HONDA. GOLDWING GL1500 OWNER'S MANUAL MANUAL DE EXPLICACION ES INSTRUKTIEBOEK © HONDA MOTOR CO., LTD 1939 IMPORTANT NOTICE 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 tyre information label. 0 ON—ROAD USE This motorcycle is designed to be used only on the road. . READ THIS OWNER'S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: A NlNG Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold. HONDA GOLDWING GL1 500 OWNER'S MANUAL All information in this publication is based on the latest produc- tion information available at the time of approval for printing. HONDA MOTOR 00., L TD. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. WELCOME The motorcycle presents 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 com» mands as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a pre-ride inspection and regular maintenance are essential to your safety. Your reward is freedom. 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. 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 Hondal CONTENTS OPERATION Page 1 MOTORCYCLE SAFETY Gimme Safe Riding Rules Protective Apparel Modifications Loading and Accesso— ries 9 PARTS LOCATION 12 Instruments and Indi- cators 18 MAJOR COMPONENTS (Information you need to operate this motorcycle) 18 Rear Suspension 21 Brakes 23 Clutch 24 Coolant 26 Fuel 29 Engine Oil 30 Final Drive Oil 31 Tubeless Tyres 34 ESSENTIAL INDIVIDUAL COMPONENTS 34 Ignition Switch 35 39 Right Handlebar Con- trols Left Handlebar trols Con- 41 FEATURES (Not required for operation) 41 Steering Lock Page 41 42 46 47 47 4s 48 49 49 50 50 52 54 60 Helmet Holders Travel Trunk And Saddlebags Fairing Pockets Trunk Side Pockets Windshield Height Ad— justment Headlight Beam Ad- justment Ventilation Louvers Seat ACC Terminal Protection Against Water Radio/Cassette Cover AM/FM Radio Cassette Deck Radio Antenna 61 OPERATION 61 62 65 66 67 69 7O 70 Pre-ride Inspection Starting the Engine Running»in Riding Reverse Riding Braking Parking AntiI> Toward left Toward right 56 Ambience button (AMB) The "ambience” circuit blends and boosts certain frequencies from both channels, for a "live performance” effect. To use the circuit, push the AMB button until "AMB." appears in the display. AMB is usable for stereo programs from both tape and FM. The ambience circuit, however, may weak FM stereo signals or poorly recorded tapes sound worse. Ambianm Button Indicator AM3 AME. 57 FEATURES (Not required for operation) Auto Volume Control Knob This function increases the volume as the speed of the motorcycle increases. Turning the knob clockwise raises the operating level. Set the knob at the center position under normal conditions and then adjust the volume control for desired sound level. Tone Control Knob Turning this knob clockwise emphasizes treble, turning it counterclockwise decreases the treble and emphasizes bass. it is usually set at the center position. Auto Volume Control Knob Tone Control Knob AVE TUNE ”6/6 ,. I 58 Headset/speaker Mode Button If you use the headset, push this button. The display will in- dicate "O” (headset). To hear sound through the speakers, push this button again, HoMsel/Speaker Mod. Button (Til/Ed Intercom Volume Control Knob AWARNWG 0 Some local governments prohibit the operator from using a headset; always obey applicable laws and regulations. To communicate with the passenger using the intercom, turn this knob clockwise. Turning this knob further increases intercom volume. When not using the intercom system, turn off this knob. NOTE: 0 The auto volume control does not function for the intercom system 0 Turn this knob only high enough for adequate volume; if turned too high, there may be “feed back” from the fairing speakers. Intercom Volume Control Knob IC VOL DFF MAX Front Headset Terminal 59 FEATURES (Not required for operation) Intercom Mute Knob The intercom mute system automatically lowers the music/program volume when you speak through the intercom. With the knob turned clockwise, you must speak more loudly to activate the mute circuit. With the knob turned counterclockwise, the mute will activate even at low speaking levels. Intercom Mm. Knob MUTE > // / / Rear Headset , Terminal RADIO ANTENNA To fold the radio antenna: Twist and pull upon the knurled coupling and then fold the radio antenna down. Antenna 60 OPERATION PRE-RIDE INSPECTION 0 If the Pie-ride Inspection is not performed, severe personal injury or vehicle damage may result. Inspect your motorcycle every day before you ride it. The items listed here will only take a few minutes to inspect, and in the long run they can save time, expense, and possibly your life. 1. Engine oil level—add engine oil if required (page 29). Check for leaks. 2. Fuel level—fill fuel tank when necessary (page 26). Check for leaks. 3. Coolant level—add coolant if required. Check for leaks (pages 24—25). 4. Front and rear brakes—check operation; make sure there is no brake fluid leakage. Add fluid if necessary (pages 21 —22). Tyres—check condition (pages 31 —33) and pressure (page 31). Throttle—check for smooth opening and closing in all steep ing positions. Lights and horn—check that headlight, tail/stoplight, turn signals, indicators and horn function properly. Engine stop switch—check for proper function (page 35). Ignition cut-off system—check for proper function (page 87). 