11/05/07 10:01:23 32KVCC00_001 Honda GLH125 SH OWNER’S MANUAL Honda Motor Co., Ltd. 2011 11/05/07 10:01:27 32KVCC00_002 IMPORTANT INFORMATION OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. Never exceed the maximum weight capacity. ON-ROAD USE This motorcycle is designed to be used only on the road. READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual. These messages are fully explained in the ‘‘A Few Words About Safety’’ section which appears before the Contents page. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold. 11/05/07 10:01:32 32KVCC00_003 Honda GLH125 SH 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 written permission. 11/05/07 10:01:37 32KVCC00_004 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-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. As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your motorcycle, other property, or the environment. Pleasant riding, and thank you for choosing a Honda ! 11/05/07 10:01:46 32KVCC00_005 The following codes in this manual indicate each country. TU U Turkey Ukraine Australia IITU IIU (TU Type II) (U Type II) The illustrations herein are based on the IITU type. The specifications may vary with each locale. This vehicle pictured in this owner’s manual may not match your actual vehicle. 11/05/07 10:01:52 32KVCC00_006 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 operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good judgment. You will find important safety information in a variety of forms, including: Safety Labels –– on the motorcycle. Safety Messages –– preceded by a safety alert symbol DANGER, WARNING, or CAUTION. These signal words mean: and one of three signal words: 11/05/07 10:01:57 32KVCC00_007 You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings –– such as Important Safety Reminders or Important Safety Precautions. Safety Section –– such as Motorcycle Safety. Instructions –– how to use this motorcycle correctly and safely. This entire manual is filled with important safety information –– please read it carefully. 11/05/07 10:02:13 32KVCC00_008 OPERATION page 1 MOTORCYCLE SAFETY 1 IMPOR T A NT SA F ET Y INFORMATION 2 PROTECTIVE APPAREL 4 LOAD LIMITS AND GUIDELINES 9 IMAGE LABELS (U, IIU) 13 PARTS LOCATION 16 INSTRUMENTS AND INDICATORS 20 MAJOR COMPONENTS (Information you need to operate this motorcycle) 20 SUSPENSION 21 BRAKES 28 CLUTCH 30 FUEL 34 ENGINE OIL 35 TYRES page 40 ESSENTIAL INDIVIDUAL COMPONENTS 40 IGNITION SWITCH 41 KEYS 42 SHUTTER (TU, IITU) 43 RIGHT HANDLEBAR CONTROLS 44 LEFT HANDLEBAR CONTROLS 11/05/07 10:02:25 32KVCC00_009 page 45 FEATURES (Not required for operation) STEERING LOCK 45 46 SEAT 47 DOCUMENT COMPARTMENT 48 LEFT SIDE COVER 49 RIGHT SIDE COVER HEADLIGHT AIM VERTICAL 50 ADJUSTMENT page 51 OPERATION PRE-RIDE INSPECTION 51 STARTING THE ENGINE 53 RUNNING-IN 57 RIDING 58 BRAKING 60 PARKING 61 ANTI-THEFT TIPS 62 11/05/07 10:02:48 32KVCC00_010 MAINTENANCE page 63 MAINTENANCE 63 THE IMPORTANCE OF MAINTENANCE 64 MAINTENANCE SAFETY 65 SAFETY PRECAUTIONS 66 MAINTENANCE SCHEDULE 69 TOOL KIT 70 SERIAL NUMBERS 71 COLOUR LABEL 72 CRANKCASE BREATHER 73 ENGINE OIL 77 SPARK PLUG 79 VALVE CLEARANCE 82 THROTTLE OPERATION 83 IDLE SPEED 84 DRIVE CHAIN 91 FRONT AND REAR SUSPENSION INSPECTION 92 SIDE STAND 93 WHEEL REMOVAL 99 BRAKE PAD WEAR 100 BRAKE SHOE WEAR 101 BATTERY page 103 FUSE REPLACEMENT 107 BRAKELIGHT SWITCH ADJUSTMENT 108 BULB REPLACEMENT 114 CLEANING 118 STORAGE GUIDE 118 STORAGE 120 REMOVAL FROM STORAGE 121 TAKING CARE OF THE UNEXPECTED 122 SPECIFICATIONS 126 CATALYTIC CONVERTERS (TU, IITU) 11/05/07 10:02:58 32KVCC00_011 MOTORCYCLE SAFETY IMPORTANT SAFETY INFORMATION Your motorcycle can provide many years of service and pleasure − if you take responsibility for your own safety and understand the challenges that you can meet on the road. There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual. Following are a few that we consider to be most important. Always Wear a Helmet It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an approved motorcycle helmet and make sure your passenger does the same. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear (page 2 ). Make Yourself Easy to See Some drivers do not see motorcycles because they are not looking for them. To make yourself more visible, wear bright reflective clothing, position yourself so other drivers can see you, signal before turning or changing lanes, and use your horn when it will help others notice you. Ride Within Your Limits Pushing the limits is another major cause of motorcycle crashes. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, f atigue and inat tent ion can significantly reduce your ability to make good judgements and ride safely. 1 11/05/07 10:03:05 32KVCC00_012 Don’t Drink and Ride Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Bike in Safe Condition For safe riding, it’s important to inspect your motorcycle before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by Honda for this motorcycle. See page 4 for more details. PROTECTIVE APPAREL For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, trousers, and a long-sleeved shirt or jacket whenever you ride. Although complete protection is not possible, wearing proper gear can reduce the chance of injury when you ride. Following are suggestions to help you choose proper gear. Not wearing a helmet increases the chance of serious injury or death in a crash. Be sure you and your passenger always wear a helmet, eye protection and other protective apparel when you ride. 2 11/05/07 10:03:10 32KVCC00_013 Helmets and Eye Protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. A bright-coloured helmet can make you more noticeable in traffic, as can reflective strips. An open-face helmet offers some protection, but a full-face helmet offers more. Always wear a face shield or goggles to protect your eyes and help your vision. Additional Riding Gear In addition to a helmet and eye protection, we also recommend: Sturdy boots with non-slip soles to help protect your feet and ankles. Leather gloves to keep your hands warm and help prevent blisters, cuts, burns and bruises. A motorcycle riding suit or jacket for comfort as well as protection. Brightcoloured and reflective clothing can help make you more noticeable in traffic. Be sure to avoid loose clothes that could get caught on any part of your motorcycle. 3 11/05/07 10:03:17 32KVCC00_014 LOAD LIMITS AND GUIDELINES Your motorcycle has been designed to carry you and one passenger. When you carry a passenger, you may feel some difference during acceleration and braking. But so long as you keep your motorcycle wellmaintained, with good tyres and brakes, you can safely carry loads within the given limits and guidelines. Loading How much weight you put on your motorcycle, and how you load it, are important to your safety. Anytime you ride with a passenger or cargo you should be aware of the following information. However, exceeding the weight limit or carrying an unbalanced load can seriously affect your motorcycle’s handling, braking and stability. Non-Honda accessories, im p r o p e r m od i f i c a t i on s , a n d p o or maintenance can also reduce your safety margin. Overloading or improper loading can cause a crash and you can be seriously hurt or killed. The following pages give more specific information on loading, accessories and modifications. 4 Follow all load limits and other loading guidelines in this manual. 11/05/07 10:03:27 32KVCC00_015 Load Limits Following are the load limits for your motorcycle: Maximum weight capacity: 150 kg (331 lb) Includes the weight of the rider, passenger, all cargo and all accessories Maximum rear carrier cargo weight: 3.0 kg (6.6 lb) The weight of added accessories will reduce the maximum cargo weight you can carry. Loading Guidelines Your motorcycle is primarily intended for transporting you and a passenger. You may wish to secure a jacket or other small items to the seat when you are not riding with a passenger. If you wish to carry more cargo, check with your dealer for advice, and be sure to read the information regarding accessories on page 7 . Improperly loading your motorcycle can affect its stability and handling. Even if your motorcycle is properly loaded, you should ride at reduced speeds and never exceed 130 km/h (80 mph) when carrying cargo. 5 11/05/07 10:03:31 32KVCC00_016 Follow these guidelines whenever you carry a passenger or cargo: Check that both tyres are properly inflated (page 35 ). If you change your normal load, you may need to adjust the rear suspension (page 20 ). To prevent loose items from creating a hazard, make sure that all cargo is securely tied down before you ride away. Place cargo weight as close to the center of the motorcycle as possible. Balance cargo weight evenly on both sides. 6 11/05/07 10:03:38 32KVCC00_017 Accessories and Modifications Modifying your motorcycle or using nonHonda accessories can make your motorcycle unsafe. Before you consider making any modifications or adding an accessory, be sure to read the following information. Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding accessories and modifications. Accessories We strongly recommend that you use only Honda Genuine Accessories that have been specifically designed and tested for your motorcycle. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation and use of non-Honda accessories. Check with your dealer for assistance and always follow these guidelines: Make sure the accessory does not obscure any lights, reduce ground clearance and banking angle, limit suspension travel or steering travel, alter your riding position or interfere with operating any controls. Be sure electrical equipment does not exceed the motorcycle’s electrical system capacity (page 125 ). A blown fuse can cause a loss of lights or engine power. 7 11/05/07 10:03:43 32KVCC00_018 Do not pull a trailer or sidecar with your motorcycle. This motorcycle was not designed for these attachments, and their use can seriously impair your motorcycle’s handling. Modifications We strongly advise you not to remove any original equipment or modif y your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycle’s handling, stability and braking, making it unsafe to ride. Removing or modif ying your lights, mufflers, emission control system or other equipment can also make your motorcycle illegal. 