11/05/07 10:01:23 32KVCC007001 ‘ Honda GLH125 SH OWNER’S MANUAL C) (C) Honda Motor Co., Ltd. 2011 ‘ \1/ ‘ L ,3 % «if \ 1 11/05/07 10:01:27 32KVCC007002 ‘ 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. a 1 This manual should be considered a permanent part of the motorcycle and should remain t ) with the motorcycle when resold. % «if \ 1 11/05/07 10:01:32 32chcuuium Honda GLH125 SH OWNER’S MANUAL All information in this publication is based on the latest producflon information available at the fine of approval for prinflng1 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. /\ \1 % (if \ 1 11/05/07 10:01:37 32chcooiuua 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-n'de 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 ! r\ \/ 11/05/07 10:01:46 32KVCC007005 ‘ - The following codes in this manual indicate each country. TU Turkey IlTU U Type I Ukraine U Australia HU l (U Tvue ID l .The lllnslral' ns herein are based on the IlTU type. . The spa _ _ons may vary with each locale. , . Tlns vehrele pictured m this owner’s manual may not match your actual vehrele. % «if \ 1 11/05/07 10:01:52 32chcooiooe 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 inionnation 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 ilnportant safety information in a variety of forms, including: I Safety Labels — on the motorcycle. . Safety Messages — preceded by a safety alert symbol A and one of three signal words: DANGER, WARNING, or CAUTION. These signal words mean: r\ \/ 11/05/07 10:01:57 32chcooioo7 m You WILL be KILLED or SERIOUSLV HUFIT if you don't follow instructions. N You CAN be KILLED or SERIOUSLY HURT iI you don’t follow instructions. . CAUTION You CAN be HURT iI you don't follow instructions. 0 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 32chcuuiuue OPERATION page 1 1 2 4 9 13 16 20 20 21 28 30 34 35 MOTORCYCLE SAFETY IMPO RTANT SAFETY INFORMATION PROTECTIVE APPAREL LOAD LIMITS AND GUIDELINES IMAGE LABELS (U, HU) PARTS LOCATION INSTRUMENTS AND INDICATORS MAJOR COMPONENTS (Information you need to operate this motorcycle) SUSPENSION BRAKES CLUTCH FUEL ENGINE OIL TYRES /\ \1 page 40 40 41 42 43 44 r\ \/ ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH KEYS SHUTTER (I‘U, IlTU) RIGHT HANDLEBAR CONTROLS LEFT HANDLEBAR CONTROLS *1 Ll/ns/m 10:02:25 32chcuuiuue page 45 FEATURES (Not required for operau'on) 45 STEERING LOCK 46 SEAT 47 DOCUMENT COMPARTMENT 4s LEFT SIDE COVER 49 RIGHT SIDE COVER 50 HEADLIGHT AIM VERTICAL ADJUSTMENT /\ \1 page 51 OPERATION 51 53 57 58 60 61 62 r\ \/ PRERIDE INSPECTION STARTING THE ENGINE RUNNING—IN RIDING BRAKING PARKING ANTI-THEFT TIPS % 11/05/07 10:02:48 32chcuuium 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 1:) 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 SI-IOE WEAR 101 BATTERY 7 I /\ \l /\ \1 page 103 FUSE REPLACEMENT 107 BRAKELIGHT SWITCH ADJUSTMENT 108 BULB REPLACEMENT 114 CLEANING 1 18 STORAGE GUIDE 118 STORAGE 120 REMOVAL FROM STORAGE 121 TAKING CARE OF THE UNEXPECI‘ED 122 SPECIFICATIONS 126 CATALYTIC CONVERTERS (TU, IITU) % 11/05/07 10; .58 32chc007011 MOTORCYCLE SAFETY IMPORTANT SAFETY INFORMATION Your motorcycle can provide many years of service and pleasure , if you take ility 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 salne. We also recommend that you wear eye protection. sturdy boots, gloves, and other protective gear (page 2 ). /\ \I Make Yourself Easy to See Some drivers do not see motorcycles because they are not looking for them. To make yourself more vi ble, 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 crashe- Never ride beyond your personal abil ies or faster than conditions warrant. Remember that alcohol. drugs, fatigue and inattention can significantly reduce your ability to make good judgements and ride safely. /\ \1 Ll/us/m 10: .05 32KVCC007012 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. AWARNING Not wearing a helmet increases the chance oi serious injury or death ll'l a crash. Be sure you and your passenger always wear a helmet, eye protection and other protective apparel when you ride. u 1/05/07 10; .10 32chcooiou 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 lnore. Always wear a face shield or goggles to protect your eyes and help your vision. /\ \1 Additional Riding Gear In addition to a helmet and eye protection, we also recommend: a 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. o A motorcycle riding suit or jacket for comfort as well as protection. Bright- coloured and reflective clothing can help make you lrlore noticeable in traffic. Be