5) to obtain the specified free play. Tighten the lock nut and check the adjustment. Stan the engine, pull in the clutch lever and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Graduafly release the clutch lever and open the throttle, The motorcycle should begin to move smoothly and accelerate gradually I” (4) Lock nut (5) Adjusting nut 40 (A) Increase free play (B) Decrease free play I! proper adjustment cannot be obtained or the clutch does not work correctly. see your Honda dealer. Other Checks: CEecF the c utch cable for kinks or signs of Wear that could cause sticking or failure. Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion, COOLANT Coolant Recommendation The owner must properly maintain the coolant to prevent freezing, overheating. and corrosion. Use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines, (SEE ANT IF REEZE 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 harmful 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 of 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 antifreeze decreases the cooling System performance and is recommended only when additional protection against freezing is needed. A concentration of less than 40/ 60 (40% antifreeze) will not provide proper corrosion protection. During freezing temperatures check the cooling system frequently and add higher concentrations of antifreeze (up to a maximum of 60% antifreeze) if required. 41 Inspection The reserve tank is behind the right middle cowl Check the coolant level in the reserve tank (1) while the engine is at the normal operating temperature with the motorcycle in an upright position. It the coolant level is below the LOWER level mark (3), remove the right middle cowl (page 69 ) and the reserve tank cap (4 ). Add coolant mixture until it reaches the UPPER level mark (2). Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap. If the reserve tank is empty. or if coolant loss is excessive. check for leaks and see your Honda dealer [or repair. (4) (1) Reserve tank (2) UPPER level mark (3) LOWER level mark (4) Reserve tank cap FUEL Fuel Tank The fuel Lank capacity including the reserve supply is: 18.0 it (4.76 US gal , 3.96 Imp gal) To open the fuel fill cap ( l ). insert the ignition key (2) and turn it clockwise. The fuel fill cap is hinged and will lift up. Do not over-fill the tank. There should be no fuel in the filler neck (3 )l After relueling, to close the fuel fill cap, push the fuel fill cap into the tiller 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. 0 Stop the engine and keep heat, sparks, and llame away. 0 Reluel only outdoors. o Wipe up spills immediately. (1) Fuelfillcap (2) Ignition key (3) Filler neck Use unleaded petrol with a research octane number of 91 or higher. The use of leaded petrol will cause premature damage to the catalytic converter. II “spark knock" or “pinking” occurs at a steady engine speed under normal loadv change brands of petrol. If spark knock or pinking persists, consult your Honda dealer, Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda's Limited Warranty. Petrol Containing Alcohol 11 you decide to use a petrol containing alcohol (gasohol), be sure it‘s octane rating is at least as high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol, and the other containing methanol. Do not use petrol that contains more than 10 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 performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete, Before buying fuel from an untamiliar station, try to find out if the fuel contains alcohol. II it does. confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a petrol that contains alcohol, or one that you think contains alcohol. switch to a petrol that you know does not contain alcohol. ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be maintained between the upper (1) and lower (2) level marks in the inspection window (3 ). 1. Start the engine and let it idle for 3—5 minutes. Make sure the low oil pressure indicator goes off. If the indicator light remains on, stop the engine immediately. 2. Stop the engine and hold the motorcycle in an upright position on finn, level ground. 3. After 273 minutes, check that the oil level is between the upper and lower level marks in the inspection window. 4‘ If required. remove the oil filler cap (4) and add the specified oil (page 93) up to the upper level mark. Do not overfill. 5. Reinstall the oil filler cap. Check for oil leaks. Running the engine with insufficient oil pressure may cause serious engine damage (3) Inspection window (4) Oil filler up (1) Upper level mark (2) Lower level mark TUBELESSTYRES To salely 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. AWARN NG Using tyres that are excessively wom or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owners manual regarding lyre inflation and maintenance. Air Pressure Keeping your tyres properly inflated provides the best combination of handling, tread lite and riding comfort. Generally. underinflated tyres wear unevenly. adversely affect handling, and are more likely to fail Irom being overheated. Overinflated tyres make your motorcycle ride more harshly, are more prone to damage (rom 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 it they are punctured. However, because leakage is often very slow. you should look closely for punctures whenever a tyre is not fully inflated. 47 Always check air pressure when your tyres are “cold" — when the motorcycle has been parked for at least three hours. It you check air pressure when your tyres are Warm" — when the motorcycle has been ridden for even a few miles 7 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. If you do, the tyres will be underinflated. The recommended “cold" tyre pressures are: Front 250 kPa (2.50 loaf/om2 36 psi) Rear 290 kPa (2.90 kgf/cm‘ 42 psil Inspection Whenever you check the tyre pressures. you should also examine the tyre treads and sidewalls for wear, damage. and foreign objects: Look for: 0 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. 