8 11/05/07 10:03:48 32KVCC00_019 IMAGE LABELS (U, IIU) The following pages describe the label meanings. Some labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read this information carefully and don’t remove the labels. There is a specific symbol on each label. The meanings of each symbol and label are as follows. If a label comes off or becomes hard to read, contact your dealer for a replacement. 9 11/05/07 10:03:57 32KVCC00_020 Read instructions contained in Owner’s Manual carefully. Read instructions contained in Shop Manual carefully. In the interest of safety, take the motorcycle to be serviced only by your dealer. DANGER (with RED background) You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. WARNING (with ORANGE background) You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. CAUTION (with YELLOW background) You CAN be HURT if you don’t follow instructions. 10 11/05/07 10:04:07 32KVCC00_021 TYRE INFORMATION LABEL Cold tyre pressure: [Driver only] Front 200 kPa (2.00 kgf/cm Rear 225 kPa (2.25 kgf/cm [Driver and passenger] Front 200 kPa (2.00 kgf/cm 225 kPa (2.25 kgf/cm Rear Tyre size: 80/100−18M/C 47P Front 90/90−18M/C 51P Rear Tyre brand: KENDA K291F Front Rear K328X , 29 psi) , 33 psi) , 29 psi) , 33 psi) DRIVE CHAIN LABEL Keep chain adjusted and lubricated. 20 − 30 mm ( 0.8 − 1.2 in) Freeplay 11 11/05/09 16:12:27 32KVCC00_022 SAFETY REMINDER LABEL For your protection, always wear helmet and protective gear. CARGO LIMIT LABEL Do not exceed 3.0 kg (6.6 lb) 12 . 11/05/07 10:04:19 32KVCC00_023 PARTS LOCATION Speedometer Headlight dimmer switch Engine stop switch (U, IIU) Fuel gauge Rearview mirror Choke lever Front brake fluid reservoir (Type II) Passing light control switch Rearview mirror Clutch lever Front brake lever Turn signal switch Throttle grip Horn button Start button Indicators Ignition switch Shutter (TU, IITU) Fuel fill cap 13 11/05/07 10:04:23 32KVCC00_024 Engine oil fill cap/dipstick Battery Main fuse Rear carrier Rear suspension spring preload adjuster Rear brake pedal Passenger footpeg Footpeg 14 11/05/07 10:04:27 32KVCC00_025 Fuel valve Other fuses Tool kit Rear suspension spring preload adjuster Passenger footpeg Shift lever Footpeg Side stand Center stand 15 11/05/07 10:04:34 32KVCC00_026 INSTRUMENTS AND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages. (1) Speedometer (2) Gear range (3) Odometer (4) Gear position indicator (5) Fuel gauge (6) High beam indicator (7) Neutral indicator (8) Right turn signal indicator (9) Left turn signal indicator (10) Tripmeter (11) Tripmeter reset knob (1) (2) (3) (4) (6) (11) (10) (7) (9) (11) 16 (5) (8) 11/05/07 10:04:48 32KVCC00_027 (Ref.No.) Description (1) Speedometer Shows riding speed. Function (2) Gear range Shows proper speed range for each gear. (3) Odometer Shows accumulated mileage. (4) Gear position indicator Indicates the engaging transmission gears. (5) Fuel gauge Shows approximate fuel supply available (page 19 ). (6) High beam indicator (blue) Lights when the headlight is on high beam. (7) Neutral indicator (green) Lights when the transmission is in neutral. 17 11/05/07 10:04:56 32KVCC00_028 (Ref.No.) Description (8) Right turn signal indicator (green) Function Flashes when the right turn signal operates. (9) Left turn signal indicator (green) Flashes when the left turn signal operates. (10) Tripmeter Shows mileage per trip. (11) Tripmeter reset knob Resets tripmeter to zero (0). 18 11/05/07 10:05:01 32KVCC00_029 Fuel Gauge When the fuel gauge needle ( 1 ) enters the red band ( 2 ), 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 when the fuel gauge needle enters the red band is approximately: 2.2 (0.58 US gal , 0.48 Imp gal) (2) (1) (1) Fuel gauge needle (2) Red band 19 11/05/07 10:05:10 32KVCC00_030 MAJOR COMPONENTS (Information you need to operate this motorcycle) SUSPENSION The spring preload adjuster ( 1 ) has 5 spring preload positions for different load or riding conditions. Adjust the spring preload by turning the spring preload adjuster with the pin spanner ( 2 ) and extension bar ( 3 ) provided in the tool kit (page 69 ). 1 (2) (3) Always adjust the spring preload adjuster position in sequence (1-2-3-4-5 or 5-4-3-2-1). Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the spring preload adjuster. Position 1 is for light loads and smooth road conditions. Positions 3 to 5 increase spring preload for a stiffer rear suspension, and can be used when the motorcycle is more heavily loaded. Be certain to adjust both spring preload adjusters to the same position. Standard position: 2 (1) (1) Spring preload adjuster (2) Pin spanner (3) Extension bar 20 2 3 4 5 11/05/07 10:05:14 32KVCC00_031 BRAKES Front Brake (Type II) This motorcycle has a hydraulic front disc brake. As the brake pads wear, 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 free travel becomes excessive and the brake pads are not worn beyond the recommended limit (page 99 ), there is probably air in the brake system and it must be bled. See your dealer for this service. 21 11/05/07 10:05:20 32KVCC00_032 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 for wear (page 99 ). Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 3 or DOT 4 brake fluid from a sealed container, or an equivalent. (1) (1) LOWER level mark 22 11/05/07 10:05:26 32KVCC00_033 (Type I) Brakes are items of personal safety and should always be maintained in proper adjustment. The distance the front brake lever ( 1 ) moves before the brake starts to engage is called freeplay. (1) Measured at the tip of the front brake lever, freeplay should be maintained at: 10−20 mm (0.4−0.8 in) Adjust the freeplay of the brake lever with the front wheel pointed straight ahead. (1) Front brake lever 23 11/05/07 10:05:37 32KVCC00_034 Adjustment: 1. Major adjustment should be made using the lower adjusting nut ( 2 ) at the front wheel. Minor adjustment can be made with the upper adjusting nut ( 3 ) on the brake lever. Pull back the rubber dust cover ( 4 ). Loosen the lock nut ( 5 ). 2. Adjust brake lever freeplay with the front brake adjusting nut. Turning the nut clockwise will decrease freeplay and turning the nut counterclockwise will increase freeplay. Make sure the cut-out on the adjusting nut is seated on the brake arm pin ( 6 ) after making final freeplay adjustment. Tighten the lock nut and install the rubber dust cover. (5) (4) (B) (A ) (A ) (6) (B) (3) (2) (2) Lower adjusting nut (6) Brake arm pin 24 (A) Decrease freeplay (B) Increase freeplay (3) Upper adjusting nut (A) Decrease freeplay (4) Rubber dust cover (B) Increase freeplay (5) Lock nut 11/05/07 10:05:48 32KVCC00_035 3. Apply the brake several times and check for free wheel rotation after the brake lever is released. After adjustment, push the brake arm ( 7 ) to confirm that there is a gap between the lower adjusting nut ( 2 ) and the brake arm pin ( 6 ). (7) (2) After adjustment, confirm the freeplay of the brake lever. If proper adjustment cannot be obtained by this method, see your dealer. Other Checks: Check the brake cable for kinks or signs of wear that could cause sticking or failure. L ubricat e t he bra ke cable w it h a commercially available cable lubricant to prevent premature wear and corrosion. Make sure the brake arm, spring and fasteners are in good condition. (6) (2) Lower adjusting nut (6) Brake arm pin (7) Brake arm 25 11/05/07 10:05:56 32KVCC00_036 Rear Brake Pedal Height Adjustment: The stopper bolt ( 1 ) is provided to allow adjustment of the pedal height. To adjust the pedal height, loosen the lock nut ( 2 ) and turn the stopper bolt. Tighten the lock nut. (1) (2) Brake Adjustment: 1. Place the motorcycle on its center stand. 2. Measure the distance the rear brake pedal ( 3 ) moves before the brake starts to take hold. Freeplay should be: 20−30 mm (0.8−1.2 in) 3. If adjustment is necessary, turn the rear brake adjusting nut ( 4 ). (A ) (3) (B) (4) (1) Stopper bolt (2) Lock nut (3) Rear brake pedal 26 (4) Rear brake adjusting nut (A) Decrease freeplay (B) Increase freeplay 11/05/07 10:06:06 32KVCC00_037 Adjust by turning the rear brake adjusting nut a half-turn at a time. Make sure the cutout on the adjusting nut is seated on the brake arm pin ( 5 ) after making final freeplay adjustment. 4. Apply the brake several times and check for free wheel rotation after the brake pedal is released. After adjustment, push the brake arm ( 6 ) to confirm that there is a gap between the rear brake adjusting nut ( 4 ) and the brake arm pin ( 5 ). (6) (4) If proper adjustment cannot be obtained by this method, see your dealer. (5) (5) (4) Rear brake adjusting nut (5) Brake arm pin (6) Brake arm After adjustment, confirm the freeplay of the rear brake pedal. Other Checks: Make sure the brake rod, brake arm, spring and fasteners are in good condition. (5) Brake arm pin 27 11/05/07 10:06:14 32KVCC00_038 CLUTCH Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep; or if the clutch slips, causing acceleration to lag behind engine speed. Minor adjustments can be made with the clutch cable adjuster ( 4 ) at the clutch lever ( 1 ). Normal clutch lever freeplay is: 10−20 mm (0.4−0.8 in) (1) 1. Pull back the rubber dust cover ( 2 ). 2. Loosen the lock nut ( 3 ) and turn the clutch cable adjuster. Tighten the lock nut and check the adjustment. 3. If the adjuster is threaded out near its limit or if the correct freeplay cannot be obtained, loosen the lock nut and turn in the clutch cable adjuster completely. Tighten the lock nut and install the dust cover. (3) (B) (2) (4) (A ) (1) Clutch lever 28 (A) Increase freeplay (2) Rubber dust cover (B) Decrease freeplay (3) Lock nut (4) Clutch cable adjuster 11/05/07 10:06:22 32KVCC00_039 4. Loosen the lock nut ( 5 ) at the lower end of the cable. Turn the adjusting nut ( 6 ) to obtain the specified freeplay. Tighten the lock nut and check the adjustment. 