sure to avoid loose clothes that could get caught on any part of your motorcycle. r\ \/ 11/05/07 10: .17 32KVCC007014 LOAD LIMITS AND GUIDELINES Your motorcycle has been designed to carry you and one passenger. When you carry a p nger, you may feel some difference during acceleration and braking. But so long as you keep your motorcycle well- niaintained, with good tyres and brakes, you can safely carry loads within the given limits and guidelines. However, exceeding the weight limit or carrying an unbalanced load can seriously affect your inotorcycle’s handling, braking and stability. No -Honda accessories, improper niodific tions, and poor maintenance can also reduce your safety margin. The following pages give more specific information on loading, accessories and modifications. Loading How much weight you put on your motorcycle, and how you load it, are important to your safety. Anytime you ride with a passenger or cargo you should be aware of the following information. AWARNING Overloading or lmproper loadan can cause a crash and you can be seriously hurt or kllled. Follow all load llmits and other loadlng guidellnes In thls manual. *1 Ll/ns/m 10:03:27 32chc007015 Load Limits Following are the load limits for your motorcycle: Maximum weight capacity: 150 kg 1331 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. «y \1 Loading Guidelines Your motorcycle is primarily intended for transporting you and a passenger You may wish to secure a jacket or other all 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 ii your motorcycle is properly loaded, you should ride at reduced speeds and never exceed 130 km/h (80 mph) when carrying cargo. r\ \/ 11/05/07 10; % «if \ 1 .31 32KVCC007016 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 0 of the motorcycle as possible. . Balance cargo weight evenly on both sides. Ll/us/m 10: .38 32KVCC00701’7 Accessories and Modifications Modifying your motorcycle or using non- Honda accessories can make your motorcycle uns Before you consider making any modifications or adding an accessory, be sure to read the following information. AWARNING Improper accessories or modifications can cause a crash In which you can be seriously hurt or killed. Follow all instructions In this 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. Ber. use Honda cannot test all other accessories, you must be personally responsible for proper selection, installation and use of non-Honda ' cessorie . Check with your dealer for a istance and always follow these guideline oMake sure the a essory does not obscure any light, 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. % 11/05/07 10; - Do not pull a trailer or sidecar with your motorcycle. This motorcycle was not designed for these attachments, and their use can seriously impair your motorcycles handling. (if \ 1 .43 32KVCC007018 Modifications We strongly advise you not to remove any original equipment or modify your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycles handling, stability and braking making it unsate to ride. Removing or modiiying your lights, muttlers, emission control system or other equipment can also make your motorcycle illegal. % 11/05/07 10:03:48 32chc007019 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. If a label comes off or becomes hard to read, contact your dealer for a replacement. /\ \l r\ \/ There is a specific symbol on each label. The meanings of each symbol and label are as follows. 11/05/07 10:03 : 57 32chc007020 10 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. D l> D B E CAUTION (with YELLOW background) You CAN be HURT if you don‘t follow instructions. 11/05/07 10:04:07 32KVCC007021 1 TVRE INFORMATION LABEL Cold tyre pressure: [Driver Only] From 200 kPa 12.00 kgf/cmz , 23 psil Rear 225 kPa 12.25 kgf/cm2 , 33 psil [Driver and passenger] Front 200 kPa 12.00 kgf/cm1,23 psil Rear 225 kPa 12.25 kgf/cm2 , 33 psil Tyre size: From BO/1UOi18M/C 47P Rear BO/SUi18M/C 51F Tyre brand: KENDA Front K291 F Rear K328X DRIVE CHAIN LABEL Keep chain adjusted and lubricated. 