0 Excessive tread wear. Also. if 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 [he lcenter of the tyre reaches the following imit: Minimum tread depth Front: 1.5 mm 10.06 in) Rear: 20 mm (0.08 in) < For Germany > German law prohibits use of tyres whose tread depth is less than 1.6 mm (I) Wear indicator (2) Wear indicator location mark 49 'l‘yre Repair If a tyre is punctured or damaged, you should replace it, not repair it. As discussed below, a tyre that is repaired, either temporarily or permanently, will have lower speed and performance limits than a new tyre. A temporary repair, such as an external tubeless tyre plug, may not be safe for normal speeds and riding conditions. If a temporary or emergency repair is made to a tyre, you should ride 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. 50 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, b'i sure the wheel is balanced before you n e. Tyre Replacement The tyres that came on your motorcycle were designed to match the perfomlance capabilities of your motorcycle and provide the best combination of handling, braking, durability and comlort. AWARNING Installing improper tyres on your motorcycle can aflect handling and stability. This can cause a crash in which you can be seriously hurl or killed. Always use the size and type at tyres recommended in this owner‘s manual. The recommended tyres for your motorcycle are: Front: 120/7OZR17M/C (58W) DUNLOP D218F MICHELIN Pilot SPORT E BRIDGESTONE BT014F RADIAL E Rear: 180/552R17M/Ci73w) DUNLOP D218 MICHELIN Pilot SPORT E BRIDGESTONE BTOMR RADIAL G Whenever you replace a tyre, use one that is equivalent to the original and be sure the wheel is balanced after the new tyre is installed. 51 Important Safety Reminders - Do not install a tube inside a tubeless tyre on this motorcycle. Excessive heat build» up can cause the tube to burst. 0 Use only tubeless tyres on this motorcycle. The rims are designed for tubeless tyres. and during hard acceleration or braking, a tube-type tyre could slip on the rim and cause the tyre to rapidly deflate. 52 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (I) is below the indicator panel. The headlight and taillights will come on whenever you turn the ignition switch ON. If your motorcycle is stopped with the ignition switch 0N and the engine is not running, the headlight and taillights will still be on, resulting in battery discharge. (1) Ignition switch Key Position Function Key Removal LOCK Steering is locked. Engine and lights cannot be Key Canbe (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 A When the hazard switch is ON, both left and Key cannot be (hazard) right turn signals flash. removed Engine and lights cannot be operated. 53 KEYS This motorcycle has two keys and a key number plate. I I mmx a s\\\\\\\\ n l I | l I I (2) (2) (1) (1) (1) Keys (2) Key number plate 54 You will need the key number if you ever have to replace a key. Store the plate in a safe place. (Except MX type) To reproduce keys. bring all keys, key gufiber plate and motorcycle to your Honda e er. Up to four keys can be registered with the immobilizer system (HISS), including the ones in hand. (Except MXtype> If all keys are lost the PGM- Fl unit/ignition control module must be replaced. To avoid this po lity 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 drop the keys or set heavy objects on them. 0 Do not grind, drill or in any way alter the original shape of the keys. 0 Keep the keys away [ram magnetic objects. 55 IMMOBILIZER SYSTEM ([1155) (Except MX type> HISS is the abbreviation of Honda Ignition Security System. The immobilizer system (HISS) protects your motorcycle from 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 ON and the engine stop switch is at “ O ” (RUN). the immobilizer system (HISS) indicator lights {or a few seconds, then goes ofl. II the indicator remains on, it means the system does not recognize the coding oi the key. Turn the ignition switch to OFF» remove the key, relnsert and turn the switch ON again. The immobilizer system has such a iunction that keeps the immobilizer system (H155) indicator blinking at 2 second intervals for 24 hours. This blinking function can be turned on or off. To alter the blinking function: 1. Turn the ignition switch ON 2. Push and hold the AD] button (1) for more than 2 seconds. The immobilizer system (HISS) indicator (2) instantly flash, the function is enabled. 3.Tum the ignition switch OFF and remove the key. (1) AD] button (2) Immobilizer system (HISS) indicator 57 I! the system repeatedly does not recognize the coding of your key, contact your Honda dealer, OThe sysLem may not recognm the key’s coding if any other immobilizer key is near the ignition switch To make sure the system recognizes the key code keep each immobilizer key on a separate ring - 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. UH all keys are lost, the PGM-FI unit/ ignition control module must be replaced. EC Directives This immob' ’zer system complies with the R St TTE (Radio equipment and telecommu- nications terminal equipment and the mutual recognition oi their coniormity) Directive (6089169 The declaration of conformity to R & 'l'l‘E Directive is provided to the owner at the time at purchase. The declaration oi conformity should be kept at a safe place. When the declaration of Conlormity is lost or is not provided, contact your Honda dealer. RIGHT HANDLEBAR CONTROIS 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 opemte, When the switch is in the Rt (OFF) position. the engine will not operate. This switch is intended primarily as a safety or emergency switch and should normally remain in the O (RUN) position, It your motorcycle is stopped with the ignition swimh 0N and the engine stop switch 12! (OFF), the headlight and taillights will still be on. resulting in battery discharge. Starter Button The starter button (2) is below the hazard