10.Battery electrolyte—check the level and add if necessary (page 96). Correct any discrepancy before you ride. Contact your authorized Honda dealer for assistance if you cannot correct the problem. moses" 61 OPERATION STARTING THE ENGINE it MINNIE . Never run the engine in a closed area. The exhaust con- tains poisonous carbon monoxide gas that can cause loss of consiousness and may lead to death. 0 Do not flood the engine by twisting the throttle repeatedly. The carburetor has an accelerator pump. NOTE: 0 This motorcycle is equipped with an ignition cut-off 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 disengaged. 0 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. 0 The electric starter will work when the transmission is in gear with the clutch disengaged. Preparation Before starting, insert the key, turn the ignition switch 0N and confirm the following: o The transmission is in NEUTRAL (neutral indicator light GM. 0 The engine stop switch is at RUN. - The red engine oil pressure warning light is ON. CAUTION: 0 The red oil pressure warning light should go off a few seconds after the engine starts.” the light stays on, stop the engine immediately and check engine oil level. Operating the engine with insufficient oil pressure can cause serious engine damage. 62 Starting Procedure To restart a warm engine, follow the procedure for “ High Air Temperature." Normal Air Temperature 10°—35°C (50°v95°Fl: 1. Push the choke lever down all the way to Fully Open (B). 2. Start the engine, leaving the throttle closed. NOTE: 0 Do not open the throttle when starting the engine with the choke open. This will lean the mixture, resulting in hard starting. 3. Immediately after the engine starts. operate the choke lever to keep fast idle at LEGO—2,500 rpm. 4. About a half minute after the engine starts, push the choke lever up all the way to fully off. 5. [f idling is unstable, open the throttle slightly. High Air Temperature 35°C (95°F) or above: 1. Do not use the choke. 2. Open the throttle slightly. 3. Start the engine. 63 OPERATION Low Air Temperature 10"C (50°F) or below: 1. 2. Follow steps 142 under “Normal Air Temperature." When engine rpm begins to pick up, operate the choke lever to keep fast idle at 2,200~2,800 rpm. 3‘ To speed warm up, open and close the throttle, keeping engine rpm below 2,800. 4. About 5 minutes after the engine starts, push the choke lever up all the way to Fully Closed (Al, 5. Continue warming up the engine by opening and closing the throttle until it will idle smoothly. CAUTION: Snapping the throttle or fast idling for more than about 5 minutes at normal air temperature may cause exhaust pipe discoloration. Extended use of the choke may impair piston and cylinder wall lubrication. Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel, To clear a flooded engine, turn the engine stop switch OFF and push the choke lever up to Fully Clo sec 0N sed (A). Open the throttle fully and crank the engine for 5 ends. Wait 10 seconds, then turn the engine stop switch and follow the “High Air Temperature” Starting Procedure (page 63k 64 RUNNING-IN During initial running-in, newly machined surfaces will be in contact with each other and these surfaces will wear in quick- ly. Running-in maintenance at 1,000 km (600 miles) is design- ed to compensate for this initial minor wear. Timely perfor- mance of running»in maintenance will ensure optimum service life and performance from the engine. The general rules are as follows: 1. Never labour the engine with full throttle at low engine speeds. This rule is applicable not only during running-in but at all times. Maximum continuous engine speed during the first 1,000 km (600 miles) must not exceed 4,000 min" (rpm) Increase the maximum continuous engine speed by 1,000 min-' (rpm) between odometer readings of 1,000 km (600 miles) and 1,600 km (1,000 miles). Drive briskly, vary speeds frequently and use full throttle for short bursts only. Do not exceed 5,500 min" (rpm). Upon reaching an odometer reading of 1,600 km (1,000 miles), you can subject the motorcycle to full throttle operation. However, do not exceed 5,500 min" (rpm) at any time (tachometer RED ZONE limit). CAUTION: The red zone indicates the maximum limits of engine speed and running the engine in the red zone will adversely affect its service life. 65 OPERATION RIDING A wnmtwe Review Motorcycle Safety {pages 1—8) before you ride. NOTE: Make sure the function of the side stand mechanism (See MAINTENANCE SCHEDULE on page 72, 73 and explana- tion for SIDE STAND on page 87.) Proper shifting will provide better fuel economy. AWARNWG CA 0 Do not downshift when traveling at a speed that would force the engine to overrev in the next lower gear; the rear wheel may lose traction, resulting in a possible loss of vehi- cle control. UTION: Do not shift gears without disengaging the clutch and clos- ing the throttle. The engine and drive train could be damag- ed by overspeed and shock. Do not tow the motorcycle or coast for long distances while the engine is off. The transmission will