5. Start the engine, pull in the clutch lever and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. T he motorcycle should begin to move smoothly and accelerate gradually. Other Checks: Check the clutch cable for kinks or signs of wear that could cause sticking or failure. L ubricate the clutch cable w it h a commercially available cable lubricant to prevent premature wear and corrosion. (5) If proper adjustment cannot be obtained or the clutch does not work correctly, see your dealer. (6) (A ) (B) (5) Lock nut (6) Adjusting nut (A) Increase freeplay (B) Decrease freeplay 29 11/05/07 10:06:30 32KVCC00_040 FUEL Fuel Valve The three way fuel valve ( 1 ) is on the left side near the carburetor. ON With the fuel valve in the ON position, fuel will flow from the main fuel supply to the carburetor. OFF With the fuel valve in the OFF position, fuel cannot flow from the tank to the carburetor. T urn the valve OFF whenever the motorcycle is not in use. RES With the fuel valve in the RES position, fuel will flow from the reserve fuel supply to the carburetor. Use the reserve fuel only when the main supply is gone. Refill the tank as soon as possible after switching to RES. The reserve fuel supply is: 2.0 (0.53 US gal , 0.44 Imp gal) Remember to check that the fuel valve is in the ON position each time you refuel. If the valve is left in the RES position, you may run out of fuel with no reserve. ON (1) (1) Fuel valve 30 OFF RES 11/05/07 10:06:39 32KVCC00_041 Fuel Tank The fuel tank capacity including the reserve supply is: 13.5 (3.57 US gal , 2.97 Imp gal) To open the fuel fill cap ( 1 ), open the tank cap cover ( 2 ), insert the ignition key ( 3 ) and turn it clockwise. The fuel fill cap will pop up and can be lifted off. Do not overfill the tank. There should be no fuel in the filler neck ( 4 ). After refueling, to close the fuel fill cap, align the latch in the cap with the slot in the filler neck. Push the fuel fill cap into the filler neck until it snaps closed and locks. Remove the key. Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately. (4) (3) (1) (1) Fuel fill cap (2) Tank cap cover (2) (3) Ignition key (4) Filler neck 31 11/05/07 10:06:43 32KVCC00_042 Use unleaded petrol with a research octane number of 91 or higher. (TU, IITU) The use of leaded petrol will cause premature damage to the catalytic converters. 32 If ‘‘spark knock’’ or ‘‘pinking’’ occurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinking persists, consult your dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda’s Limited Warranty. 11/05/07 10:06:48 32KVCC00_043 Petrol Containing Alcohol If you decide to use a petrol containing alcohol (gasohol), be sure it’s octane rating is at least as high as that recommended by Honda. There are two types of ‘‘gasohol’’: one containing ethanol, and the other containing methanol. Do not use petrol that contains more than 10 % ethanol. Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. The use of petrol containing more than 10 % ethanol (or more than 5 % methanol) may: Damage the painting of the fuel tank. Damage the rubber tubes of the fuel line. Cause corrosion of the fuel tank. Cause poor drivability. Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol. If it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a petrol that contains alcohol, or one that you think contains alcohol, switch to a petrol that you know does not contain alcohol. Never use petrol containing more than 5 % methanol, even if it has cosolvents and corrosion inhibitors. 33 11/05/07 10:06:59 32KVCC00_044 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 on the oil fill cap/dipstick ( 3 ). 1. Start the engine and let it idle for 3−5 minutes. 2. Stop the engine and put the motorcycle on its center stand on level ground. 3. After 2 − 3 minutes, remove the oil fill cap/dipstick, wipe it clean, and reinsert the oil fill cap/dipstick without screwing it in. Remove the oil fill cap/dipstick. The oil level should be between the upper and lower level marks on the oil fill cap/ dipstick. 4. If required, add the specified oil (page 73 ) up to the upper level mark. Do not overfill. 5. Reinstall the oil fill cap/dipstick. Check for oil leaks. Running the engine with insufficient oil pressure may cause serious engine damage. (3) (1) (2) (1) Upper level mark (2) Lower level mark (3) Oil fill cap/dipstick 34 11/05/07 10:07:05 32KVCC00_045 TYRES To safely operate your motorcycle, the tyres must be the proper type and size, in good condition with adequate tread, and correctly inflated. Using tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Air Pressure Properly inflated tyres provide the best combination of handling, tread life, and riding comfort. Generally, underinflated tyres wear unevenly, adversely affect handling, and are more likely to fail from being overheated. Underinflated tyres can also cause wheel damage in rocky terrain. Overinflated tyres make your motorcycle ride harshly, are more prone to damage from surface hazards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install new caps. Follow all instructions in this owner’s manual regarding tyre inflation and maintenance. 35 11/05/07 10:07:14 32KVCC00_046 Always check air pressure when your tyres are ‘‘cold’’ − when the motorcycle has been parked for at least three hours. If you check air pressure when your tyres are ‘‘warm’’ − when the motorcycle has been ridden for even a few miles − the readings will be higher than if the tyres were ‘‘cold’’. This is normal, so do not let air out of the tyres to match the recommended cold air pressures given below. If you do, the tyres will be underinflated. The recommended ‘‘cold’’ tyre pressures are: kPa (kgf/cm , psi) Driver only Front Rear 200 (2.00 , 29) 225 (2.25 , 33) Driver and one passenger Front Rear 200 (2.00 , 29) 225 (2.25 , 33) 36 Inspection Whenever you check the tyre pressures, you should also examine the tyre treads and sidewalls for wear, damage, and foreign objects: Look for: Bumps or bulges in the side of the tyre or the tread. Replace the tyre if you find any bumps or bulges. Cuts, splits or cracks in the tyre. Replace the tyre if you can see fabric or cord. Excessive tread wear. Also, if you hit a pothole or hard object, pull to the side of the road as soon as you can safely and carefully inspect the tyres for damage. 11/05/07 10:07:17 32KVCC00_047 Tread Wear Replace tyres immediately when the wear indicator ( 1 ) appears at on the tyre. (2) (1) (1) Wear indicator (2) Wear indicator location mark 37 11/05/07 10:07:21 32KVCC00_048 Tube Repair and Replacement If a tube is punctured or damaged, you should replace it as soon as possible. A tube that is repaired may not have the same reliability as a new one, and it may fail while you are riding. If you need to make a temporary repair by patching a tube or using an aerosol sealant, ride cautiously at reduced speed and have the tube replaced before you ride again. Any time a tube is replaced, the tyre should be carefully inspected as described on page 36 . 38 11/05/07 10:07:29 32KVCC00_049 Tyre Replacement The tyres that came on your motorcycle were designed to match the performance capabilities of your motorcycle and provide the best combination of handling, braking, durability and comfort. Installing improper tyres on your motorcycle can affect handling and stability. This can cause a crash in which you can be seriously hurt or killed. Always use the size and type of tyres recommended in this owner’s manual. T he r ecommended t yres f or your motorcycle are: Front: 80/100−18M/C 47P KENDA K291F Rear: 90/90−18M/C 51P KENDA K328X Type: bias-ply, tube 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. Also remember to replace the inner tube whenever you replace a tyre. The old tube will probably be stretched, and if installed in a new tyre, it could fail. 39 11/05/07 10:07:35 32KVCC00_050 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch ( 1 ) is below the indicator panel. (OFF) (ON) (1) (LOCK) (1) Ignition switch Key Position LOCK (Steering lock) Function Steering is locked. Engine and lights cannot be operated. Key Removal Key can be removed Engine and lights cannot be operated. Key can be removed Key cannot be removed OFF Engine and lights can be operated. ON 40 11/05/07 10:07:44 32KVCC00_051 KEYS This motorcycle has two keys ( 1 ) and a key number plate ( 2 ). You will need the key number if you ever have to replace a key. Store the plate in a safe place. To reproduce keys, bring all keys, key number plate and motorcycle to your dealer. TU, IITU U, IIU (2) (2) (1) (1) Key (1) (2) Key number plate 41 11/05/07 10:07:52 32KVCC00_052 SHUTTER (TU, IITU) This motorcycle has equipped the ignition switch with the shutter, when separating from motorcycle, lets close a shutter for theft prevention. To close the shutter, ignition key is removed, align the projection ( 1 ) of the shutter key ( 2 ) with the slot ( 3 ) of the shutter, and turn the shut ter key counterclockwise or move the knob ( 4 ) downward. To open the shutter, align the projection of the shutter key with the slot of the shutter, and turn the shutter key clockwise. (2) (3) (1) Projection (2) Shutter key 42 〈CLOSE〉 (4) 〈OPEN〉 (1) (3) Slot (4) Knob 11/05/07 10:08:00 32KVCC00_053 RIGHT HANDLEBAR CONTROLS Engine Stop Switch (U, IIU) The engine stop switch ( 1 ) is next to the throttle grip. When the switch is in the (RUN) position, the engine will operate. When the switch is in the (OFF) position, the engine will not operate. This switch is intended primarily as an emergency switch and should normally remain in the (RUN) position. Start Button The start button ( 2 ) is next to the throttle grip. When the start button is pressed, the starter motor cranks the engine. See page 54 for the starting procedure. (U, IIU) If your motorcycle is stopped with the ignition switch ON and the engine stop switch (OFF), the headlight, position light, taillight and license light will still be on, resulting in battery discharge. (1) (2) (1) Engine stop switch (2) Start button 43 11/05/07 10:08:09 32KVCC00_054 LEFT HANDLEBAR CONTROLS (2) Headlight Dimmer Switch ( 1) Push the dimmer switch to (HI) to select high beam or to (LO) to select low beam. (1) Passing Light Control Switch ( 2 ) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing. (3) Turn Signal Switch ( 3) Move to to signal a left turn, to signal a right turn. Press to turn signal off. (4) Horn Button ( 4 ) Press the button to sound the horn. (1) (2) (3) (4) 44 Headlight dimmer switch Passing light control switch Turn signal switch Horn button 11/05/07 10:08:16 32KVCC00_055 FEATURES (Not required for operation) STEERING LOCK To lock the steering, turn the handlebars all the way to the left or right, turn the key ( 1 ) to (LOCK) while pushing in. Remove the key. T o unlock the steering, turn the key to (OFF). To lock (A ) (1) (B) Do not turn the key to (LOCK) while riding the motorcycle; loss of vehicle control will result. (C) To unlock (1) Ignition key (A) Push in (B) Turn to LOCK (C) Turn to OFF 45 11/05/07 10:08:24 32KVCC00_056 SEAT To remove the seat ( 1 ), insert the ignition key into the seat lock ( 2 ) and turn it clockwise. Pull the seat back and up. To install the seat, insert the front prong ( 3 ) into the front stay ( 4 ) and the rear prongs ( 5 ) into the rear stays ( 6 ) on the frame. Push forward and then down on the rear of the seat. (5) (3) (1) Be sure the seat is locked securely in position after installation. (2) (4) (1) Seat (2) Seat lock (3) Front prong 46 (6) (4) Front stay (5) Rear prongs (6) Rear stays 11/05/07 10:08:29 32KVCC00_057 DOCUMENT COMPARTMENT The document compartment ( 1 ) is located under the seat (page 46 ). This owner’s manual and other documents should be stored in this compartment. When washing your motorcycle, be careful not to flood this area with water. (1) (1) Document compartment 47 11/05/07 10:08:39 32KVCC00_058 LEFT SIDE COVER The left side cover must be removed for fuse maintenance, and to access the tool kit. (3) Removal: 1. Insert the ignition key ( 1 ) into the lock and turn it clockwise. 