switch (3). When the starter button is pressed, the starter motor cranks the engine, the headlight will automatically go out. but the taillights will stay on, If the engine stop switch is in the 8 (OFF) position. the starter motor will not operate, See page 76 tor the starting procedure. (1) Engine stop switch (2) Starter button (3) Hazard switch Hmrd Switch When the hazard switch (3) is A (ON) position, both left and right turn signals start flashing. With the ignition switch is A position, the signals continue flashing even the engine or other lights are OFF. (3) Hazard switch LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch (1) Push the dimmer switch to 50 (HI) to select high beam or to 20 (L0) to select low beam. Turn Signal Switch (2) Move to ¢' (L) to signal a left turn, ¢> (R) to signal a right turn. Press to turn signal ofl. Horn Button (3) Press the button to sound the horn. Passing Light Control Switch (4) When this switch is pressed» the headlight flashes on to signal approaching cars or when passing. u) Headlight dimmer switch (2) Turn signal switch (3) Horn butloll (4) Passing light control switch 61 FEATURES (Not required for operation) SPEERING LOCK To lock the steering, turn the handlebars all the way to (he left or right. turn the ignition key (1) to LOCK while pushing in. Remove the key. To unlock the steering. lum lhe key to OFF while pushing in. Do nol mm the key to LOCK while riding the xlnowrcycle: loss of vehicle control will resu t. Tn m1; (A) U (B) (1) Ignition key (A) Push in (B) Turn to LOCK (C) Turn to OFF SEAT Front seat To remove the front seat (I), pull up (he seat end and remove me two mounting bolts (2). and (hen pull me seat back and up. To install the front seat, insert the tabs (3) into the recess under the frame and tighten the mounting bolts securely‘ (1) Front seat (2) Mountingholts (3) Tabs 63 Rear seat To remove the rear seat (4), insert the ignition key (5) into the seal lock (6). Turn it clockwise, then pull the rear seat up and back. To install the seat, insert the prongs (7) into the seat hook (8) and the guide hooks (9), and then push down on the front of the seat. Be sure the seat is locked securely in position alter installation. (4) Rear seat (5) Ignition key (6) Seat lock (7) Prongs (a) Seat hook (9) Guide hooks HELMET HOLDER The helmet holder is located below the rear seat. Remove the rear seat (see page 64 ). Route the helmet wire (1) through the helmet D- ring (2) and hook the loops of the helmet wire onto the helmet holder (3). Install the rear seat and lock it securely, The helmet wire is furnished in the tool kit (page90). AWARNING Riding with a helmet attached to the holder can imertere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed. Use the helmet holder only while parked. Do not ride with a helmet secured by the holder. (1) Helmet wire (2) Helmet Dring (3) Helmet holder 65 DOCUMENT BAG The document bag (1) is in the document canpartment (2) under the rear seat (page 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. (1) Document bag (2) Document compartment STORAGE COMPARTMENT FOR U— SHAPED ANTI-THEFT LOCK There is a storage compartment to store a U~shaped anti-theft lock under the rear seat (page 64 ). Some Ushaped locks may not be stored in the compartment due to their size or design, LOWER COW]. The lower cowl must be removed to service the spark plugs, to replace the oil filter. or to remove the middle cowl. Removal: L Remove the bolts A (1), bolts B (2) and bolt C (3). 2. Remove the clips A (4) and clips B (5). Installation: Ilnstallation can be done in the reverse order of removal, (5) (3) (4) (1) BollsA (4) CliPSA (2) Bolts B (5) Clips B (3) BoltC MIDDLE COWL Removal: Installation: fie middle cowl must be removed to IInstallation can be done in the reverse service the spark plugs or to replace the oil order of removal filter. 1. Remove the lower cowl (page 68 ). 2. Remove the bolts (1). 3. Remove the clips A (2 ). 4. Loosen the screws (3). (1) Bolts (2) ClipsA (3) Screws 69 CHE A removal and installation: Installation Removal (DSlightly open the retaining pawls and then (DPress down on the center pin to release push them out. the lock. @Insert the dip into the hole. @Pull out the clip from the hole. ®Lightly press down on the center pin to lock the clip. (D f. @3 ® ® 70 HEADLIGHT AIM VERTICAL ADJUSTMENT Vertical adjustment can be made by turning the screws (1) and (2) in or out as necessary. Obey local laws and regulations. (B) (2) (1) (A) (B) (1) (2) (A) (1) Screw (low beam) (A) Up (2) Screw (high beam) (5) Down OPERATION PRE-RIDE INSPECTION For your safety, it is very important to take a few moments before each ride to walk around your motorcycle and check its condition. If you detect any problem. be sure you take care of it, or have it corrected by your Honda dealer. AWARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed. Always perform a pre-ride inspection before every ride and correct any problems. 72 L Engine oil level- add engine oil if required (page 46). Check for leaks, 2. Fuel level—{ill fuel tank when necessary (page 43 ). Check for leaks. 3. Coolant leveliadd coolant il requiredl Check for leaks (pages 41 - 42 ). 4. Front and rear brakes-check operation; make sure there is no brake fluid leakage (pages 36 7 38 ). 5.’I‘yres—check condition and pressure (pages 47 7 49 ). 6. Drive chainicheck condition and slack (page 108 7 109 ). Adjust and lubricate if necessary. 7. Throttle—check for smooth opening and full closing in all steering positions (page 105 ). Br Lights and horn—check that, headlight, stop/tail light, turn signals, indicators and horn function properly 9. Engine stop switchscheck for proper function (page 59 ). 10. Side stand ignition cut—off systemicheck for proper funcn’on (page 116 ). 73 STARTING THE ENGINE Always follow the proper starting procedure described below. This motorcycle is equipped with a side stand ignition cut-o“ system. The engine cannot be started if the side stand is down, unless the transmission is in neutral. 