20 7 30 mm1 0.87 1.2 in1Freeplay 11 SAFETY REMINDER LABEL For your protection], always wear helmet and protective gear. CARGO LIMIT LABEL g m Do not exceed 3.0 kg (6.6 Ibb (66 up) 12 % «if \ 1 11/05/07 10:04:19 32chc007023 ‘ PARTS LOCATION s d t Headlight M ”m er Engine slup switch dimmer switch F“ 61 gauge r U) Rearview minur Front brake Chuke lever fluid reservoir (Type 11) Passing 1ig1ii comrol swiicii \ / Rearview mirror r ) Front brake lever Turn signal switch Throme grip Horn button Sian blltmn Indiualurs Ignifiun switch Shutter (TUr HTU) Fuel fill my 13 w + WEE? % 11/05/07 10:04:22 22chc007024 /\ \1 Engine oil fill cap/dipstick Battery Rear carrier preload adjuster Main [use Passenger Iootpeg Footpeg /\ \/ Rear brake pedal % Shin lever 11/05/07 10:04:27 22chc007025 Footpeg /\ \1 Fuel valve Center stand /\ \1 Other [uses Side stand Passenger footpeg 15 a \ 1 in/ns/m 10:04:34 32KVCC007026 INSTRUMENTSAND 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) Triprneter (ll) Tripmeter reset knob 16 Ll/us/m 10:04:48 32chc007027 (ReLNo.) Description Function (1) Speedometer Shows riding speed. (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 ). / f. (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 Ll/us/m 10:04 : 56 32chcuuiuze (ReLNo.) Description Function (8) Right turn signal indicator (green) 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 % «lf \ 1 11/05/07 10:05:01 32chc007029 l 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 II (0.58 US gal , 0.48 Imp gal) (1) Fuel gauge needle (2) Red band 19 w + w? $2? +«~ Ll/DS/DV 10:05:10 32KVCC007030 ‘ MAJOR COMPONENTS (Information you need to operate this motorcycle) SUSPENSION The spring preload adjuster (1) has Espring 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 ). Always adjust the spring preload adjuster position in sequence (1 3-4.5 or 54-324). O Attempting to adjust directly from 1 to 5 or i: ) 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 tor a stitler 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) Spring preload adjuster (2) fin spanner (3) Extension bar 20 7‘ + is % (if \ 1 11/05/07 10:05:14 32chc007031 BRAKES Front Brake (Type 11) 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 liinit (page 99 ), there is probably air in the brake system and it must be bled. See your dealer for this service. 21 $2? +«~ Ll/DS/DV 10:05:20 32KVCC007032 i 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 ). 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. 22 Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. (1) LOWER level mark w + WE? $2? +«~ Ll/DS/DV 10:05:26 32KVCC007033 ‘ (Type 1) 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. Measured at the tip of the front brake lever, Ireeplay should be maintained at: 10*20 mm (O.4*0.8 in! Adjust the freeplay of the brake lever with the front wheel pointed straight ahead. (1) Front brake lever 23 Tl + is *1 in/ns/m 10:05:37 32chc007034 /\ \l Adjustment: 2. . N ajor 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). (6) (A) Deereaseireep1ay (B) Increase free-play (2) Lower adjusting nut (6) Brake arm pin (3) Upper adjustingnut (4) Rubber dust cuver Adjust brake lever freeplay with the front brake adjusting nut. Turning the nut clockwise will decrease Ireeplay 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. (A) Decrease freeplay (B) increase ireeplay (5) Lock nut 24 7 l + % 7 l 11/05/07 10:05:48 32chc007035 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). (2) (2) Loweradjusting nut (7) Brake ann (6) Brake arm pin /\ \1 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. Lubricate the brake cable with a commercially available cable lubricant to prevent premature wear and corrosion. Make sure the brake arm, spring and fasteners are in good condition. 25 /\ \1 r. \ 1 Ll/ns/m 10:05:56 32chc007035 Rear Brake Brake Adjustment: Pedal Height Adjustment: 111—117. ace t e motorcycle on its center stand. he stopper Bot IS provided to allow 2. Measure the distance the rear brake adjustment of the pedal height. To adjust pedal (3) moves before the brake starts the pedal height, loosen the lock nut (2) to take hold. and turn the stopper bolt. Tighten the lock Freeplay should be: 20*30 mm 018* 1.2 in) 3. If adjustment is necessary, turn the rear brake adjusting nut (4). <1) Stopper bolt (2) Lock nut (4) Rear brake (A) Decr 'se free-play (3) Rear brake pedal adjusting nut (B) Increase freeplay 26 7 l + % «if \ 1 11/05/07 10:06:06 32chc007037 Adjust by turning the rear brake adjusting After adjustment, push the brake arm (6) nut a half-turn at a time. Make sure the cut- to confirm that there is a gap between the out on the adjusting nut is seated on the rear bmke adjusting nut (4) and the brake brake arm pin (5) after making final ann pin (5). ireepiay adjustment. 