not be proper- ly lubricated and damage may result. Do not exceed 4,500 min” lrpml when running the engine without a load. Serious engine damage may result. NOTE: Be careful when revving the engine or accelerating in 1st or 2nd gear as the engine speed will easily enter the red zone. 66 REVERSE RIDING For reverse maneuvering, make sure there are no obstacles or people in the area; avoid steep or uneven surfaces. AWARMM, 0 Do not carry a passenger while moving in reverse. The weight of a passenger will increase the possibility and results of maneuvering errors. You may fall over. 1. Make sure the transmission is in neutral (neutral indicator ON) and the side stand is up. 2. Sitting astride the motorcycle, start the engine and shift the reverse lever into the reverse position as shown, then make sure the reverse system indicator comes on. Reverse 67 OPERATION 3. Push the start/reverse button and guide the motorcycle backward cautiously. CAUTION: 0 Do not push the start/reverse button more than a minute to prevent battery discharge. 4. Release the start/reverse button, and the motorcycle will stop. 5. After stopping the motorcycle, disengage the reverse lever, and make sure the reverse gear indicator goes off and the neutral indicator comes on. CAUTION: 0 Do not engage or disengage reverse when the motorcycle is moving or the reverse years could be damaged. NOTE: 0 If the reverse lever is moved to the reverse position with the engine off, the engine cannot be started‘ Reverse System Overload: The reverse system is designed to move the motorcycle at a constant slow speed. If the motorcycle begins moving slower or faster than this speed. due to obstacles or steep pavement angle, the system will shut off (reverse system indicator OFF)‘ To resume reverse operation or normal forward operation. move the reverse lever to the disengaged position and carefuL Iy roll the motorcycle to a more»leve| unobstructed surface, then start again, 68 BRAKING This motorcycle is equipped with a unified braking system. Depressing the brake pedal applies the rear brake and the left front disc. Operating the brake lever applies the right front disc. For full braking effectiveness, use both the pedal and lever simultaneously, as you would with a conventional motorcycle brake system. For normal braking, apply both the brake pedal and lever while down-shifting to match your road speed. For maximum brak- ing, close the throttle and firmly apply the pedal and lever; disengage the clutch before the motorcycle stops. ’ wanvwc 0 Independent use of only the brake lever or brake pedal reduces stopping performance. Extreme braking may cause either wheel to lock, reducing control of the motorcycle. 0 When 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 of your actions should be smooth under these conditions. Sudden acceleration, braking or turning may cause loss of control. For your safety, exercise extreme caution when braking, accelerating or turning. ' When descending a long, steep grade, use engine compres- sion braking by do wnshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness. 0 Riding with your foot resting on the brake pedal or your hand on the brake lever may actuate the brake/ight, giving a false indication to other drivers. It may also overheat the brakes, reducing effectiveness. 69 OPERATION PARKING 1. 2. After stopping the motorcycle, shift the transmission into neutral, turn the ignition switch OFF and remove the key. Use the side or center stand to support the motorcycle while parked. CAUTION: 3. Park the motorcycle on firm, level ground to prevent it from falling over. If you park on a slight incline, aim the front of the motorcy- cle uphill to reduce the possibility of rolling off the side stand or overturning. Lock the steering to help prevent theft (page 41). NOTE: 0 When stopping for a short time near traffic at night, the ig— nition switch may be turned to P and the key removed. This will turn on the taillight to make the motorcycle more visible to traffic. The battery will discharge if the ignition switch is left at P for too long a time. ANTI-THEFT TIPS 1. P 9:55” NAME: ADDRESS: Always lock the steering and never leave the key in the igni- tion switch. This sounds simple but people do forget. Be sure the registration information for your motorcycle is accurate and current. Park your motorcycle in a locked garage whenever possible. Use an additional anti-theft device of good quality. Put your name, address, and phone number in this Owner's Manual and keep it on your motorcycle at all times. Many times stolen motorcycles are identified by information in the Owner's Manuals that are still with them. PHONE NO: 70 MAINTENANCE When sen/ice is required, remember that your authorized Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it. The scheduled maintenance and the anticipated maintenance may also be performed by a qualified service facility that normally does this kind of work; or you may perform most of the work yourself if you are mechanically qualified and have the pro- per tools and service data. These instructions are based on the assumption that the motorcycle will be used exclusively for its designed