1f 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 converter in your motorcycle‘s exhaust system, avoid extending idling and the use of leaded petrol. 74 Your motorcycle‘s exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide can collect rapidly In enclosed areas such as a gamge. 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 {or 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 0 The transmission is in NEUTRAL (neutral indicator light ON). 0The engine stop switch is at O (RUN). I The malfunction indicator (MIL) is ON. 0 The low oil pressure indicator is ON. 0 The PGM-FI indicator is OFF, 0 The coolant temperature indicator is OFF. OThe immobilizer system (I-IISS) indicator is OFF. (except MX type) The mallunction indicator (MIL) and low oil pressure indicator should go off a few seconds alter the engine starts. If the malfunction indicator (MIL) and the low oil pressure indicator light during operation, stop the engine immediately and check the engine oil level. If the ignition switch is turned ON with the engine stop switch fl (OFF), the low oil pressure indicator and malfunction indicator (MIL) will not light. After turning the engine stop switch to O (RUN), both indicators will light as usual alter approximately 8 seconds. Operating the engine with insufficient oil pressure can cause serious engine damage 75 Starting Procedure This motorcycle has a fuel-injected engine with an automatic fast idle. Follow the procedure indicated below. Any Air Temgerature 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 of! the fuel supply). 76 Flooded Engine I! the engine fails to start alter repeated attempts, it may be flooded. 1. Leave the engine stop switch set to O (RUN). 2, Open throttle fully. 3. Press the starter button for 5 seconds, 4. Follow the normal starting procedure. It the engine starts with unstable idle, open the throttle slightly. If the engine does not start. wait {or 10 seconds, then follow steps 1 — 4 again. Ignition Cut Off Your motorcycle is designed to automatically stop the engine and fuel pump it the motorcycle is over—turned (a banking sensor cuts off the ignition system). Before restarting the engine, you must tum the ignition switch to the OFF position and then back to ON. 77 RIINNINGIN Help assure your motorcycle 5 future reliability and performance by paying extra attention to how you ride during the first 500 km (300 miles). During this period. avoid lull-throttle starts and rapid acceleration. 78 RIDING Review Motorcycle Saiety (pages 1 7 8) before you ride, Make sure you understand the iunction of the side stand mechanism. (See MAIN- TENANCE SCHEDULE on page 89 and explanation for SIDE STAND on page 116). 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. LAIter 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 ls! (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 shift to 2nd gear by raising the gearshilt pedal This sequence is repeated to progres sively shift to 3rd. 4th, 5th and 6th(top) gearr 79 5. Coordinate the throttle and brakes for smooth deceleration. 6. Both front and rear brakes should be used at the same time and should not be applied strongly enough to lock the wheel, or braking effectiveness will be reduced and control of the momrcycle be difficult. BRAKING 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 Important Salety Reminders: 0 Independent operation of only the brake lever or brake pedal reduces stopping performance. 0 Extreme application of the brake controls may cause wheel lock. reducing control of the motorcycle. 0 When possible. reduce speed or brake belore 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 of your actions should be smooth under these conditions. Rapid acceleration, braking or turning may cause loss of control. For your safety, exercise extreme caution when braking. accelerating or turning. OW'hen descending a long, steep grade, use engine compression braking by doWn« shifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduoe their effectiveness. CRiding with your foot resting on the brake pedal or your hand on the brake lever may actuate the stoplight, giving a false indication to other drivers. It may also overheat the brakes, reducing effectiveness. 81 PARKING 1. After 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 stand to support the motorcycle while parked. Park the motorcycle on firm, level ground to prevent it from falling over. If 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, 15.1an the steering to help prevent theit (page 62 ). 82 Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking your motorcycle. To avoid possible heat damage to your motorcycle or personal belongings, do not cover the exhaust muffler with a protective cover or any clothing within 20 minutes after shutting off the engine. ANl‘l-THEFI‘TIPS 1. Always lock the steering and never leave the key in the ignition switch. This sounds simple but people do target. 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 information in the Owner’s Manuals that are still with them. NAME: ADDRESS: 83 MAINTENANCE THE IMPORTANCE OF MAINTENANCE A well»maintained motorcycle is essential for sale, economical and troublefree riding. It will also help reduce air pollution To help you properly care [or your motorcycle, the following pages include a Maintenance Schedule and a Mainlenanoe Record for regularly scheduled maintenance. These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the Maintenance Schedule. Consult your Honda dealer [or recommendations applicable to your individual needs and use. If your motorcycle overturns 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 tailing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always lollow the inspection and maintenance recommendations and schedules in this owner’s manual. MAINTENANCE SAFEI'Y This section includes instructions on some important maintenance tasks. You can