4. Apply the brake several times and check for free wheel rotation after the brake pedal is released. If proper adjustment cannot be obtained by this method, see your dealer. (a) Rearbrake adjusting nut (6) Brakean'n (5) Brake arm pin After adjustment, confirm the treepiay 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 /\ \1 a \ 1 Ll/ns/m 10:06:14 32chcooime CLUTCH 1. Pull back the rubber dust cover (2). Clutch adjustment may be required if the 2. Loosen the lock nut (3) and turn the motorcycle stalls when shifting into gear or clutch cable adjuster. Tighten the lock tends to creep; or if the clutch slips, causing nut and check the adjustment. acceleration to lag behind engine speed. 3. If the adjuster is threaded out near its Minor adjustments can be made with the limit or if the correct freeplay cannot be clutch cable adjuster (4) at the clutch lever obtained, loosen the lock nut and turn in (1). the clutch cable adjuster completely. Nonnal clutch lever freeplay is: Tighten the lock nut and install the dust 10*20 mm(0.470.8in| cover. TK¥ kl _ (2) Rubber dust cuver (A) Increase freeplay (1) Clutch lever (a) Locknut (B) Decrease freeplay (4) Clutch cable adjuster ’ (1) 23 7 l + *1 Ll/ns/m 10:06:22 32chc007039 P Loosen the lock nut (5) at the lower end of the cable. Turn the adj ting nut to) to obtain the specified freeplay. Tighten the lock nut and check the adjustment. . 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. The motorcycle should begin to move smoothly and accelerate gradually. m If proper adjustment cannot be obtained or the clutch does not work correctly, see your dealer. /\ \1 Other Checks: 1 fleck the c utch cable for kinks or signs of wear that could cause sticking or failure. Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion. (5) Lock nut (6) Adjusting nut (A) Increase treeplay (B) Decrease treeplay 29 /\ \1 *1 Ll/ns/m 10:06 : 30 32chcooiuau FUEL Fuel Valve a l L Remember to check that the fuel valve is in the ON position each time you refuel. If the The three way fuel valve (1) is on the left valve is left in the RES position, you may side near the carburetor. ON run out of fuel with no reserve. Wh the fuel valve in the ON position, fuel will flow from the main fuel supply to the ON OFF RES carburetor. OFF With the fuel valve in the OFF position, fuel cannot flow from the tank to the carburetor. 4 t Turn the valve OFF whenever the motorcycle is not in use. RES W 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 D (0.53 US gal , 0.44 Imp gall 30 (1) Fuel valve + \ éltiij 11/05/07 10:06:39 32chcuuiu41 i Fuel Tank The fuel tank capacity including the reserve A WAR N I N G supply is: 13.5 1213.57 US gal , 2.97 Imp gall Petrol is highly liammable and explosive. You can be burned or To open the fuel fill cap (1), open the tank seriously injured when handling luel. cap cover (2), insert the ignition key (3) and turn it clockwise. The fuel fill cap will . Stop the engine and keep heat, pop up and can be lifted off. sparks, and flame away. Do not ovelfill the tank. There should be no a Reluel only outdoors. fuel in the filler neck (4). . Wipe up spills Immediately. _ Alter refueling, to close the fuel fill cap, : 4) align the latch in the cap with the slot in the l: ) filler neck. Push the fuel fill cap into the filler neck until it snaps closed and locks. Remove the key. (3) (l) (2) (1) Fuel fill cap (3) Ignition key (2) Tank can cover (4) Filler neck 31 % 11/05/07 10:06:43 32chc007042 Use unleaded petrol with a research octane number of 91 or higher. (TU, llTU) The use of leaded petrol will cause premature damage to the catalytic converters. 32 /\ \l If “ p rk knock" or “pinking" occurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinking persis s, consult your dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda‘s Limited Warranty. r\ \/ % 11/05/07 10; .48 32chc007043 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 con- taining 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 n also contain cosolvents and corrosion inhi itors for methanol. Never use petrol containing more than 5 % methanol. even if it has cosolvents and corrosion inhibitors. /\ \l The use of petrol containing more than 10 96 ethanol (or more than 5 % methanol) may: . Damage the painting of the fuel tank. 0 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. 33 r\ \/ % 11/05/07 10:06 : 59 32chc007044 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 7 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. 34 at i L 5. Reinstall the oil fill cap/dipstick. Check for oil leaks. Running the engine with insufficient oil pressure may cause serious engine damage. (1) Upper level mark (2) Lowerlevel mark (3) 0mm Lap/dipstick + i at? Ll/us/m 10: .05 32chcuuiu45 TYRES To safely operate your motorcycle, the tyres must be the proper type and size, in good condition with adequate tread, and correctly inflated. AWARNING Using tyres that are excessively worn or Improperly inilated can cause a crash in which you can be seriously him orkilled. Follow all instructions In this owner's manual regarding tyre inilation and maintenance. 