2. Carefully pull the side cover ( 2 ) out from the grommets ( 3 ). Installation: 1. Align the prongs with the grommets. 2. Push the side cover while turning the ignition key clockwise. (2) (1) (1) Ignition key (2) Side cover 48 (3) Grommets 11/05/07 10:08:49 32KVCC00_059 RIGHT SIDE COVER The right side cover must be removed for battery and main fuse maintenance. (3) Removal: 1. Remove the screw ( 1 ). 2. Carefully pull the side cover ( 2 ) out from the grommets ( 3 ). Installation: 1. Align the prongs with the rubber grommets. 2. Push the prongs in. 3. Install the screw. (1) (1) Screw (2) Side cover (2) (3) Grommets 49 11/05/07 10:08:58 32KVCC00_060 HEADLIGHT AIM VERTICAL ADJUSTMENT Vertical adjustment can be made by moving the headlight case ( 1 ) as necessary. (TU, IITU) (1) (TU, IITU) To move the headlight case, loosen the bolt ( 2 ). Tighten the bolt after adjustment. Obey local laws and regulations. (U, IIU) To move the headlight case, loosen the bolts ( 3 ). Tighten the bolts after adjustment. Obey local laws and regulations. (A ) (B) (2) (U, IIU) (3) (1) (A ) (B) (1) Headlight case (2) Bolt (3) Bolts 50 (A) Up (B) Down 11/05/07 10:09:09 32KVCC00_061 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 dealer. 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. 1. Fuel level−Fill fuel tank when necessary (page 31 ). 2. Throttle−Check for smooth opening and full closing in all steering positions (page 82 ). 3. Engine oil level−Add engine oil if necessary (page 34 ). Check for leaks. 4. Drive chain−Check condition and slack, adjust and lubricate if necessary (page 84 ). 5. (Type II) Brakes − Check operation; Front: check brake fluid level and pads wear (pages 21 − 22 , 99 ). Rear: check shoes wear and freeplay, adjust if necessary (pages 26 − 27 , 100). (Type I) Brakes − Check operation; Front and Rear: check shoes wear and freeplay, adjust if necessary (pages 23 − 25 , 26 − 27 , 100). 51 11/05/07 10:09:15 32KVCC00_062 6. Lights and horn−Check that lights, indicators and horn function properly. 7. (U, IIU) Engine stop switch−Check for proper function (page 43 ). 8. Side stand ignition cut-off system−Check for proper function (page 92 ). 9. Wheels and tyres − Check condition, air pressure and adjust if necessary (pages 35 − 39 ). 52 11/05/07 10:09:24 32KVCC00_063 STARTING THE ENGINE Always follow the proper starting procedure described below. This motorcycle is equipped with a side stand ignition cut-off system. The engine cannot be started if the side stand is down, unless the transmission is in neutral. If the side stand is up, the engine can be started in neutral or in gear with the clutch lever pulled in. After starting with the side stand down, the engine will shut off if the transmission is put in gear before raising the side stand. (TU, IITU) To protect the catalytic converters in your motorcycle’s exhaust system, avoid extending idling and the use of leaded petrol. Y our motorcycle’s exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. Do not run the engine with the garage door closed. Even with the door open, run the engine only long enough to move your motorcycle out of the garage. Do not use the electric starter for more than 5 seconds at a time. Release the start button for approximately 10 seconds before pressing it again. Preparation Before starting, insert the key, turn the ignition switch (ON) and confirm the following: The transmission is in neutral (neutral indicator is ON). (U, IIU) The engine stop switch is at (RUN). The fuel valve is ON. 53 11/05/07 10:09:35 32KVCC00_064 Starting Procedure To restart a warm engine, follow the procedure for ‘‘High Air Temperature.’’ Normal Air Temperature 10°−35°C (50°−95°F) 1. Pull the choke lever ( 1 ) back all the way to Fully ON (A ), if the engine is cold. 2. With the throttle closed, press the start button. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. (1) (B) Do not use the electric starter for more than 5 seconds at a time. Release the start button for approximately 10 seconds before pressing it again. 3. Immediately after the engine starts, operate the choke lever to keep fast idle. 4. About a quarter minute after the engine starts, push the choke lever forward all the way to Fully OFF ( B). 5. If idling is unstable, open the throttle slightly. 54 (A ) (1) Choke lever (A) Fully ON (B) Fully OFF 11/05/07 10:09:41 32KVCC00_065 High Air Temperature 35°C (95°F) or above 1. Do not use the choke. 2. With the throttle 1/8−1/4 open, press the start button. Low Air Temperature 10°C (50°F) or below 1. Follow steps 1 − 2 under ‘‘Normal Air Temperature.’’ 2. When engine speed begins to pick up, operate the choke lever to keep fast idle. 3. Continue warming up the engine until it runs smoothly and responds to the throttle, when the choke lever is at Fully OFF ( B). 55 11/05/07 10:09:45 32KVCC00_066 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 ignition switch to (ON) and move the choke lever to Fully OFF ( B). Open the throttle fully and press the start button for 5 seconds. If the engine starts, quickly close the throttle, then open it slightly if idling is unstable. If the engine does not start, wait 10 seconds, then follow the Starting Procedure. 56 11/05/07 10:09:48 32KVCC00_067 RUNNING-IN Help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first 500 km (300 miles). During this period, avoid full-throttle starts and rapid acceleration. 57 11/05/07 10:09:55 32KVCC00_068 RIDING Review Motorcycle Safety (pages 1 − 12 ) before you ride. Make sure you understand the function of the side stand mechanism. (See MAINTENANCE SCHEDULE on page 68 and explanation for SIDE STAND on page 92 ). (TU, IITU) 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. 1. After the engine has been warmed up, the motorcycle is ready for riding. 2. While the engine is idling, pull in the clutch lever and depress the shift lever to shift into 1st (low) gear. 58 3. Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throt tle. 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 shift lever. T his sequence is repeated to progressively shift to 3rd, 4th and 5th (top) gears. 11/05/07 10:10:00 32KVCC00_069 5. Raise the shift lever to shift to a higher gear and depress the shift lever to shift to a lower gear. Each stroke of the shift lever engages the next gear in sequence. The shift lever automatically returns to the horizontal position when released. 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 vehicle control. Do not shift gears without disengaging the clutch and closing the throttle. The engine and drive train could be damaged by overspeed and shock. Do not tow the motorcycle or coast for long distances while the engine is off. The transmission will not be properly lubricated and damage may result. Do not run the engine at high rpm with the transmission in neutral or the clutch lever pulled in. Serious engine damage may result. 59 11/05/07 10:10:09 32KVCC00_070 BRAKING (Type II) Your motorcycle is equipped with a hydraulically-activated disc brake in front and a mechanically-activated drum brake at the rear. Operating the brake lever applies the front disc brake. Depressing the brake pedal applies the rear drum brake. (Type I) Y our mot orcycle is equipped w it h mechanically-activated drum brakes. Operating the brake lever applies the front drum brake. Depressing the brake pedal applies the rear drum brake. 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. 60 Important Safety Reminders: Independent operation of only the brake lever or brake pedal reduces stopping performance. Extreme application of the brake controls may cause wheel lock, reducing control of the motorcycle. When possible, reduce speed or brake before entering a turn; closing the throttle or braking in mid-turn may cause wheel slip. Wheel slip will reduce control of the motorcycle. 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. 11/05/07 10:10:16 32KVCC00_071 When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness. Riding with your foot resting on the brake pedal or your hand on the brake lever may actuate the brakelight, giving a false indication to other drivers. It may also overheat the brakes, reducing effectiveness. PARKING 1. After stopping the motorcycle, shift the transmission into neutral, turn the fuel valve OFF, turn the handlebar fully to the left, turn the ignition switch (OFF) and remove the key. 2. Use the side or center stand to support the motorcycle while parked. Park the motorcycle on firm, level ground to prevent it from falling over. If you must park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility of overturning or rolling off the center or side stand. 3. Lock the steering to help prevent theft (page 45 ). 61 11/05/07 10:10:22 32KVCC00_072 (TU, IITU) 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. ANTI-THEFT TIPS 1. Always lock the steering and never leave the key in the ignition switch. This sounds simple but people do forget. 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: PHONE NO: 62 11/05/07 10:10:29 32KVCC00_073 MAINTENANCE THE IMPORTANCE OF MAINTENANCE A well-maintained motorcycle is essential for safe, economical and trouble-free riding. It will also help reduce air pollution. To help you properly care for your motorcycle, the following pages include a Maintenance Schedule and a Maintenance R ecord f or 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 f requent service than specified in the Maintenance Schedule. Consult your dealer for recommendations applicable to your individual needs and use. If your motorcycle overturns or becomes involved in a crash, be sure your dealer inspects all major parts, even if you are able to make some repairs. Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. 