pertorm some of these tasks with the tools pio‘l/ided 7 it you have basic mechanical s is Other tasks that are more dilficult and require special tools are best performed by professionals Wheel removal should normally be handled only by a Honda technician or other ualified mechanic; instructions are include in this manual only to assist in emergency service. Some of the most important safety precautions followr However, we cannot warn you oi every conceivable hazard that can arise in pertorming maintenance. Only you can decide whether or not you should perform a given task. AWARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always tollow the procedures and precautions in this owners manual 85 SAFETY PRECAUTIONS I Make sure the engine is oif before you begin any maintenance or repairs. This will help eliminate several potential hazards: tCarbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation Whenever you operate the engine, t Burns from hot. parts. Let the engine and exhaust system cool before touching. - lniury from moving parts. Do not run the engine unless instructed 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 falling over, park it on a firm. level surface, using the side stand or a maintenance stand to provide support 86 0To reduce the possibility oi a fire or explosion. be careiul when working around petrol or batteries, Use only nonflammable solvent. not petrol, to clean parts. Keep cigarettes. sparks and flames away from the battery and all Inelrelated parts Remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it To ensure the best quality and reliability, use only new genuine Honda pans or their equivalents for repair and replacement, MAINTENANCE SCHEDULE Periorm the Preride Inspection (page 72 l a! each scheduled maintenance period. I' INSPECT AND CLEAN, ADJUSTt LUBRICA‘H-Z OR REPLACE IF NECESSARY o CLEAN R. REPLACE A: ADJUST L: LUBRICATE The iollowing Maintenance Schedule specifies all maintenance required Do keep your motorcycle in peak operating condition. Maintenance work should be penoi-med in accordance with standards and specifications of Honda by properly trained and equipped technicians. YuIIr Honda dealer meets all oi these requirements. 9 Should be serviced by your Honda dealer, unless (he owner has proper tools and service den and is mechanically qualified Refer to the Official Honda Shop Manual. u In the interest oi soiery we recommend Lhese itemsoe servioed only by your Honda dealer. Honda recommends that your Honda dealer should road test your motorcycle aiier each periodic mainienunce is carried out. NOTES: u) At higher odometer readings. repeat at the irequency interval established here. t2) Service more irequently when I-id'llg in unusually wet or dusty areas. (3) Replace every 2 years, or at indicated odometer interval, Whichever comes first. Replaeement requires mechanical skill. 87 u SPARK PLUGS V V'E C CE EN IL GlNE L :rER ENGINE IDLE D IATO c LING SYSTEM FREQUENCY “”3“ng“ A onomnex READING INOTE(1)| Hm >< REFER A x mi 0.6 4 12 16 24 TO N M NT" 12 13 36 PAGE I , I I ‘ , EVERY 24mm (16.90!) mi) I, 100 EVERY 000m 000 R R 93 FREQUENCY gggfivm ” ODOMETER READING [NOTE (1)] FIRST X1 12 3D 35 Refer X10001!" 0.6 4 8 12 16 20 ‘ m UTE 12 4 30 36 DRIVE CHAIN EVER km I L 103 CHAIN SLIDER I I l I R B FADW'EAR I SYSFEM I BRAKE HTSW” t H HT LUTCHSYSFEM AND ‘ ON t 30'. F t. WHEE t! H TOOL KIT The toolkit ( 1) is in the toolbox behind the right middle cowl. Some roadside repairs, minor adjustments and pans replacement can be performed with the tools contained in the kit. 0 Spark plug wrench t 10 X 12 mm Box end wrench o 22 mm Box end wrench 0 32 mm Box end wrench I 8 X 12 mm Open end wrench 0 10 X 14 mm Open end wrench 0 5 mm Hex wrench 0 No. 2 Phillips screwdriver 0 Nor 2 screwdriver ' Screwdriver handle t Pliers 0 Extension bar 0 Pin spanner - 07 mm Feeler gauge - Helmet holder wire 0 Tool bag 90 To access the tool box (2), loosen the screw (3) and remove the clip A (4). To open the tool box, insert the ignition key (5) and turn it 90" counterclockwise. (3) (1) Toolkit (4) ClipA (2y Toolbox (5) Ignition key (3) Screw SERIAL NUMBERS The frame number (1) is stamped on the The frame and engine serial numbers are right side of the steering head. required when registering your motorcycle. They may also be required by your dealer The engine number (2) is stamped on rear when ordering replacement parts. of the crankcase. Record the numbers here for your reierence. FRAME NO. ENGINE N0. (1) Frame number (2) Engine number 91 COLOUR LABEL The colour label (1) is attached to the rear fender below the rear seat (see page 64 )l It is helpful when ordering replacement parts, Record the colour and code here for your reference‘ COLOUR CODE (1) Colour label 92 ENGINE 01L Refer to the Salety Precautions on page 86 , Oil Recommendation API 36 or higher except classification oils labeled as energy conserving on the circular API service label Viscosity SAE 10W40 JASO T 903 MA standard Suggested Oil Honda “4’STROKE MOTORCYCLE OIL" or equivalent. Your motorcycle does not need oil additives. Use the recommended oil Do not use ’15 with graphite or molybdenum additives. They may adversely affect clutch operation, Do not use API SH or higher oils displaying a circular API “energy Conserving" service label on the container. They may aliect lubrication and clutch performance. NOT RECOMMENDED OK Do not use nondetergent, vegetable, or caster based mciug oils. 93 Viscosity: Viscosity grade of engine oil should be based on average atmospheric temperature in your riding area. The [allowing provides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures 94 JASO T 903 standard mmhrd is an index for choosing engine oils for 4—stroke motorcycle engines There are two classes: MA and M11 Oil conforming to the slandard is Labeled on the oil container. For example, the following label shows the MA classification. M A \ (2) PRODUCT MEETlNG JASO 7 903 COMPANV GUARANTEEING THIS MA PERFORMANCE: (1) Code number of the sales company of the oil (2) Oil classification 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 88 ). When ninning in very dusty conditionsv oil changes should be performed more frequently than specified in the maintenance schedule. Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain Used engine oil may cause skin cancer if repeatedly left in Contact with the skin {or 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 alter handling used oil. 96 Changing the oil filter requires a special oil filter tool and a torque wrench. it 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 [or this installation. see your Honda dealer as soon as possible to verify proper assembly. Change the engine oil with the engine at normal operating temperature and the motorcycle on its side stand to assure complete and rapid draining. 1 To drain the oil remove the oil filler cap. case drain plug (1) and sealing washer (2). (l) Crankcase drain plug (2) Sealing washer 2. Remove the lower cowl (page 68 ). 3. Remove the right middle cowl (page 69 J‘ 97 4. Remove the bolt (3 ). 5. Pull out the prong (4) from the tank stay 8)) and move the coolant reserve tank Take care not to spill the coolant. 6. Remove the oil filter (7) with a filter wrench and let the remaining oil drain outl Discard the oil filter. (4) (3) Bolt (4) Prong (3) (5) (5) Tank stay (6) Coolant reserve tank (7) on film 7. Apply a thin coat of engine oil to the new oil filter rubber seal (8 ). 8. Using a special tool and a torque wrench, install the new oil filter and tighten to a lorq ue of: 26N- m(27kgtm 20lbf-ft) 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. (8) Oil filter mbber seal 9. Check that the sealing washer on the drain plug is in good condition and install the plug. Replace the sealing washer every other time the oil is changed, or each time if necessary. Oil drain plug Torque: 30 N~m(3.1kgf-m , 22 |bt~ftl 10. Fill the crankcase with the recommended grade oil: approximately: 2.9 u (3.1 us qt , 2,6 Imp qt) 11‘ Reposition the coolant reserve tank and tighten securely. 12. Install the oil filler cap. 13. Start the engine and let it idle for 3—5 minutes. 14. 2—3 minutes after stopping the engine. check that the oil level is at the upper level mark in the inspection window with the motorcycle upright on firm. level ground. Make sure there are no oil leaks. 15. Install the right middle cowl (page 69 ). 16. Install the lower cowl (page 68 ). SPARK PLUGS Refer to the Safety Precautions on page 86 . Recommended plugs: Standard: |MR9C- SHES (NGK) or VUH27D (DENSO) N se a spark plug with an improper hea‘tl range. Severe engine damage could res t. 100 This motorcycle uses the spark plugs that have an iridium coated center electrode. Be sure to observe the following when servicing the spark plugs. . Do not clean the spark plug If the electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one. 0 Use only “wire-type Ieeler gauge” to check the spark plug gap to prevent damaging the iridium coating of the center electrodes. Never use “leaf—type feeler gauge". a Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one. 1. Remove the lower cowl (page 68 ) and middle cowls (page 69 ). 2. Remove the radiator lower mount nut ( l) and radiator lower mount bolt (2 ). 3. To access the radiator upper mount bolt (3). remove the wire band (4 ). 4. Remove the radiator upper mount bolt. 5. Remove the clips (5). ’77 '77 Wy/i/z/ 77 // I 0 7%”??? 0 7 x' ”7777’ 7 7%]; 7/77 [/7 ’77 7 777M” 4 77/77/777 ”hm/77’, (l) Radiator lower mount nut (2) Radiator lower mount bolt (3) Radiator upper mount bolt (4) Wire band (5) Clips 101 6. Move the radiator (6) out of the way and 8. Disconnect the ignition coil connectors remove the grommet (7) from the hack ‘3 . 9. Disconnect the ignition coils (10) from (8 )i 7. Pull the radiator toward the front. the spark plugs. (8 (9) [6) Radiator (8) Hook (9) Ignition coil connectors (7) Grommet (10) Ignition coils 102 10. Clean any dirt from around the spark plug 11. Inspect the electrodes and center bases. porcelain [or deposits, erosion or carbon Remove the spark plugs using the spark fouling. If the erosion or deposit is heavy. plug wrench (11 ) furnished in the tool kit. replace the plug. 12, Make sure that the 1.0 mm wire-type feeler gauge does not insert between the spark plug gap (12). if the gauge is inserted into the gap, replace the plug with a new one. T (12) (l 1) Spark plug wrench (12) Spark plug gap 103 13. Make sure the plug washer is in good 16. Reinstall the ignition coils. condition. 17. Connect the ignition coil connectors to 14. Wlth the plug washer attached. thread the ignition coils as before removal the spark plug in by hand to prevent 18. Install the remaining parts in the reverse crossthreadingr order of removal. 15. Tighten each spark plug: 0 [t the old plug is good: 1/8 tum after it seats. 0 If installing a new plug. tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 1/ 2 turn alter it seats. DENSO: 1 turn after it seats. b)Then loosen the plug c) Next, fighten the plug again: 1/ 8 turn after it seats. Improperly tightened spark plugs can damage the engine. If a plug is too loose. a piston may be damaged. If a plug is too tight, the threads may be damaged. 104 THROTTLE OPERATION Refer to the Safety Precautions on page 86 l 1. Check for smooth rotation 01 the throtfle grip [mm the fully open to the fully closed position at both full steering positions. 2, Measure the throttle grip freeplay at the throttle grip flange. The standard freeplay should be approximately: 274 mm (0.1 70.2 in) To adjust the freeplay, loosen the lock nut (1) and turn the adjuster (2), (1) Lock nut (2) Adjuster 105 IDLE SPEED Refer to the Safety Precautions on page 86 . The engine must be at normal operating temperature for accurate idle speed adjustment. 10 minutes of stopand—go riding is sulficient. 1. Warm up the engine, shift to neutral, and place the motorcycle on its side stand. 