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 siidace hazards, and wear iinevenly. Make sure the valve stem caps are secure. If necessary, install new caps. 35 % 11/05/07 10:07:14 32chcuuiuae 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/cmz, psi) Driver Front 200 (2.00 , 29! only Rear 225 (2.25 , 33) Driver and Front 200 (2.00 , 29! one passenger Rear 225 (2.25 , 33y 36 /\ \1 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. r\ \/ u \ 1 Ll/ns/m 10:07:17 32chc007047 Tread Wear Replace tyres immediately when the wear indicator (1) appears at on the tyre. <1) Wearinrlicaior (2) Wear indicaior location mark 7 \ + 37 *1 Ll/ns/m 10:07:21 32chcuuiuae Tube Repair and Replacement /\ \I 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 iail 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. Anytime a tube is replaced, the tyre should 3b 33 4 i be carefully inspected as described on page r\ \/ 11/05/07 10:07:29 32chcuuiu49 Tyre Replacement The tyres that came on your motorcycle were de gned to match tlle performance capabilities of your motorcycle and provide tlle best combination of handling, braking, durability and comfort. AWARNING Installing improper tyres on your motorcycle can allect 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. The recommended tyres for your motorcycle are: Front: BO/100i18M/C 47P KENDA KZB’IF Rear: 30/90i1BM/C 51 P 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 tlle new tyre is installed. Also remember to replace tlle illner 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 32KVCC007050 ‘ ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH RHOFF) 0(0N) The ignition switch (1) is below the 1 indicator panel. ( ) (1) Ignition switch Key Position Function Key Removal 8 Steering is locked. Engine and lights cannot Key can be LOCK be operated. removed (Steering lock) fl Engine and lights cannot be operated. Key can be OFF removed 0 Engine and lights can be operated. Key cannot be ON removed 40 u \ 1 Ll/ns/m 10:07:44 32chc007051 KEYS You will need the key number if you ever This motorcycle has two keys (1) and a key have to replace a key. Store the plate in a number plate (2). safe place. To reproduce keys, bring all keys, key number plate and motorcycle to your dealer. TU, HTU U, IIU (l) (1) (1) Key (2) Key number plate 41 % «if \ 1 11/05/07 10:07:52 32chc007052 SHUITER (TU, llTU) This motorcycle has equipped the ignition (CLOSE> 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 shutter key counterclockwise or move the knob (4) downward. 0 To open the shutter, align the projection of the shutter key with the slot of the shutter, and turn the shutter key clockwise. (OPEM (2) " ' if m l K A gem (1) Prujection (3] Slot (4) Knob (2) Shutter key 42 7 l + % 11/05/07 10:08 i 00 32chcooiosz 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 o (RUN) position, the engine will opemte. When the switch is in the la: (OFF) position, the engine will not operate. This switch is intended primarily as an emergency switch and should normally remain in the o (RUN) position. If your motorcycle is stopped with the ignition switch ON and the engine stop switch E (OFF), the headlight, position light, taillight and license light will still be on, resulting in battery discharge. /\ \I 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 lor the starting procedure. (Ur HU) (1) Engine stop switch (2) Start button 43 /\ \1 % «if \ 1 11/05/07 10:08:09 32chc007054 ‘ LEFI‘ HANDLEBAR CONTROLS (2) Headlight Dimmer Switeh (1) Push the dimmer switch to :0 (HI) to select high beam or to 50 (L0) to select low beam. Passing Light Control Switeh (2) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing. Turn Signal Switch (3) Move to ¢a tosignalalefllurn, i:> to signal a n'ght tuin. Press to turn signal off. Horn Button (4) Press the button to Sound the horn. (1) Headlight dimmer switch (2) Passing light control switch (3) Turn signal switch (4) Hornbuflun 44 7‘ + lea % «if \ 1 11/05/07 10:08:16 32chc007055 FEATURES (N at required for operation) STEERING LOCK To lock the steering, turn the handlebars all the way to the lelt or right, turn the key (1) to B (LOCK) while pushing in. Remove the key. To unlock the steering, turn the key to 18: (om Do not turn the key