63 11/05/07 10:10:33 32KVCC00_074 MAINTENANCE SAFETY This section includes instructions on some important maintenance tasks. You can perform some of these tasks with the tools provided − if you have basic mechanical skills. Other tasks that are more difficult and require special tools are best performed by professionals. Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service. Some of the most important saf ety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. 64 Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual. 11/05/07 10:10:40 32KVCC00_075 SAFETY PRECAUTIONS Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. Burns from hot parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Read the instructions before you begin, and make sure you have the tools and skills required. To help prevent the motorcycle from falling over, park it on a firm, level surface, using the center stand or a maintenance stand to provide support. To reduce the possibility of a fire or explosion, be careful when working around petrol or batteries. Use only nonflammable solvent, not petrol, to clean parts. Keep cigarettes, sparks and flames away from the battery and all fuel-related 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 Honda Genuine Parts or their equivalents for repair and replacement. 65 11/05/07 10:10:50 32KVCC00_076 MAINTENANCE SCHEDULE Perform the Pre-ride Inspection (page 51 ) at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE The following items require some mechanical knowledge. Certain items (particularly those marked ＊ and ＊＊ ) may require more technical information and tools. Consult your dealer. Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the Official Honda Shop Manual. In the interest of safety, we recommend these items be serviced only by your dealer. Honda recommends that your dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 66 1. At higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or at full throttle. 4. Replacement requires mechanical skill. 5. Replace the PAIR air filter every 3 years or 24,000 km (16,000 mile). Replacement requires mechanical skill. 11/05/07 10:11:01 32KVCC00_077 ITEMS FUEL LINE FUEL LEVEL FUEL STRAINER SCREEN T HR OT T L E OPERATION CHOKE OPERATION AIR CLEANER CR A NK CA SE BREATHER SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL STRAINER SCREEN ENGINE OIL CENTRIFUGAL FILTER ENGINE IDLE SPEED SECONDARY AIR SUPPLY SYSTEM FREQUENCY (NOTE 1) PRE-RIDE ANNUAL REGULAR Refer 4 8 12 CHECK REPLACE to CHECK × 1,000 km 1 (page 51 ) × 1,000 mi 0.6 2.5 5 7.5 page − I I I I 2 years (NOTE 4) − I − C C C NOTE I (NOTE 2) (NOTE 3) I I I I 82 I I I I − − 72 EVERY 16,000 km (10,000 mi) R I I R C C C I I R R I R I I R C C 77 79 34, 73 − R − C I (NOTE 5) I I I I I I 3 years 83 − 67 11/05/07 10:11:12 32KVCC00_078 ITEMS DRIVE CHAIN BRAKE FLUID (DISC BRAKE ONLY) BRAKE SHOES WEAR (DRUM BRAKE ONLY) BRAKE SHOES/PADS WEAR (DISC BRAKE ONLY) BRAKE SYSTEM (DISC BRAKE ONLY) BRAKE SYSTEM (DRUM BRAKE ONLY) BRAKELIGHT SWITCH HEADLIGHT AIM LIGHTS/HORN ENGINE STOP SWITCH CLUTCH SYSTEM SIDE STAND SUSPENSION NUTS, BOLTS, FASTENERS WHEELS/TYRES STEERING HEAD BEARINGS 68 FREQUENCY (NOTE 1) ANNUAL REGULAR Refer PRE-RIDE 4 8 12 CHECK REPLACE to CHECK × 1,000 km 1 (page 51 ) × 1,000 mi 0.6 2.5 5 7.5 page EVERY 1,000 km (600 mi) I, L I 84 I (NOTE 4) 2 years I I I I 22 NOTE I I I I I 100 I I I I I 99, 100 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 21-22, 99 23-27, 100 107 50 − − 28 92 91 − I I I I I I 35 − I I I I I I I I 11/05/07 10:11:24 32KVCC00_079 TOOL KIT The tool kit ( 1 ) is in the tool box ( 2 ) behind the left side cover (page 48 ). Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. 8 mm Open end wrench 10 × 12 mm Open end wrench 14 × 17 mm Open end wrench Pliers Spark plug wrench No. 2 Phillips screwdriver No. 2 screwdriver Extension bar Tool bag Pin spanner (2) (1) (1) Tool kit (2) Tool box 69 11/05/07 10:11:33 32KVCC00_080 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 f or your reference. FRAME NO. The frame number ( 1 ) is stamped on the right side of the steering head. The engine number ( 2 ) is stamped on the left side of the crankcase. ENGINE NO. (1) (2) (1) Frame number 70 (2) Engine number 11/05/07 10:11:39 32KVCC00_081 COLOUR LABEL The colour label ( 1 ) is attached to the frame behind the left side cover (page 48 ). It is helpful when ordering replacement parts. Record the colour and code here for your reference. COLOUR CODE (1) (1) Colour label 71 11/05/07 10:11:45 32KVCC00_082 CRANKCASE BREATHER Refer to the Safety Precautions on page 65 . 1. Remove the crankcase breather tube ( 1 ) from the air cleaner housing and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube. Service more frequently when riding in rain or at full throttle. (1) (1) Crankcase breather tube 72 11/05/07 10:11:59 32KVCC00_083 ENGINE OIL Refer to the Safety Precautions on page 65 . Oil Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label Viscosity SAE 10W-30 JASO T 903 standard MA Suggested Oil Honda ‘‘4-STROKE MOTORCYCLE OIL’’ or equivalent. Your motorcycle does not need oil additives. Use the recommended oil. Do not use oils w ith graphit e 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 affect lubrication and clutch performance. NOT RECOMMENDED OK Do not use non-detergent, vegetable, or castor based racing oils. 73 11/05/07 10:12:07 32KVCC00_084 Viscosity: Viscosity grade of engine oil should be based on average atmospheric temperature in your riding area. The following provides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures. JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification. (1) (2) (1) Oil code (2) Oil classification 74 11/05/07 10:12:14 32KVCC00_085 Engine Oil Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule (page 67 ). When running in very dusty conditions, oil changes should be perf ormed more f requently than specif ied 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. Changing the oil requires a torque wrench. If you do not have it and the necessary skill, we recommend that you have your dealer perform this service. If a torque wrench is not used for this installation, see your dealer as soon as possible to verify proper assembly. Change the engine oil with the engine at normal operating temperature and the motorcycle on its center stand to assure complete and rapid draining. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. 75 11/05/07 10:12:23 32KVCC00_086 1. Place a drain pan under the crankcase. 2. To drain the oil, remove the oil fill cap/ dipstick, oil drain bolt ( 1 ), and sealing washer ( 2 ). (2) (1) Oil drain bolt (2) Sealing washer 76 (1) 3. Check that the sealing washer on the drain bolt is in good condition and install the bolt. Replace the sealing washer every other time the oil is changed, or each time if necessary. Engine oil drain bolt torque: 30 N·m (3.0 kgf·m , 22 lbf·ft) 4. Fill the crankcase with the recommended grade oil; approximately: 0.8 (0.8 US qt , 0.7 Imp qt) 5. Install the oil fill cap/dipstick. 6. Start the engine and let it idle for 3−5 minutes. 7. 2−3 minutes after stopping the engine, check that the oil level is at the upper level mark on the oil fill cap/dipstick with the motorcycle upright on firm, level ground. Make sure there are no oil leaks. 11/05/07 10:12:34 32KVCC00_087 SPARK PLUG Refer to the Safety Precautions on page 65 . Recommended plugs: Standard: CPR7EA−9 (NGK) For extended high speed riding: CPR8EA−9 (NGK) 1. Disconnect the spark plug cap ( 1 ) from the spark plug. 2. Clean any dirt from around the spark plug base. Remove the spark plug using a spark plug wrench ( 2 ) furnished in the tool kit (page 69 ). (2) Never use a spark plug with an improper heat range. Severe engine damage could result. (1) (1) Spark plug cap (2) Spark plug wrench 77 11/05/07 10:12:47 32KVCC00_088 3. Visually inspect the spark plug electrodes for wear. The center electrode should have square edges and the side electrode should not be eroded. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. 4. Check the spark plug gap ( 3 ) using a wire-type feeler gauge. If adjustment is necessary, bend the side electrode ( 4 ) carefully. The gap should be: 0.80−0.90 mm (0.031−0.035 in) (4) 5. Make sure the plug washer is in good condition. 6. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 7. Tighten the spark plug: If the old plug is good: 1/8 turn after it seats. If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats. (3) An improperly tightened spark plug 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. 8. Reinstall the spark plug cap. Take care to avoid pinching any cables or wires. (3) Spark plug gap (4) Side electrode 78 11/05/07 10:12:57 32KVCC00_089 VALVE CLEARANCE Refer to the Safety Precautions on page 65 . Excessive valve clearance will cause noise and eventual engine damage. Little or no clearance will prevent the valve from closing and cause valve damage and power loss. Check valve clearance when the engine is cold at the specified intervals. 1. Remove the crankshaft hole cap ( 1 ) and timing hole cap ( 2 ). 2. Remove the bolts ( 3 ) and cylinder head cover bolts ( 4 ). 3. Remove the cylinder head cover ( 5 ). (4) (4) The checking or adjusting of the clearance should be performed while the engine is cold. The clearance will change as the engine temperature rises. (5) (2) (1) (3) Bolts (4) Cylinder head cover bolts (5) Cylinder head cover (3) (1) Crankshaft hole cap (2) Timing hole cap 79 11/05/07 10:13:02 32KVCC00_090 4. Rotate the generator flywheel counterclockwise until the T mark ( 6 ) on the flywheel lines up with the index mark ( 7 ) on the crankcase. In this position, the piston may either be on the compression or exhaust stroke. The adjustment must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed. This condition can be determined by moving the rocker arms. If they are free, it is an indication that the valves are closed and that the piston is on the compression stroke. If they are tight and the valves are open, rotate the flywheel 360° and realign the T mark to the index mark. 80 (7) (6) (6) T mark (7) Index mark 11/05/07 10:13:10 32KVCC00_091 5. Check the clearance of both valves by inserting a feeler gauge ( 8 ) between the adjusting screw ( 9 ) and the valve stem. Clearance should be: Intake: 0.08 mm (0.003 in) Exhaust: 0.12 mm (0.005 in) 6. If it is necessary to make an adjustment, loosen the adjusting screw lock nut ( 10 ) and turn the adjusting screw so there is a slight resistance when the feeler gauge is inserted. 