2. Adjust idle speed with the throttle stop screw (1). Idle speed (ln neutral): 1,300 i 100 min“(rpm) (1) Throttlesmp screw (A) Increase (B) Decrease 106 COOLANT Refer to the Salety Precautions on page 86 . Coolant Replacement Coolant should be replaced by a Honda dealer, unless the owner has pro r tools and service data and is mec anically 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 let the engine and radiator cool down belore removing the radiator cap. 107 DRIVE CHAIN Refer to the Safety Precautions on page 86 . The service liie oi the drive chain is dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprockets. The drive chain should be checked and lubricated as part of the Preride Inspection (page 72). Under severe usage. or when the motorcycle is ridden in unusually dusty or muddy areas. more frequent maintenance will be necessary. Inspection: . urn the engine off, place the motorcycle on its side stand and shift the transmission into neutral. 2. Check slack in the lower drive chain run midway between the sprockets. Drive chain slack should be adjusted to allow the {allowing vertical movement by hand: 25-35 mm (1.0i1.4 in) 108 3. Roll the motorcycle forward. Stop. Check the drive chain slack. Repeat this procedure several times. Drive chain slack should remain constant. If the chain is slack only in oermin sections. some links are kinked and binding. Binding and kinking can trequently be eliminated by lubrication. (1) Drive chain 4, Roll the motorcycle forward. Stop and place it on its side stand. Inspect the drive chain and sprockets for 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 O»rings SPROCKETS I“Excessively Worn Teeth ‘Broken or Damaged Teeth A drive chain with damaged rollers. loose pinsv or missing O-rings 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. If links cannot be freed, the chain must be replaced. Damaged sprocket Worn sprocket Teeth Teeth Replace Replace Normal sprocket Teeth GOOD 109 Ad'ustment: rive c am slack should be checked and adjusted if necessary, every 1,000 km(600 miles) When operated at sustained high speeds or under conditions of frequent rapid acceleration, the chain may require more frequent adjustment. (1) Rear axle nut (2) Dock nut (3) Adjusting bolts (4) index mark (5) Corresponding scale 110 It the drive chain requires adjustment, the procedure is as follows: 1P.lace the motorcycle on its side stand with the transmission in neutral and the ignition switch off 2 Loosen the rear axle nut (1) 3. Loosen the lock nuts (2) on both athusting bolts (3). 4.Turn both adjusting bolts an equal number of turns until the correct drive chain slack is obtained Turn the adjusting bolts counterclockwise to tighten the chain, Turn the adjusting bolts clockwise and push the rear wheel toward the front to provide more slack. Adjust the chain slack at a point midway between the drive sprocket and the rear wheel sprocket. Roll the motorcycle forward. Stop and place it on its side stand. Recheck chain slack Chain slack should be: 25*35 mm (10* 1,4 in) 5i Align the chain acUuster index marks (4) with the corresponding scale (5) graduations on both sides of the swingarm. Both left and right marks should correspond. It the axle is misaligned, turn the left or right adjusting bolt until the marks correspond on the scale gmduation on the swingarm and recheck chain slack. 6. Tighten the axle nut to specified torque. Axle nut torque: 113 Mm (11.5 kgf-m , 83 |bf~ft) If a torque wrench is not used (or this installation, see your Honda dealer as soon as possible to verify proper assembly. 7. Tighten the adjusting bolts lightly by turning it cmnterclockwise, then tighten the lock nuts by holding the adjusting bolts with a spanner, 8. Recheck drive chain slack 111 Wear Ingpgctl n: Check the ch wear label when adjusting the chain. If the red zone (6) on the label aligns with the index mark (7) on the chain adjuster plate after 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 (1.0-1.4 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: DID 525HV or RK 525R021 This motorcycle has a staked master link drive chain which requires a special tool for cutting and staking. Do not use an ordinary anaslber link with this chain See your Honda ea er. 112 (6) Red zone (7) Index mark Lubrication and Cleaning: u neat/e every . (600 miles) or sooner ii chain appears dry. The drive chain on this motorcycle is equipped with small O-rings between the link plat/es. These O-rings retain grease inside the chain to improve its service life. The Grings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents. Clean the side surfaces of the chain with a dry cloth. Do not brush the rubber O-rings. Brushing will damage them. Wipe dry and lubricate only with SAE 80 or 90 gear oil. Commercial chain lubri- cants may contain solvents which could damage the rubber O-rings. 113 DRIVE CHAIN SLIDER Refer to the Safety Precautions on page 86 , Check the chain slider (l) [or wear. The chain slider must be replaced if it is worn to the wear limit line (2). For replacement, see your Honda dealer‘ (1) Chain slider (2) Wear limit line 114 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page 86 , 1. Check the fork assembly by locking the front brake and pumping the fork up and down vigorously. Suspension action should be smooth and there must be no oil leakage. 2. Swingarm bearings should be checked by pushing hard against the side of the rear wheel while the motorcycle is on a support block. Free play indicates worn bearings. 3. Carefully inspect all front and rear suspension fasteners for tightness. 115 SIDE STAND Refer to the Safety Precautions on page 86 . Perform the following maintenance in accordance w1th the maintenance schedule. Functional Check: Chet: E the s1de stand spring (1) [or damage or loss of tension and the side stand assembly for freedom of movement, 0Check the side stand ignition cut—off s yste:m 1. Sit astride the motorcycle; out the side stand up and the transmission in neutral 2. Start the engine and with the clutch lever pulled in, shilt the transmission into gear. 3. Lower the side stand. The engine should stop as you put the side stand down. I! the side stand system does not operate as described, see your Honda dealer [or service. 