to B (LOCK) while riding the motorcycle; loss of vehicle control will result. (1) Ignition key (A) Push in (B) Tum to LOCK (C) Tum to OFF 45 7 i + a \ 1 in/ns/m 10:08:24 32KVCC007056 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. Be sure the seat is locked securely in f V position after installation. (1) Seat (4) Front stay (2) Seat luck (5) Rear prungs (3) Front prong (6) Rear stays 46 7 l + $2? +«~ Ll/DS/DV 10:08:29 32KVCC007057 ‘ DOCUMENT COMPAKI‘MENT 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) Doulment compamnem 47 w + lat? % «if \ 1 11/05/07 10:08:39 32chcooiuse LEFI‘ SIDE COVER The left side cover must be removed for {use maintenance, and to access the tool kit. 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. <1) Ignition key (2) Side cover 43 /\ \/ (a) Grommets n \ 1 Ll/os/m 10:08:49 32chc007059 RIGHT SIDE COVER The right side cover must be removed for battery and main fuse maintenance. Removal: 1. Remove the screw (1). 2. Carefully pull the side cover (2) out from the grommets (3). Installation: 7LAlign the prongs with the rubber o grommets. 2. Push the prongs in. 3. Install the screw. (1) Screw (2) Side cover 7 l + (a) Grommets 49 % «if \ 1 11/05/07 10:08:58 32chcooiusu HEADLIGHT AIM VERTICAL (TU, IrrU) ADJUSTMENT Vertical adjustment can be made by moving the headlight case (1) as necessary. (TU, llTU) To move the headlight case, loosen the bolt (2)- Tighlen the bolt after adjustment. Obey local laws and regulations. 0 (u, IIU) To move the headlight case, loosen the bolts ( 3 ) . Tighten the bolts after adjustment. Obey local laws and regulations. (1) Headlight case (A) Up (2) Bull (B) Down (3) Balls 50 7 l T : Ll/us/m 10:09:09 32KVCC007061 OPERATION PRE-RIDE INSPECTION For your safety, i 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. AWARNING Improperly malntainlng thls motorcycle or laIling to correct a problem before riding can cause a crash m which you can be serlously hurt or killed. Always penorm a pre-ride inspection belore every ride and correct any problems. 1. Fuel level7Fill fuel tank when necessary (page 31). 2. Throttle7Check for smooth opening and full closing in all steering positions (page 82 ). 3. Engine oil level7Add engine oil if necessary (page 34 ). Check for leaks. 4. Drive chain7 Check condition and slack. adjust and lubricate if necessary (page 84 ). 5. (Type II) Brakes 7 Check operation; Front: check brake fluid level and pads wear (pages 21 7 22 , 99). Rear: check shoes wear and Ireeplay, adjust if necessary (pages 26 7 27 .100). (Type 1) Brakes 7 Che koperation; Front and Re heck shoes wear and Ireeplay, adjus f necessary (pages 23 7 25 , 26 7 27,100). 51 % «if \ 1 11/05/07 10:09:15 32KVCC007062 6. Lights and homicheck that lights, indicators and horn function properly. 7. (U, HU) Engine stop switchicheck for proper function (page 43). 8. Side stand ignition cut-off systemi Check for proper function (page 92 ). 9. Wheels and tyres 7 Check condition, air pressure and adjust if necessary (pages 35 7 39). 52 % 11/05/07 10; .24 32chcooiuea STARTING THE ENGINE Always follow the proper starting procedure described below. This motorcycle is equipped with a side stand ignition cutoff system. The engine cannot be started if the side stand is down unless the transmission is in neutral. If the side stand is n, 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,IU[I) To protect the catalytic converters in your motorcycle's exhaust system, avoid extending idling and the use of leaded petrol. /\ \1 Your motorcycle’s exhaust contains poisonous carbon monoxide gas. High levels of carbon lnonoxide 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 OtON) and confirm the following: . The transm sion is in neutral (neutral indicator is ON). - (U, HU) The engine stop switch is at 0 (RUN). o The fuel valve is ON. 53 /\ \1 *1 in/ns/m 10:09:35 32chcuuiuea Starting Procedure To restart a warm engine, follow the procedure ler “High Air Temperature." Normal Air Temperature 7 0°795017) 1.Pullthec o e ever ac a the way to Fully ON (A), if the engine is cold. 2. With the throttle cleserl, press the start button. 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. 0: .Immediately after the engine starts, operate the choke lever to keep last idle. About a quarter minute after the engine starts, push the choke lever forward all the way to Fully OFF (B). If idling is unstable, open the throttle slightly. P 5-" 54 Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. <1) choke lever (A) Fully ON (B) Fully OFF /\ \1 % 11/05/07 10:09:41 32chcooiues /\ \I High Air Temperature Low Air Temperature 9 <) or above <) or below 1. Do not use the choke. 