pur- pose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more fre» quent service than specified in the MAINTENANCE SCHEDULE. Consult your authorized Honda dealer for recommendations applicable to your individual needs and use. 71 MAINTENANCE MAINTENANCE SCHEDULE The following items require some mechanical knowledge. Cer— tain items (particularly those marked « and u) may require more technical information and tools. Consult your authorized Honda dealer. Perform the Pre»ride Inspection (page 61) at each scheduled maintenance period I : INSPECT AND CLEAN, ADJUST, REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE LUBRICATE 0R wHIcm/ER .. onoMuzn mums morz w raseumcv CW5; rmsr “.me I s \2 i3 2: so as ' “poem as 1 a u is 20 u mmwm irm NOTE Mourns s u is 24 an as - ruELuNE l | l — - maumsommou l r r 7 . CARWRI‘TDRCHDKi l l r AIR amp: NOVE 2 n a 71 7 m CMMKCASEEREMNER norm c c c c c c u smx nues n a R 337 u mews mi. N x a n 29‘ 7H: mom: ml. mm: a n n a 30-82 - cmunzron I I ‘ swmnomuricu ~ maumommzspzm r r r l l l l as RADIATOR ccouur nor; i r r a 2:— 25 - commcsvsrm l . l , sscouommwmvsvsrw norss r . r 7 72 4‘ IIEM FREDUEMEV WHICHEVER .p onoMEIEII READING mm II n ,Owkm 6I2I82t30 Imam A auIszo MOMYHS Is 2A Rug. In we EINAI DRIVE an as aAnERv 9am amE mm mm A 2I722 BRAKE m: WEAR 95 BRAKE SvSIEM 2172155 BRAKE uGRI SWIrcR READIIGRI AIM 45 CLUYCN svsIEM mm mm NOTE A 23 REVERSE OPERAIIoN SIDE SYAND s7 SUSPENSION CRUISE VALVE ELEMENT AIR pump ELEMENY AIR DRIER NuIS. sous, FASYEMERS quELSmRES HHH SVEERWG READ HEARINGS I I I I I I I l sNouLD BE SERVICED av AN ALIYHORIZED NoNnA DEALER, UNLESS rNE cIWNER HAS FROFER YOOLS AND SERVICE DATA AND IS MECNANICALLY QUALIFIED, REFER m YNE OFFICIAL HONDA SERVICE MANUAL ~~ IN THE INYfREST or SAFH’V, WE RECOMMEND THESE ITEMS BE SERVIcED ONLY av AN AumoRIzEn NOTES I HONDA DEALER, PP!“ "Imam 5km V Swrlzelland lvne onw AI hIghev odomexer readmas, Iepeax a! me hequenty ImemI emu-shed here Sum. mm lmnuamly when "ding m unumaHv we: 01 dusw areas Service mm llequenllv when dmg In lam, or .u lull Imam. Replace evevy z veavs, m 31 Women odumeiev mmvaI, wh-chavel coma: um Rep‘acemlm reg-me: 73 MAINTENANCE TOOL KIT The tool kit is in the saddlebag. Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. 0 0.7 mm Feeler gauge 0 0.8 mm Feeler gauge 0 Spark plug wrench 010 x 12 mm Box end wrench 14 x 17 mm Box end wrench 22 mm Box end wrench 27 mm Box end wrench 7 x 8 mm Open end wrench 10 x 12 mm Open end wrench 014 x 17 mm Open end wrench 74 Breaker bar 0 Pliers Phillips! Standard screwdriver Screwdriver Handle grip 4 mm Hex wrench 5 mm Hex wrench 6 mm Hex wrench 8 mm Hex wrench Toolbox SERIAL NUMBERS The frame and engine serial numbers are required when registering your motorcycle. They may also be required by your dealer when ordering replacement parts. Record the numbers here for your reference. The frame number is stamped on the right side of the steering head. The engine number is stamped on the right side of the crankcase, near the oil level gauge. COLOUR LABEL The colour label is attached inside the fuel strainer compart- ment lid. It is helpful when ordering replacement parts. Record the colour and code here for your references VlN FRAME NO. ENGINE N0. COLOUFl CODE Engine Number 75 MAINTENANCE MAINTENANCE PRECAUTIONS 0 If your motorcycle is overturned or involved in a collision, inspect control levers, cables, brake hoses, calipers, ac- cessories, and other vital parts for damage. Do not ride the motorcycle if damage impairs safe operation. Have your authorized Honda dealer inspect the major components, in- cluding frame, suspension and steering parts, for misalign- ment and damage that you may not be able to detect. . Stop the engine and support the motorcycle securely on a firm, level surface before performing any maintenance. 0 Use new, genuine Honda parts or their equivalent for maintenance and repair. Parts which are not of equivalent quality may impair the safety of your motorcycle. 76 01) (Air cleaner element) (Refer to the maintenance precautions on page 61 J The numbers are shown in sequence of disassembly. AIR CLEANER 77 MAINTENANCE The air cleaner should be serviced at regular intervals (page 73). Service more frequently when riding in unusually wet or dusty areas. 1. Remove the seat (page 49D. 2. Remove the parts in sequence, according to the order in the illustration. NOTE: 0 Be careful not to break any tabs. 3. Remove and discard the air cleaner element. 4. Install a new air cleaner element. 5. Install removed parts in the reverse order of removal. NOTE: 0 Make sure to engage all tabs and to secure all fasteners. CRANKCASE BREATHER (Refer to the maintenance precaution on page 61.) 1. Remove the front left side cover. 2. Remove the drain plug from the tube and drain deposits. 3. Reinstall the drain plug. NOTE: 0 Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the transparent section of the drain tube. crankcase Breath" Tuba 78 ENGINE OIL (Refer to the maintenance precautions on page 61 .) 