116 (1) Side stand spring WHEEL REMOVAL Refer to the Safety Precautions on page 86 . This motorcycle is equipped with a side stand only. Therefore. if front or rear wheel removal is required. it will be necessary to raise the center of the motorcycle with a jack or other firm support. If none is available, see your Honda dealer for this service. Front Wheel Removal 1, Raise the front wheel off the ground by placing a support block under the engine, 2. Remove the right and left caliper assemblies (1) from the fork leg by removing the fixing bolts (2). To avoid damage to the brake hose. support the caliper assembly so that it doesn't hang lrom the hose. Do not twist the brake hose. (1) Bmke mliper assembly (2) Fixingbolts 117 Do not depress the brake lever when the 3. Remove the front axle bolt (3), and then caliper assembly is removed. The caliper loosen the right and left lront axle pinch pistons will be forced out of the linders bolts (4), with subsequent loss of brake flui . I! this 4‘ Withdraw the front axle shaft (5) and occurs. servicing of the brake system will be remove the front wheel. necessary. See your Honda dealer [or this service. (3) (3) Front axle bolt (5) Front axle shalt (4) Front axle pinch bolts 118 Installation: . Position the front wheel between the fork legs and insert the front axle shaft from the left side, through the left fork leg and wheel hub‘ 2. Align the end of front axle shaft (6) with the surface of fork leg (7), 3‘ Temporarily tighten the front axle pinch bolts on the left fork leg until they lightly seat. 4. Tighten the front axle bolt to the specified torque: 59 N-m (6‘0 kgf‘m , 43 Ibf-ft) 5. Tighten the front axle pinch bolts on the right fork leg to the specified torque: 22 N‘m12,2 kgf‘m ,16lbf‘fll 6. Make sure that the front fork spacers (8 ) are installed into the caliper bracket properly. 7. Install the right and left caliper assemblies to the fork legs and tighten the fixing bolts to the specified torque: 45 N‘m (4.6 kgf-m , 33 lbf'f!) To avoid damaging the brake pads while installing the caliper assemblies. carefully fit both brake discs between the pads. 8. Operate the front brake and pump the fork several times. (8) (6) End affront axle 5mm (7) Surface of fork leg (3) Front fork spacers 1‘9 9, Measure the clearance (9) between each surface of the left brake disc (10) and the left brake caliper body (11) (not brake pads) with a 0.7 mm (0.028 in) feeler gauge (12) (see illustration). (10) (11) (9) Clearante (n) Caliperbudy (12) Feelergauge (10) Brake disc 120 10. If the feeler gauge inserts easily, tighten the left front axle pinch bolts to the specified torque: 22 N-m (2.2 kgf>m ,16let) If the feeler gauge cannot be inserted easily, pull the left fork outward or push inward to adjust the clearance Then tighten the left front axle pinch bolts to the specified torque. .After installing the wheel. apply the brakes sevelal times, then recheck the both discs for caliper body (not brake pads) to disc clearance. Do not operate the motorcycle without adequate clearance. 0 Check for free wheel rotation after the brake lever is released. Recheck the wheel if the brake drags or if the wheel does not rotate freelyl 0 Verify proper brake operation before riding. 1 Failure to provide adequate disc to caliper body (not brake pads) clearance may dam- age the brake discs and impair braking efficiency. It the 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. 121 RearWheel Removal 1. Raise the rear Wheel 0“ the ground by placing a support block under the engine. 2. Loosen the rear axle nut (1). 3. Loosen the lock nuts (2) and adjusting bolts (3) 4. Remove the rear axle nut and washerl 5. Remove the drive chain (4) from the driven sprocket by pushing the rear wheel forward. (1) Rear axle nut (2) Locknuts 122 (3) Adjusting bolts (7) Right chain adjust plate 6. Remove the rear axle shaft (5), rear wheel, lei! chain adjust plate (6), right chain adjust plate (7) and side collar from the swingarm. Do not depress the brake pedal while the wheel is of! the motorcycle. The caliper pistons will be forced out of the cylinders with subsequent loss of brake fluid If this owurs, servicing of the brake system will be necessary. See your Honda dealer for this service. (4) Drive chain (5) Rear aide shah (6) Left chain adjust plate Installation Notes: 0 To install the rear wheel, reverse the removal procedure. 0 Make sure that the slot (3) on the swingarm (9) is located in the lug (10) in the brake caliper bracket (11) 0Tighten the axle nut to the specified torque: 113 Nm (11.5 kgfrm , 83 lbf-ft) 0 Adjust the drive chain. When installing the Wheel, carefully fit the brake disc between the brake pads to avoid damaging the pads. After installing the wheel, apply the brake several times and then check if the wheel rotates Ireely. Recheck the wheel if the })rakle drags or if the wheel does not route ree y. 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 oi braking capacity. (10) Lug (11) Brake caliper bracket (8) Slot (9) Swingarm 123 BRAKE PAD WEAR Refer to the Safety Precautions on page 86 . Brake pad wear depends upon the severity of usage, the type of riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval (page 89). Front Brake Always inspect each pad in both right and left brake calipers. Check the wear indicator grooves (1) in each paid If either pad is worn to the bottom of the grooves, replaoe both pads as a set. See your Honda dealer for this service. 124 < FRONT BRAKE) Illustration shows left side, right side similar. (1) Wear indicator grooves Rear Brake Check the cutouts (2) in each pad. I! either pad is worn to the cutouts, replace both pads as a set, See your Honda dealer for this service.