7. After completing the adjustment, tighten the adjusting screw lock nut while holding the adjusting screw to prevent it from turning. Adjusting screw lock nut torque: 14 N·m (1.4 kgf·m , 10 lbf·ft) 8. Finally, recheck the clearance to make sure that the adjustment has not been disturbed. Reinstall the cylinder head cover, timing mark hole cap and the crankshaft hole cap. 9. Install the remaining parts in the reverse order of removal. If a torque wrench is not used for this installation, see your dealer as soon as possible to verify proper assembly. (9) (8) (10) (8) Feeler gauge (9) Adjusting screw (10) Adjusting screw lock nut 81 11/05/07 10:13:15 32KVCC00_092 THROTTLE OPERATION Refer to the Safety Precautions on page 65 . Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. 82 11/05/07 10:13:23 32KVCC00_093 IDLE SPEED Refer to the Safety Precautions on page 65 . The engine must be at normal operating temperature for accurate idle speed adjustment. 10 minutes of stop-and-go riding is sufficient. Do not attempt to compensate for faults in other systems by adjusting idle speed. See your dealer for regularly scheduled carburetor adjustments. 1. Warm up the engine, shift to neutral and place the motorcycle on its center stand. 2. Adjust idle speed with the throttle stop screw ( 1 ). Idle speed (In neutral): 1,400 ± 100 min (rpm) (1) (A ) (1) Throttle stop screw (B) (A) Increase (B) Decrease 83 11/05/07 10:13:34 32KVCC00_094 DRIVE CHAIN Refer to the Safety Precautions on page 65 . The service life of the drive chain ( 1 ) 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, adjusted and lubricated as part of the Preride Inspection (page 51 ). Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary. Inspection: 1. Turn the engine off, place the motorcycle on its center stand, and shift the transmission into neutral. 2. Check slack in the lower drive chain run midway between the sprockets. Drive chain slack should be adjusted to allow the following vertical movement by hand: 20−30 mm (0.8−1.2 in) 84 3. Rotate the rear wheel. Stop. Check the drive chain slack. Repeat this procedure several times. Drive chain slack should remain constant. If the chain is slack only in certain sections, some links are kinked and binding. Binding and kinking can frequently be eliminated by lubrication. Excessive chain slack may allow the drive chain to damage the engine cases. (1) (1) Drive chain 11/05/07 10:13:41 32KVCC00_095 4. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Damaged Sprocket Teeth REPLACE Worn Sprocket Teeth REPLACE Normal Sprocket Teeth GOOD If the drive chain or sprockets are excessively worn or damaged, they should be replaced. Never use a new chain with worn sprockets; rapid chain wear will result. 85 11/05/07 10:13:50 32KVCC00_096 Adjustment: Drive chain slack should be checked and adjusted, if necessary, every 1,000 km (600 miles). When operated at sustained high speeds or under conditions of frequent rapid acceleration, the chain may require more frequent adjustment. (2) (3) (5) (1) Axle nut (2) Drive chain lock nut (3) Drive chain adjusting nut 86 (1) (4) (4) Index mark (5) Drive chain adjuster If the drive chain requires adjustment, the procedure is as follows: 1. Place the motorcycle on its center stand on a firm, level surface with the transmission in neutral and the ignition switch OFF. 2. Loosen the axle nut ( 1 ). 3. Loosen the drive chain lock nuts ( 2 ) on both sides of the swingarm. 4. Turn both drive chain adjusting nuts ( 3 ) an equal number of turns until the correct drive chain slack is obtained. Turn the drive chain adjusting nuts clockwise to tighten the chain, or counterclockwise to provide more slack. Adjust the chain slack at a point midway between the drive sprocket and the rear wheel sprocket. Rotate the rear wheel and recheck slack at other sections of the chain. Chain slack should be: 20−30 mm (0.8−1.2 in) 11/05/07 10:13:59 32KVCC00_097 5. Check the rear axle alignment by making sure the drive chain adjuster index marks ( 4 ) align with the front edge of the drive chain adjusters ( 5 ). Both left and right marks should correspond. If the axle is misaligned, turn the left or right drive chain adjusting nut until the marks correspond on the front edge of the drive chain adjusters and recheck chain slack. 7. Tighten the drive chain adjusting nuts lightly, then tighten the drive chain lock nuts by holding the drive chain adjusting nuts with a spanner. 8. Recheck drive chain slack. 9. Rear brake pedal freeplay is affected when repositioning the rear wheel to adjust drive chain slack. Check rear brake pedal freeplay and adjust as necessary (page 26 ). If the drive chain slack is excessive when the rear axle is moved to the furthest limit of adjustment, the drive chain is worn and must be replaced. Damage to the bottom part of the frame may be caused by excessive drive chain slack of more than: 50 mm (2.0 in) 6. Tighten the rear axle nut to the specified torque. Rear axle nut torque: 68 N·m (6.9 kgf·m , 50 lbf·ft) If a torque wrench is not used for this installation, see your dealer as soon as possible to verify proper assembly. 87 11/05/07 10:14:04 32KVCC00_098 Lubrication: Lubricate every 1,000 km (600 miles) or sooner if chain appears dry. Use SAE 80 or 90 gear oil or a commercially prepared drive chain lubricant s in preference to motor oil or other lubricants. Saturate each chain link joint so that the lubricant penetrates between the link plates, pins, bushings, and rollers. Chain: 428H−120 88 11/05/07 10:14:15 32KVCC00_099 Removal and Cleaning: When the drive chain becomes dirty, it should be removed and cleaned prior to lubrication. 1. With the engine off, carefully remove the master link retaining clip ( 1 ) with a pair of pliers. Do not bend or twist the clip. Remove the master link. Remove the drive chain from the motorcycle. 2. Clean the drive chain in high flash-point solvent and allow it to dry. Inspect the drive chain for possible wear or damage. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Never use a new drive chain on badly worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain or sprocket will wear rapidly. 4. Lubricate the drive chain (page 88 ). (1) Never use petrol or low flash point solvents for cleaning the drive chain. A fire or explosion could result. 3. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. (1) Master link retaining clip 89 11/05/07 10:14:19 32KVCC00_100 5. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. The master link is the most critical part affecting the security of the drive chain. Master links are reusable, if they remain in excellent condit ion, but it is recommended that a new master link retaining clip be installed whenever the drive chain is reassembled. Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. 6. Adjust the drive chain (page 86 ) and rear brake pedal freeplay (page 26 ). (1) (1) Master link retaining clip 90 11/05/07 10:14:25 32KVCC00_101 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page 65 . 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 bushings should be checked by pushing hard against the side of the rear wheel while the motorcycle is on the center stand and feeling for looseness of the bushings. 3. Carefully inspect all front and rear suspension fasteners for tightness. 91 11/05/07 10:14:33 32KVCC00_102 SIDE STAND Refer to the Safety Precautions on page 65 . Perform the following maintenance in accordance with the maintenance schedule. Functional Check: Check the side stand spring ( 1 ) for damage or loss of tension and the side stand assembly for freedom of movement. Check the side stand ignition cut-off system: 1. Sit astride the motorcycle; put the side stand up and the transmission in neutral. 2. Start the engine and with the clutch lever pulled in, shift the transmission into gear. 3. Lower the side stand. The engine should stop as you put the side stand down. If the side stand system does not operate as described, see your dealer for service. 92 (1) (1) Side stand spring 11/05/07 10:14:46 32KVCC00_103 WHEEL REMOVAL Refer to the Safety Precautions on page 65 . (1) Front Wheel Removal (Type II) 1. Place the motorcycle on its center stand. 2. Raise the front wheel off the ground by placing a support block under the engine. 3. Remove the speedometer cable ( 1 ) by removing the screw ( 2 ). 4. Remove the front axle nut cap ( 3 ). 5. Remove the front axle nut ( 4 ). 6. Remove the front axle shaft ( 5 ), front wheel and side collar. Do not depress the brake lever 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 dealer for this service. (3) (4) (2) (5) (1) Speedometer cable (2) Screw (3) Front axle nut cap (4) Front axle nut (5) Front axle shaft 93 11/05/07 10:14:56 32KVCC00_104 (Type I) 1. Place the motorcycle on its center stand. 2. Raise the front wheel off the ground by placing a support block under the engine. 3. Remove the speedometer cable ( 1 ) by removing the screw ( 2 ). 4. Remove the front brake adjusting nut ( 3 ) and remove the front brake cable ( 4 ) from the brake arm ( 5 ). 5. Remove the front axle nut cap ( 6 ). 6. Remove the front axle nut ( 7 ). 7. Remove the front axle shaft ( 8 ), front wheel and side collar. (7) (2) (5) (1) (3) (4) (6) (8) (1) Speedometer cable (2) Screw (3) Front brake adjusting nut (4) Front brake cable 94 (5) (6) (7) (8) Brake arm Front axle nut cap Front axle nut Front axle shaft 11/05/07 10:15:09 32KVCC00_105 Front Wheel Installation (Type II) 1. Install the side collar into the right side wheel hub. 2. Position the wheel between the fork legs and insert the front axle shaft from the right side, through the right fork leg and wheel hub. 3. To avoid damaging the brake pads while installing the wheel, carefully fit the brake disc between the pads. 4. Make sure that the lug ( 1 ) on the fork leg is located in the slot ( 2 ) on the speedometer gearbox ( 3 ). 5. Tighten the front axle nut to the specified torque. Front axle nut torque: 59 N·m (6.0 kgf·m , 44 lbf·ft) 6. After installing the wheel, apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely. 7. Install the speedometer cable and tighten the screw securely. 8. Install the front axle nut cap. If a torque wrench is not used for installation, see your dealer as soon as possible to verif y proper assembly. Improper assembly may lead to loss of braking capacity. (2) (1) (3) (1) Lug (2) Slot (3) Speedometer gearbox 95 11/05/07 10:15:20 32KVCC00_106 (Type I) 1. Install the side collar into the right side wheel hub. 2. Position the wheel between the fork legs and insert the front axle shaft from the right side, through the right fork leg and wheel hub. 3. Make sure that the lug ( 1 ) on the left fork leg is located in the slot ( 2 ) of the brake panel ( 3 ). 