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 service SE, SF or $6. Viscosity: Viscosity grade of engine oil should be barsed on average at- mospheric temperature in your riding area. The following pro- vides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures. Single grade 20w74o 20w—50 V -- Mulll grade —10 0 IO 20 30 40.0 i—I—__A___A—l 20 M) 60 80 ‘IDDF 79 MAINTENANCE 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 61). NOTE: 0 Change the engine oil with the engine at normal Operating temperature and the motorcycle on its center stand to assure complete and rapid draining. CAUTION: 0 To prevent oil leaks and filter damage, never support the engine on the oil filter, 1. To drain the oil, remove the front right side cover (page 29), then oil filler cap, drain bolt and sealing washer. AWARNWG 0 A warmed-up engine and the oil in it are hot; be careful not to burn yourself. // 1/ Draln eon Oil Fillcr Cap 80 2. Remove the under cover and oil filter with a filter wrencht Discard the oil filter. Oil Filter Undnr Cover 3. Apply a thin coat of engine oil to the new oil filter rubber seal. Oil Filter 4. Install the new oil filter and tighten it: 10 N~m (1.0 kg-m, 7 ft-lb) 81 MAINTENANCE 5‘ Check that the sealing washer on the drain plug is in good condition and Install the drain plug. Oil Drain Plug Torque: 40 N»m 14.0 kg-m, 29 ft-lbl 6‘ Fill the crankcase with the recommended grade oil; approximately: 3.7%7 (3.8 US qt, 3.3 Imp qt) 7. Install the oil filler cap. 8. Start the engine and let it idle for 2—3 minutes. 9‘ Stop the engine. Check that the oil level is at the upper level mark on the dipstick (page 29L Make sure there are no oil leaks. NOTE: 0 When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. 0 Please dispose of used engine oil in a manner that is com» patible with the environment. We suggest you take it in a sealed container to your local service station for reclama- tion. Do not throw it in the rubbish or pour it on the ground. CAUTION: 0 Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unliker 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 possible after handling used oil. 82 SPARK PLUGS (Refer to the maintenance precautions on page 61 .l 1. Remove the parts in sequence, according to the order in the following illustration (Left side shown; right side similar). Installation note: When installing, the sequence should be: 4, 8, 7, 6, 5, 3, 2, 1. Recommended plugs: Standard: DPR7EA-9 (NGK), X22EPR»U9 (ND) For cold climate: (Below 5°C/41°Fl DPRSEA-Q (NGK), X20EPR-U9 (ND) For extended high speed riding: DPRSEA—S (NGK), X24EPR-U9 (ND) 2. Disconnect the spark plug caps from the spark plugs. 3. Clean any dirt from around the spark plug bases. Remove the spark plugs using the plug wrench furnished in the tool kit. 83 MAINTENANCE 4. 8. Inspect the electrodes and center porcelain for deposits, erosion or cabcn fouling. If the erosion or deposit is heavy. replace the plug. Clean a carbon or wet»fouled plug with a plug cleaner, otherwise use a wire brush. Check the spark plug gap using a wiretype feeler gauge. If adjustment is necessary, bend the side electrode carefully. The gap should be: 0.8—0.9 mm l0.031—0.035 in) Make sure the plug washer is in good condition. With the plug washer attached, thread the spark plug in by hand to prevent crossthreading. 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 1/8—1/4turn after the plug seats. Reinstall the spark plug caps. CAUTION: The spark plug must be securely tightened. Arr improperly tightened plug can become very hot and possibly damage the engine. Never use a spark plug with an improper heat range. Severe engine damage culd result. Side Electrode (0.031 —0.035 In) 0.3—0.9 mm ~‘= l - Wash" 84 FINAL DRIVE OIL (Refer to the maintenance precautions on page 61.) Change the oil as specified in the maintenance schedule. NOTE: 5" Change the oil with the final drive at normal operating temperature and the motorcycle upright on firm, level ground to assure complete and rapid draining. . To drain the oil, remove the oil filler cap and drain plug. After the oil has completely drained, check that the sealing washer on the drain plug is in good condition and install the drain plug. Drain Plug Torque: 20 Nm (2.0 kg-m, 14 ft-lbl Fill the final drive with the recommended grade oil; approx» imately: 140 om3 14.7 US 02, 4.9 Imp 02). Make sure the final drive oil is filled up to the lower edge of the inspection hole with the recommended oil. Install the oil filler cap. on Filler Cap Lower Edge 85 MAINTENANCE IDLE SPEED (Refer to the maintenance precautions on page 61.) The idle speed adjustment procedure given here should only be used when changes in altitude affect normal idle speed as set by your dealer. See your authorized Honda dealer for regularly scheduled carburetor adjustments, including individual car- buretor adjustment and synchronization. NOTE: 0 The engine must be at normal operating temperature for ac- curate idle speed adjustment. Ten minutes of stop»and-go riding is sufficient. 1. Warm up the engine, shift to neutral and place the motorcy» cle on its center stand, 2. Open the fuel strainer compartment. 3, Adjust idle speed with the adjusting knob. Idle Speed (In neutral): 800180 rpm Adjusting Knob Full Shiner Compartment 86 SIDE STAND (Refer to the maintenance precautions on page 61.) Perform the following maintenance in accordance with the maintenance schedule. Functional Check: 3. 