4. Tighten the front axle nut to the specified torque. Front axle nut torque: 59 N·m (6.0 kgf·m , 44 lbf·ft) 5. Adjust the front brake (pages 23 − 25 ). 6. After installing the wheel, apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely. 7. Install the speedometer cable and tighten the screw securely. 8. Install the front axle nut cap. If a torque wrench is not used for installation, see your dealer as soon as possible to verif y proper assembly. Improper assembly may lead to loss of braking capacity. (3) (2) (1) Lug (2) Slot 96 (1) (3) Brake panel 11/05/07 10:15:31 32KVCC00_107 Rear Wheel Removal 1. Place the motorcycle on its center stand. 2. Remove the rear brake adjusting nut ( 1 ). Disconnect the brake rod ( 2 ) from the brake arm ( 3 ). (8) (11) (9) (7) (3) (1) 3. Disconnect the brake stopper arm ( 4 ) from the brake panel by removing the cotter pin ( 5 ), stopper arm nut ( 6 ), washer and rubber grommet. 4. Loosen the drive chain lock nuts ( 7 ) and drive chain adjusting nuts ( 8 ). 5. Remove the rear axle nut ( 9 ). 6. Remove the rear axle shaft ( 10 ), drive chain adjusters ( 11 ) and side collars, then remove the drive chain ( 12 ) from the driven sprocket by pushing the rear wheel forward. 7. Remove the rear wheel f rom the motorcycle. (11) (8) (6) (5) (2) (1) Rear brake adjusting nut (2) Brake rod (3) Brake arm (4) Brake stopper arm (5) Cotter pin (4) (6) Stopper arm nut (7) Drive chain lock nuts (8) Drive chain adjusting nuts (9) Rear axle nut (7) (10) (10) Rear axle shaft (11) Drive chain adjusters (12) (12) Drive chain 97 11/05/07 10:15:40 32KVCC00_108 Rear Wheel Installation 1. Install the side collars into the left and right side wheel hub. 2. Tighten the rear axle nut and brake stopper arm nut to specified torque. Rear axle nut torque: 68 N·m (6.9 kgf·m , 50 lbf·ft) Brake stopper arm nut torque: 10 N·m (1.0 kgf·m , 7 lbf·ft) 3. Adjust the brake (page 26 ) and drive chain (page 84 ). 4. After installing the wheel, apply the brake several times and check for free wheel rotation when released. A used cotter pin may not effectively secure a fastener. Always replace a used cotter pin with a new one. 98 If a torque wrench is not used for installation, see your dealer as soon as possible to verif y proper assembly. Improper assembly may lead to loss of braking capacity. 11/05/07 10:15:47 32KVCC00_109 BRAKE PAD WEAR (Type II) Refer to the Safety Precautions on page 65 . 〈FRONT BRAKE〉 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 t he pa ds a t each r egular maintenance interval (page 68 ). Front Brake Check the wear indicator marks ( 1 ) on each pad. If either pad is worn to the wear indicator mark, replace both pads as a set. See your dealer for this service. (1) (1) Wear indicator marks 99 11/05/07 10:15:56 32KVCC00_110 BRAKE SHOE WEAR Refer to the Safety Precautions on page 65 . 〈FRONT BRAKE〉(Type I) (1) (3) (Type I) The front and rear brakes are equipped with brake wear indicators. (Type II) The rear brake is equipped with a brake wear indicator. When the brake is applied, an arrow ( 1 ) attached to the brake arm ( 2 ) moves toward a reference mark ( 3 ) on the brake panel ( 4 ). If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced. See your dealer for this service. When the brake service is necessary, see your dealer. Use only Honda Genuine Parts or its equivalent. (4) (2) 〈REAR BRAKE〉 (1) (3) (4) (2) (1) Arrow (2) Brake arm 100 (3) Reference mark (4) Brake panel 11/05/07 10:16:04 32KVCC00_111 BATTERY Refer to the Safety Precautions on page 65 . It is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance-free (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), contact your dealer. An improperly disposed of battery can be harmful to the environment and human health. Always confirm local regulations for battery disposal. The battery gives off explosive hydrogen gas during normal operation. Your battery is a maintenance-free type and can be permanently damaged if the cap strip is removed. This symbol on the battery means that this product must not be treated as household waste. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance. 101 11/05/07 10:16:14 32KVCC00_112 Removal: 1. Make sure the ignition switch is OFF. 2. Remove the right side cover (page 49 ). 3. Remove the fuse holder ( 1 ) from the battery holder ( 2 ). 4. Disconnect the negative (−) terminal lead ( 3 ) from the battery first, then disconnect the positive (＋) terminal lead ( 4 ). 5. Remove the battery holder by removing the bolts ( 5 ). 6. Pull out the battery from the battery box. (2) Installation: 1. Reinstall in the reverse order of removal. Be sure to connect the positive (＋) terminal first, then the negative (−) terminal. 2. Check all bolts and other fasteners are secure. (4) (5) (1) (2) (3) (4) (5) 102 (3) Fuse holder Battery holder Negative (−) terminal lead Positive (＋) terminal lead Bolts (1) 11/05/07 10:16:20 32KVCC00_113 FUSE REPLACEMENT Refer to the Safety Precautions on page 65 . Blown fuse When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your dealer for repair. 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. 103 11/05/07 10:16:30 32KVCC00_114 Fuse Holder: The fuse holders ( 1 ) are located behind the left side cover. The specified fuses are: 10A, 15A 1. Remove the left side cover (page 48 ). 2. Remove the fuse holder from the fuse holder cover ( 2 ). 3. Open the fuse holder and lift out the old fuse ( 3 ) with the clips ( 4 ). 4. Slide the old fuse out of the clips and discard it. 5. Slide the clips onto the ends of the spare fuse ( 5 ), push them back into the fuse holder, and close the fuse holder. The spare fuse is attached to the fuse holder cover. 6. Close the fuse holder and install it in the fuse holder cover. 7. Install the left side cover. Do not pry the clips open to get a fuse out; you could bend them and cause poor contact with the new fuse. A loose fuse could cause damage to the electrical system and even start a fire. 104 (4) (1) (3) (4) (5) (2) (1) (2) (3) (4) (5) Fuse holders Fuse holder cover Old fuse Clips Spare fuse 11/05/07 10:16:42 32KVCC00_115 Main Fuse: The main fuse ( 1 ) is located behind the right side cover. The specified fuse is: 20A 1. Remove the right side cover (page 49 ). 2. Remove the fuse holder ( 2 ) from the battery holder ( 3 ). 3. Open the fuse holder and lift out the main fuse with the clips ( 4 ). 4. Slide the main fuse out of the clips and discard it. 5. Slide the clips onto the ends of the spare main fuse ( 5 ), push them back into the fuse holder, and close the fuse holder. The spare fuse is attached to the fuse holder. 6. Close the fuse holder and install it to the battery holder. 7. Install the right side cover. Do not pry the clips open to get a fuse out; you could bend them and cause poor contact with the new fuse. A loose fuse could cause damage to the electrical system and even start a fire. (4) (1) (2) (5) (4) (3) (1) (2) (3) (4) (5) Main fuse Fuse holder Battery holder Clips Spare main fuse 105 11/05/07 10:16:49 32KVCC00_116 If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating. REMOVAL (3) Pull up (3) (1) Replacing a fuse with one that has a higher rating greatly increases the chances of damaging the electrical system. (2) Slide INSTALLATION (1) Push in (3) (1) Fuse holder (2) Fuse 106 (3) Clips If the replacement fuse of the same rating burns out in a short time, there is probably a serious electrical problem on your motorcycle. Leave the blown fuse in that circuit and have your motorcycle checked by your dealer. 11/05/07 10:16:55 32KVCC00_117 BRAKELIGHT SWITCH ADJUSTMENT Refer to the Safety Precautions on page 65 . (1) (2) Check the operation of the brakelight switch ( 1 ) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut ( 2 ). Turn the nut in the direction (A ) if the switch operates too late and in direction ( B) if the switch operates too soon. (B) (A ) (1) Brakelight switch (2) Adjusting nut 107 11/05/07 10:17:04 32KVCC00_118 BULB REPLACEMENT Refer to the Safety Precautions on page 65 . The light bulb becomes very hot while the light is ON, and remains hot for a while after it is turned OFF. Be sure to let it cool down before servicing. (TU, IITU) Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break. Wear clean gloves while replacing the bulb. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. 108 Be sure to turn the ignition switch (OFF) when replacing the bulb. Do not use bulbs other than those specified. After installing a new bulb, check that the light operates properly. 11/05/07 10:17:15 32KVCC00_119 Headlight Bulb (TU, IITU) 1. Remove the bolts ( 1 ) from the front cowl ( 2 ). 2. Disconnect the connector ( 3 ). 3. Pull out the socket ( 4 ) without turning. 4. Remove the seat rubber ( 5 ). 5. Remove the headlight bulb ( 6 ) while pressing down on the pin ( 7 ). 6. Install a new bulb in the reverse order of removal. (5) (1) (4) (6) (7) (2) (1) Bolts (2) Front cowl (3) (3) Connector (7) (4) Socket (5) Seat rubber (6) Headlight bulb (7) Pin 109 11/05/07 10:17:26 32KVCC00_120 (U, IIU) 1. Remove the screws ( 1 ) from the headlight case. 2. Gently pull the lower end of the headlight ( 2 ) forward and remove the headlight. 3. Remove the seat rubber ( 3 ). 4. Remove the socket ( 4 ) while pressing down on the pin ( 5 ). 5. Slightly press the headlight bulb ( 6 ) and turn it counterclockwise. 6. Install a new bulb in the reverse order of removal. Install the dust cover with its ‘‘TOP’’ mark ( 7 ) facing up. (6) (4) (5) (2) (7) (3) (1) (1) Screws (2) Headlight 110 (3) Seat rubber (4) Socket (5) Pin (6) Headlight bulb (7) ‘‘TOP’’ mark 11/05/07 10:17:38 32KVCC00_121 Position Light Bulb (TU, IITU) 1. Remove the front cowl and disconnect the connector (page 109 ). 2. Pull the position light socket ( 1 ) and remove it. 3. Pull out the bulbs ( 2 ) without turning. 4. Install a new bulb in the reverse order of removal. (U, IIU) 1. Remove the headlight ( 1 ) (page 110 ). 2. Pull the position light socket ( 2 ) and remove it. 3. Pull out the bulb ( 3 ) without turning. 4. Install a new bulb in the reverse order of removal. (2) (2) (2) (3) (1) (1) Socket (2) Bulbs (1) (1) (1) Headlight (2) Socket (3) Bulb 111 11/05/07 10:17:44 32KVCC00_122 Brake/Tail Light Bulb 1. Remove the taillight lens ( 1 ) by removing the screws ( 2 ). 