4. Check the spring for damage or loss of tension and the side stand assembly for freedom of movement. Check the ignition out-off system: . Sit astride the motorcycle; put the side stand up and the trasmission in neutral. . Start the engine and with the clutch pulled in, shift the transmission into gear.. Move the side stand fully down‘ The engine should stop as you put the side stand down. If the side stand system does not operate as described, see your authorized Honda dealer for service. 87 MAINTENANCE FRONT WHEEL REMOVAL (Refer to the maintenance precautions on page 61.) For related torque specifications, see page 91. The numbers are shown in sequence of disassembly. 38 Wheel removal requires mechanical skill and professional tools such as a floor jack and torque wrench. We recom- mend it be done only by your authorized Honda dealer or other qualified mechanic. . Raise the front wheel off the ground by placing a support block under the engine. Remove the parts in sequence, according to the order in the illustration. CAUTION: To avoid damage to the brake hose, support the caliper assembly so that it doesn’t hang from the hose. Do not twist the brake hose. Avoid getting grease, oil or dirt on the disc or pad surfaces, because such contamination can cause poor brake perfor- mance or rapid pad wear after reassembly. NOTE: Do not depress the brake lever and brake pedal when the wheel is off the motorcycle. The caliper pistons will be forced out of the cylinders with subsequent loss of brake fluid. If this occurs, servicing of the brake system will be necessary. See your authorized Honda dealer for this service. 89 MAINTENANCE Installation 1. Reassemble removed parts in the reverse order of removal. NOTE: - When installing the wheel, position the speedometer gear— box so that the lug on the gearbox is against the rear of the stopper lug on the left fork. CAUTION: 0 When installing the wheel, fit both brake discs carefully be- tween the brake pads to avoid damaging the pads. 2. Measure the clearance between the out side surface of the left brake disc and the left caliper holder with a 07 mm (0.028 in) feeler gauge. If the gauge inserts easily, tighten the right and left axle pinch bolts to the specified torque. 90 Specified torque: Axle bolt: 90 NM (9.0 kg-m, 65 ft-lb) Caliper mounting bolt, upper: 23 N-m (2.3 kg-m, 16 it-Ibl Caliper mounting bolt, lower: 12 Mm (1.2 kg~m, 9 ft-lbl Axle pinch bolt: 22 N~m (2.2 kg-m, 16 lt-lbl AWARNWG AWARM . If a torque wrench was not used for installation, see your authorized Honda dealer as soon as possible to verify pro- per assembly. Improper assembly may lead to loss of brak- ing capability. If the feeler gauge cannot be inserted easily, pull the left fork outward or push inward until the gauge can be in- serted and tighten the axle pinch bolts with the gauge inserted. After tightening, remove the gauge. After installing the wheel, apply the brakes several times, then recheck both discs for caliper holder to disc clearance. Do not operate the motorcycle without adequate clearance. Failure to provide adequate disc to caliper holder clearance may damage the brake discs and impair braking efficiency. 91 (Refer to the maintenance precautions on page 61.) For related torque specifications, see page 94. The numbers are shown in sequence of disassembly. MAINTENANCE REAR WHEEL REMOVAL (Each side) 15) (Each side) w M s h c a e M u d b m o 0 fl 6 lead conmcmr ol ‘ and! side.) (Disconnect m. AWARNING Wheel removal requires mechanical skill and professional tools such as a torque wrench. We recommend it be done only by your authorized Honda dealer or other qualified mechanic. 1. Place the motorcycle on its center stand. 2. Remove the parts in sequence, according to the order in the illustration. CAUTION: Support the caliper assembly before removing the rear axle so that the caliper does not hang from the brake hose Do not twist the brake hose. A void getting grease, oil or dirt on the disc or pad surfaces, because such cantaminau‘on can cause poor brake perfor- mance or rapid pad wear altar reassembly. Do not damage the muffler gaskets when handling the mufflers. NOTE: Do not depress the brake pedal while the wheel Is off the motorcycle. The caliper pistons will be forced out of the cylinder with subsequent loss of brake fluid. If this occurs, servicing of the brake system will be necessary. See your authorized Honda dealer for this service. Installation 1. Reassemble removed parts in the reverse order of removal. CAUTION: Do not pinch, or twist the air hose when installing the right saddlebag. NOTE: Apply a |ithium>based multipurpose grease with molyb- denum disulfide additive to the rear hub splines. final drive gear splines and flange pins when the rear wheel is reassembled. Be sure the splines on the wheel hub fit into the final drive case and the splines on the final drive case fit into the driveshaft end. 93 MAITNENANCE CA 0 Rear Hub (l Flnal Drive Gear Spline: UTION: When installing the wheel carefully, fit the brake disc be- tween the brake pads to avoid damaging the pads. After installing the wheel, apply the brake several times and then check that