2. Slightly press the bulb ( 3 ) and turn it counterclockwise. 3. Install a new bulb in the reverse order of removal. (3) (1) (1) Taillight lens (2) Screws 112 (3) Bulb (2) 11/05/07 10:17:53 32KVCC00_123 Front/Rear Turn Signal Bulb 1. Remove the screw A ( 1 ). 2. Remove the reflector ( 2 ) and turn signal lens ( 3 ) by removing the screws B ( 4 ). 3. Slightly press the bulb ( 5 ) and turn it counterclockwise. 4. Install a new bulb in the reverse order of removal. (4) (2) (5) (3) (TU, IITU) Use only the amber bulb. (1) (1) Screw A (2) Reflector (3) Turn signal lens (4) Screws B (5) Bulb 113 11/05/07 10:18:00 32KVCC00_124 License Light Bulb 1. Remove the screws ( 1 ). 2. Remove the license light cover ( 2 ). 3. Pull out the bulb ( 3 ) without turning. 4. Install a new bulb in the reverse order of removal. (2) (3) (1) (1) Screws (2) License light cover (3) Bulb 114 11/05/07 10:18:10 32KVCC00_125 CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect for damage, wear, and oil or brake fluid leakage. Avoid cleaning products that are not specifically designed for motorcycle or automobile surfaces. They may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your motorcycle. If your motorcycle is still warm from recent operation, give the engine and exhaust system time to cool off. We recommend avoiding the use of high pressure water spray (typical in coinoperated car washes). High pressure water (or air) can damage certain parts of the motorcycle. Washing the Motorcycle 1. Rinse the motorcycle thoroughly with cool water to remove loose dirt. 2. Clean the motorcycle with a sponge or soft cloth using cool water. Avoid directing water to muffler outlets and electrical parts. 3. Clean the plastic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing it frequently with fresh water. Take care to keep brake fluid or chemical solvents off the motorcycle. They will damage the plastic and painted surfaces. The inside of the headlight lens may be clouded immediately after washing the motorcycle. Moisture condensation inside the headlight lens will disappear gradually by lighting the headlight in high beam. Run the engine while keeping the headlight on. 115 11/05/07 10:18:22 32KVCC00_126 4. After cleaning, rinse the motorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. 5. Dry the motorcycle, start the engine, and let it run for several minutes. 6. Test the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking performance. 7. Lubricate the drive chain immediately after washing and drying the motorcycle. Braking efficiency may be temporarily impaired immediately after washing the motorcycle. Anticipate longer stopping distance to avoid a possible accident. Finishing Touches After washing your motorcycle, consider using a comme r cia lly-a v a ilable spr a y cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instructions on the container. Removing Road Salt Road Salt used on roads during winter and salt from seawater causes rust. Wash your motorcycle as follows after it has run through salty water or on roads treated with Road Salt. 1. Clean the motorcycle using cool water (page 115 ). Do not use warm water. This worsens the effect of the salt. 2. Dry the motorcycle and make sure the metal is protected with the wax. 116 11/05/07 10:18:32 32KVCC00_127 Clean the Seat Due to the top coat design, the seat surface tends to catch and trap dirt or dust in its texture. Using plenty of water, clean the seat with a sponge and mild detergent. Painted Aluminum Wheel Maintenance Aluminum may corrode from contact with dirt, mud, or road salt. Clean the wheels af ter riding through any of these substances. Use a wet sponge and mild detergent. Avoid stiff brushes, steel wool, or cleaners containing abrasives or chemical compounds. After washing, dry with a soft, clean cloth. Exhaust Pipe and Muffler Maintenance When the exhaust pipe and muffler are painted, do not use a commercially available abrasive kitchen cleaning compound. Use a neutral detergent to clean the painted surface on the exhaust pipe and muffler. If you are not sure if your exhaust pipe and muffler are painted, contact your dealer. After washing, rinse with plenty of water and dry with a clean cloth. Clean the Mat Colour Painted Surface Using plenty of water, clean the mat colour painted surface with a soft cloth or sponge. Dry with a soft, clean cloth. Use neutral detergent to clean mat colour painted surface. Do not use waxes containing compounds. 117 11/05/07 10:18:40 32KVCC00_128 STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non-use of the motorcycle. In addition, necessary repairs should be made BEFORE storing the motorcycle; otherwise, these repairs may be forgotten by the time the motorcycle is removed from storage. STORAGE 1. Change the engine oil. 2. Empty the fuel tank into an approved petrol container using a commercially available hand siphon or an equivalent method. Spray the inside of the tank with an aerosol rust-inhibiting oil. Reinstall the fuel fill cap on the tank. To assure proper performance after storage lasting more than one month, it is important to drain the carburetor. 118 Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately. 11/05/07 10:18:47 32KVCC00_129 3. To prevent rusting in the cylinder, perform the following: Remove the spark plug cap from the spark plug. Using tape or string, secure the cap to any convenient plastic body part so that it is positioned away from the spark plug. Remove the spark plug from the engine and store it in a safe place. Do not connect the spark plug to the spark plug cap. Pour a tablespoon (15−20 cm ) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth. Crank the engine several times to distribute the oil. Reinstall the spark plug and spark plug cap. 4. Remove the battery. Store in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month. 5. Wash and dry the motorcycle. Wax all painted surfaces. Coat chrome with rustinhibiting oil. 6. Lubricate the drive chain (page 88 ). 7. Inflate 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. 119 11/05/07 10:18:53 32KVCC00_130 REMOVAL FROM STORAGE 1. Uncover and clean the motorcycle. 2. Change the engine oil if more than 4 months have passed since the start of storage. 3. Charge the battery as required. Install the battery. 4. Drain any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol. 5. Perform all Pre-ride Inspection checks (page 51 ). Test ride the motorcycle at low speeds in a safe riding area away from traffic. 120 11/05/07 10:18:58 32KVCC00_131 TAKING CARE OF THE UNEXPECTED IF YOU CRASH Personal safety is your first priority after a crash. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. Call f or emergency assistance if needed. Also follow applicable laws and regulations if another person or vehicle is involved in the crash. If there is minor damage, or you are unsure about possible damage, ride slowly and cautiously. Sometimes, crash damage is hidden or not immediately apparent, so you should have your motorcycle thoroughly checked at a qualified service facility as soon as possible. Also, be sure to have your dealer check the frame and suspension after any serious crash. If you decide that you are capable of riding safely, first evaluate the condition of your motorcycle. If the engine is still running, turn it off and look it over carefully; inspect it for fluid leaks, check the tightness of critical nuts and bolts, and secure such parts as the handlebar, control levers, brakes, and wheels. 121 11/05/07 10:19:10 32KVCC00_132 SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase CAPACITIES Engine oil After draining After disassembly Fuel tank Fuel reserve Passenger capacity Maximum weight capacity 122 2,048 mm (80.6 in) 766 mm (30.2 in) …Type II 752 mm (29.6 in) …Type I 1,084 mm (42.7 in) …TU, IITU 1,067 mm (42.0 in) …IIU 1,048 mm (41.3 in) …U 1,299 mm (51.1 in) 0.8 (0.8 US qt , 0.7 Imp qt) 1.0 (1.1 US qt , 0.9 Imp qt) 13.5 (3.57 US gal , 2.97 Imp gal) 2.0 (0.53 US gal , 0.44 Imp gal) Operator and one passenger 150 kg (331 lb) 11/05/07 10:19:16 32KVCC00_133 ENGINE Bore and stroke Compression ratio Displacement Spark plug Standard For extended high speed riding 52.4 × 57.8 mm (2.06 × 2.28 in) 9.2 : 1 124.7 cm (7.61 cu-in) CPR7EA−9 (NGK) CPR8EA−9 (NGK) Spark plug gap Idle speed 0.80−0.90 mm (0.031−0.035 in) 1,400 ± 100 min (rpm) Valve clearance Intake Exhaust 0.08 mm (0.003 in) 0.12 mm (0.005 in) 123 11/05/07 10:19:26 32KVCC00_134 CHASSIS AND SUSPENSION Caster Trail Tyre size, Front Tyre size, Rear Tyre type POWER TRANSMISSION Primary reduction Gear ratio, 1st 2nd 3rd 4th 5th Final reduction 124 26°30’ 100.0 mm (3.94 in) 80/100−18M/C 47P KENDA K291F 90/90−18M/C 51P KENDA K328X bias-ply, tube 3.350 3.076 1.875 1.409 1.120 0.937 3.000 11/05/07 10:19:39 32KVCC00_135 ELECTRICAL Battery YTX7L−BS 12V−6Ah (10HR) 0.22 kW/5,000 min (rpm) Generator LIGHTS Headlight Brake/Tail light Turn signal light Position light License light Instrument light Neutral indicator Turn signal indicator High beam indicator Gear position indicator FUSE Main fuse Other fuses Front Rear 12V−35/35W 12V−21/5W 12V−10W × 2 12V−10W × 2 12V−5W …U, IIU 12V−5W × 2 …TU, IITU 12V−5W LED 12V−1.7W 12V−3.4W × 2 12V−1.7W LED 20A 10A, 15A 125 11/05/07 10:19:46 32KVCC00_136 CATALYTIC CONVERTERS (TU, IITU) This motorcycle is equipped with catalytic converters. Each catalytic converter contains precious metals that serve as catalysts, promoting chemical reactions to convert the exhaust gasses without affecting the metals. The catalytic converters act on HC, CO, and NOx. Replacement parts must be original Honda parts or their equivalents. Defective catalytic converters contribute to air pollution, and can impair your engine’s performance. Follow these guidelines to prot ect your motorcycle’s cat alyt ic converters. The catalytic converters must operate at a high temperature for the chemical reactions to take place. They can set on fire any combustible materials that come near them. Park your motorcycle away from high grasses, dry leaves, or other flammables. Keep the engine in good running condition. A poorly running engine can cause the catalytic converter to overheat causing damage to the converter or the motorcycle. Always use unleaded petrol. Even a small amount of leaded petrol can contaminate the catalyst metals, making the catalytic converters ineffective. If your engine is misfiring, backfiring, stalling, or otherwise not running properly, stop riding and turn off the engine. Have your motorcycle serviced as soon as possible. 126