the wheel rotates freely when releas- ed. Recheck the wheel if the brake drags or if the wheel does not rotate freely. RNWG If a torque wrench was not used for installation, see your authorized Honda dealer as soon as possible to verify pro- per assembly. Improper assembly may lead to loss of brak- ing capability. Specified torque: Axe nut: 110 Mm (1 1.0 kg-m, 80 ft-Ibl Axle pinch bolt: 32 N~m (3.2 kg-m, 24 ft-lb) Shock absorber bolt. upper: 23 N~m (2.3 kg-m, 16 ft-Ibl Shock absorber bolt, lower right: 23 N-m (2.3 kg-m, 16 ft-lb) lower left: 70 NM (7.0 kg-m, 51 ft—lbl 94 BRAKE PAD WEAR (Refer to the maintenance precautions on page 61.) Brake pad wear will depend upon the severity of usage, type of riding and condition of the roads. The pads will wear faster on dirty and wet roads. Inspect the pads visually during all regular service intervals to determine the pad wear. If either pad wears to the wear limit, both pads must be replaced as a set. NOTE: 0 Use only genuine Honda replacement friction pads offered by authorized Honda dealers. When brake service is necessary consult your Honda dealer. Other Checks: Make sure that there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. FR NT 0 Wear Limit REAR Well Limlt 95 MAINTENANCE BA'I'I'ERY (Refer to the maintenance precautions on page 61.) If the motorcycle is operated with insufficient battery elec- trolyte, sulfation and battery plate damage will occur. If rapid loss of electrolyte is experienced, or if your battery seems to be weak, causing slow starting or other electrical problems, see your authorized Honda dealer. Battery Electrolyte: The battery is under the seat. Remove the rear right side cover to check the battery electrolyte. The electrolyte level must be maintained between the UPPER and LOWER LEVEL marks on the side of the battery. It the electrolyte level is low, disconnect the negative (—l ter- minal lead from the battery first, then disconnect the positive terminal lead. Disconnect the battery breather tube. Remove the bolt and battery holder. Pull out the battery‘ Remove the battery filler caps. Carefully add distilled water to UPPER LEVEL mark, using a small syringe or plastic funnel. Rel! Right Side Cover 96 CAUTION: When checking the battery electrolyte level, or adding distilled water, make sure the breather tube is connected to the battery breather outlet. Use only distilled water in the battery. Tap water will shorten the service life of the battery. Filling the battery above the UPPER LEVEL line may cause the electrolyte to overflow, resulting in corrosion to engine or nearby parts. Immediately wash off any spilled electrolyte. The battery breather tube must be routed as shown on the label. Do not bend or twist the breather tube. A bent or kinked breather tube may pressurize the battery and damage its case. AWARNWG The battery gives of! explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging or using the batteries in an enclosed space. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. — If electrolyte gets on your skin, flush with water. — If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. Electrolyte is poisonous. — If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. 97 MAINTENANCE FUSE REPLACEMENT (Refer to the maintenance precautions on page 61.) The main fuse®, 30A, is attached to the starter magnetic switch. The main fuse. 55A, is located near the battery. The reverse system fuses, 5A, are near the battery. Remove the rear right side cover (page 96) for access to fuses. The circuit fuse box is located near the fuel tank. Remove the rear left side cover (page 49) and fuse box cover for access to circuit fuses. Spare fuses are behind the fuse box cover. The specified fuses are shown on the fuse box cover. RIGHT SIDE Reverse Fuses 98 When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your authorized Honda dealer for repair. CAUTION: 0 Turn the ignition switch OFF before checking or replacing fuses to prevent accidental short-cilcuiting. To replace the main fuse ® , disconnect the lead connector of the starter magnetic switch. To replace the main fuse , loosen the screws. Tighten the screws securely. To replace reverse fuses, open the cap and pull out the fuses. To replace any fuses in the fuse box, pull the old fuse out of the clips with the fuse remover. Push a new fuse into the clips. LEFT SIDE Fuse Remy-r 99 MAINTENANCE AWARNINK} 0 Never use a fuse 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. Fuse Blown Fun Rumover mmmm HIIIrmu um" n’mu =3 100 CLEANING Cle an your motorcycle regularly to protect the surface finishes and inspect for damage, wear, and oil, coolant, or hydraulic fluid seepage. 1. Clean the windshield with a soft cloth or sponge and plenty CA a of watert Dry with a soft clean cloth. Remove minor scrat» ches with commercially available plastic polishing com- pound. Replace the windshield if scratches cannot be removed and they obstruct clear vision. UTION: Do not let battery electrolyte, brake fluid or other acid chemicals get on the windshield. They will damage the plasu'c. Avoid spraying high pressure water (typical in coin- aperated car washes] at the following areas: Brake Master Cylinders Fairing Pockets or Accessories Clutch Master Cylinder Ignition Switch Radiator Fins Steering Lock Wheel Hubs Handlebar Switches Muffler Outlets Instrument panel Under Seat Radio Unit 2. After cleaning, rinse the motorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. 3. Dry the motorcycle, start the engine, and let it run for several minutes. 4. Test the brakes before riding the motorcycle. Several ap- plications may be necessary to restore normal braking performance. Braking efficiency may be temporarily impaired immediately after washing the motorcycle. Antichaate longer stopping distance to avoid a possible accident. 101 CLEANING Aluminum Wheel Maintenance Aluminum corrodes when it comes in contact with dust, mud, road salt, etc. After riding, clean the wheels with a wet sponge and mild detergent, then rinse well with water and wipe dry with a clean cloth. After cleaning, apply wax to the cleaned surfaces thoroughly. If the wheels have stains or lose their luster, polish the sur- faces with a cleaner containing compounds, then apply wax. Be sure to remove wax or cleaner from the brake disc thoroughly after applying wax or polishing with a cleaner con» taining compounds CAUTION: 0 Do not use steel wool to clean the wheels, as they can cause damage. 102 STORAGE GUIDE STORAGE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non— use of the motorcycle. In addition, necessary repairs should be made BEFORE storing the motorcycle; otherwise, these repairs may be forgotten by the time the motorcycle is removed from storage. 1. Change the engine oil and filter. 2. Make sure the cooling system is filled with a 50/50% an- tifreeze solution. 3. Drain the fuel tank and carburetors into an approved gasoline container. Spray the inside of the tank with an aerosol rust»inhibiting oil. Reinstall the fuel cap on the tank. NOTE: 0 If storage will last more than one month, carburetor drain- ing is very important, to assure proper performance after storage. AWARNWG 0 Petrol is extremely flammable and is explosive under cer- tain conditions. Perform this operation in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks near the equipment while draining fuel. 4. Remove the spark plugs and pour a tablespoon (15—20 cm3l of clean engine oil into each cylinder. Crank the engine several times to distribute the oil, then reinstall the spark plugs. NOTE: 0 When turning the engine over, the Engine Stop Switch should be OFF and each spark plug placed in its cable cap and grounded to prevent damage to the ignition system. 5. Remove the battery. Store in an area protected from freez- ing temperatures and direct sunlight. Check the electrolyte level and slow charge the battery once a month. 103 STORAGE GUIDE 6. Wash and dry the motorcycle. Wax all painted surfaces. Coat chrome with rust-inhibiting oil. 7. lnflate the tyres to their recommended pressures. Place the motorcycle on blocks to raise both tyres off the ground. 8. Cover the motorcycle (don't use plastic or other coated materials) and store in an unheated area, free of dampness with a minimum of daily temperature variation. Do not store the motorcycle in direct sunlight. 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. Check the battery electrolyte level and 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. Check the final drive oil, adding the recommended gear oil if necessary, Change the final drive oil as specified by the Maintenance Schedule. Perform all Pre-ride inspection checks (page 61). Test ride the motorcycle at low speeds in a safe riding area away from traffic. 104 SPECIFICATIONS DIMENSIONS Overall length 2,630 mm (1035 in) Overall width 955 mm ( 37.6 in) Overall height 1,525 mm ( 60.0 in) Wheelbase 1,700 mm ( 66.9 inl Ground clearance 140 mm ( 5.5 in) WEIGHT Dry weight 386 kg (807 lbs) CAPACITIES Engine oil 3.5 I (3.1 Imp gt, 3.7 US qt) After draining Final drive gear oil 140 cm3 (4.9 Imp oz, 4.7 US oz) After draining Fuel tank 24.0 I (5.3 Imp gal, 6.3 US gal) Cooling system capacity 4.1 (7 (3.6 Imp qt. 4.3 US qt) Passenger capacity load Operator and one passenger Maximum weight 185 kg (408 lb) capacity ENGINE Bore and stroke 71 x 64 mm (2.8 x 2.5 in) Compression ratio 9.8 : 1 Displacement 1,520 cc (92.7 cu.inl Spark plug Standard X22EPR»U9 (ND), DPR7EA-9 (NGKI For cold climate X20EPR-U9 (ND). (Below 5°C, 41°F) DPRSEA-Q (NGK) For extended high X24EPR»U9 (NDI. speed riding DPR8EA-9 (NGKI Spark plug gap 0.8—0.9 mm (0.031 v0.036 in) Idle speed 800 1 80 rpm CHASSIS AND SUSPENSION Caster 30° Trail 115 mm (4.5 in) Tyre size, from 130/7048 63H Tyre size, rear 160/8046 75H 105 SPECIFICATIONS POWER TRANSMISSION Primary reduction 1.592 Secondary reduction 0.971 Gear ratio, 1st 2.667 2nd 1.722 3rd 1273 4th 0.964 OD 0.759 Final reduction 2.833 ELECTRICAL Battery 1 2V-20AH Generator 0.55 kw/5,000 rpm LIGHTS Headlight 12V—60/55W Tail/stoplight 12V—5/21W Turn signal light 12V—21W Position light 12V 5W License light 12V 5W FUSES 65A, 5A (Reverse fuse) 55A, 30A (Main fuse) 15A, 10A, 5A (Other fuse) 106 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (al The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (bl The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. 107