1. Follow steps 7 2 under \lonnal Air 2. With the throttle l/Sil/A open, press Temperature." the start button. 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 r\ \/ u \ 1 Ll/ns/m 10:09:45 32chcuuiuee 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 0 (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 lollow the Starting Procedure. 56 r\ \/ % «if \ 1 11/05/07 10:09:48 32chcuuiue7 RUNNING-IN Help assure your motorcycles 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. % 11/05/07 10:09:55 32chcooiuee RIDING Review Motorcycle Safety (pages 1 712) before you ride. Make sure you understand the function of the side stand mechanism. (See MAIN- TENANCE SCHEDULE on page 68 and explanation for SIDE STAND on page 92 ). (TU, HTU) 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 lst (low) gear. 53 /\ \l 3. Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start. 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. This sequence is repeated to progressively shift to 3rd, 4th and 5th (top) gears. P /\ \1 % 11/05/07 10; 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. (if \ 1 .oo 32chcuuiues oDo 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. a 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. 0 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 r\ \/ % 11/05/07 10:10:09 32chc00707u BRAKING (pre 11) . , . Your motorcycle IS equipped with a hydraulically-activated disc brake in front and a mechan ll activated dmm brake at the rear. Operating the brake lever applies the front disc brake. Depressing the brake pedal applies the rear drum brake. (FyPeI) . . . Your motorcycle is equipped With mechanically-activated drum brakes. Operating the brake lever applies the front dmm 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 /\ \1 Important Safety Reminders: - Independent operation of only the brake lever or brake pedal reduces stopping performance I Extreme applic ion of the brake controls may cause wheel lock, reducing control of the motorcycle. cWhen possible, reduce speed or brake before entering a turn; closing the throttle or braking in mid-turn may cause wheel slip. W'heel slip will reduce control of the motorcycle. - When riding in wet or rainy conditions, or on loose suriaces, 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. /\ \1 *1 ln/ns/m 10:10:16 32chcooiu71 .When descending a long, steep grade, use engine compression braking by down- shifting, with intermittent use oi 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 hrakelight, giving a false indication to other drivers. It may 1:) also overheat the brakes, reducing effectiveness. /\ \l PARKING .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 fl (OFF) and remove the key. Use the side or center stand to support the motorcycle while parked. N 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 overtuming or rolling off the center or side stand. 3. Lock the steering to help prevent theft (page 45 ). 61 r\ \/ u 1/05/07 10; .22 32chcuuiu72 (TU, IH‘U) 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 lninutes after shutting off the engine. 62 /\ \l ANT IrTI-IEFF 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 all 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 N0: r\ \/ 11/05/07 10: .29 32KVCC0070’73 MAINTENANCE THE IMPORTANCE OF MAINTENAN A well- maintaineEd motorcycle is essential for safe economical and troublefree riding. It will also help reduce air pollution. To help you properly care for your motorcycle, the following pages include a Maintenance Schedule and a Maintenance Record for regularly scheduled maintenance. These instructions are based on the assumption that the motorcycle will be used exclusively for its desgned purpose. Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the Maintenance Schedule. Con lt your dealer for recommendations appli able 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. AWARNING Improperly maintaining this motorcycle or tailing to correct a problem beiore 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: .33 32KVCC0070’74 MAINTENANCE SAFETY This section includes instructions on some important maintenance task . You can perform some of these tasks with the tools provided 7 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 as st in emergency service. Some of the most important safety 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 AWARNING Failure to properly lollow maintenance Instructions and precautions can cause you to be seriously hurt or Killed. Always follow the procedures and precautions in this ownei‘s manual. % 11/05/07 10; .40 32chcuuiu75 SAFEI'Y PRECAUTIONS . Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: .Cnrbon monoxide poisoning from engine exhaust Be sure there ls 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. I Read the instructions before you begin, and make sure you have the tools and skills required. oTo 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. /\ \I .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 /\ \1 % «if \ 1 11/05/07 10:10:50 32chc007075 MAINTENANCE SCHEDULE Pertonn the Prende lnspectinn (page 51 ) at each scheduled maintenance period. l INSPECT AND CLEAN ADJUST, LUBRICATE OR REPLACE IF NECEseARv c CLEAN R: REPLACE A ADJUST L: LUBRICATE The tnllnwiugttems require some mechanical knowledge. Certain ttenrs (particularly thnse marked * and a as ) may require more technical intonnation and tools Consult your dealer. - Should he servtced by your dealer, unless the owner has proper tnols and seryice data and is mechanically qualified. Reter tn the Uflicial Honda Shnp Manual n ln the interest oi satety, we recommend these items be serviced only by your dealer. l-londa recommends that your dealer should road test your motorcycle atter each periodic maintenance is canted out. NOTES. 1. At higher ndorneter readings, repeat at the trequency in|enrdl established here 2. Sery' ~e more irequeutly when riding in uuus ally wet or dusty areas 3. Serytce more irequeutly when riding in rain or at iull throttle 4. Replacement requires mechanical skill. 5. Replace the PAIR air tilter every 3 years or 240000 km 00,000 mile), Replacement requires mechanical skill 56 r\ \/ 11/05/07 10:11:01 32KVCC007077 ITEMS NOTE PRERIDE CHECK (page 51 ) EREQL‘ENCY (NOTE I) x mun km 4 x LUUUmi v.5 2.5 12 7:3 ANNUAL CHECK REGL'LAR REPLACE ReIer ELIEL LINE (NOTE 1) I R 5 I I 2 yeam ELIEL LEVEL I ELIEL STRAINER SCREEN C C C THROTTLE OPERATION I I CHOKE OPERATION I AIR CLEANER (NOTE 2) I) CRANKCASE BREATHER (NOTE 3) I EVERY 15000 km (10,000“) C I C 074—- SPARK PLUG R VALVE CLEARANCE I ENGINE OIL R ¢ ! ENGINE OIL STRAINER SCREEN - u ENGINE OIL CENTRIFL'GAL EILTER o OWHH ENGINE IDLE SPEED SECONDARY AIR SUPPLY SYSTEM (NOTE 5) :3 yeam 67 .1; Lugs/07 10:11:12 32chcuuiu7e ITEMS NOTE PRERIDE CHECK FREQUENCY (NOTE 1) x mun km x mun mi 14 U”: A > ANNUAL CHECK REGULAR REPLACE ReIer m page DRIVE CHAIN (page 51) I EVERY 1.0m! km (mo m) I. L BRAKE FLUID (DISC BRAKE ONLY) (NOTE 1) I I I I 2 yeam BRAKE SHOES WEAR (DRUM BRAKE ONLY) I I I I BRAKE SHOES/PADS WEAR (DISC BRAKE ONLY) I I I BRAKE SYSTEM (DISC BRAKE ONLY) BRAKE SYSTEM (DRUM BRAKE ONLY) BRAKELIGHT SWITCH HEADLIGHT AIM LIGHTS/HORN ENGINE STOP SWITCH CLUTCH _ EM SIDE STAND SUSPENSION NUTS BOLTS FASTENERS u WHEELS/TY RES u STEERING HEAD BEARINGS 68 u \ 1 ln/ns/m 10:11:24 32chc007079 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 o 10 X 12 mm Open end wrench - 14 X 17 mm Open end wrench u Pliers - Spark plug wrench 1:) . No. 2 Phillips screwdriver - No. 2 screwdriver 0 Extension bar - Tool bag o Pin spanner <1) Tuol kit (2) Tuol bux 69 7 x + % 7 l ll“ \ 1 11/05/07 10:11:33 32chcooiueu SERIAL NUMBERS The frame and engine serial numbers are The frame number (1) is stamped on the required when registering your motorcycle. right side of the steering head. They may also be required by your dealer when ordering replacement parts. The engine number (2) is stamped on the Record the numbers here for your left side of the crankcase. reference. FRAME NO. ENGINE NO. (1) Frame number (2) Engine number 70 /’\ \1 u \ 1 ln/ns/m 10:11:39 32chcooiue1 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] Colour label A _¢» 71 a \ 1 Ll/ns/m 10:11:45 32chcooiue2 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) Crankcase breather tube 72 7 l + 11/05/07 10:11:59 32KVCC007083 ENGINE OIL Refer to the Safety Precautions on page 65 . Oil Recommendau‘on API SG or higher except classification oils labeled as energy conserving on the circular API service label / \ Viscosity SAE 1t>W-3t> \ ’ JASO ’1‘ 903 MA standard Suggested Oil Honda “ALSTROKE MOTORCYCLE OIL" or equivalent. Your motorcycle does not need oil additives. Use the recommended oil. Do not use oi with graphite or molybdenum additiv . They may adversely affect clutch operation. [)0 not use API SH or higher oi1s displaying a circular API “energy conserving" service label on the container. They may affect luhncation and clutch performance. we NOT RECOMMENDED OK Do not use non-detergent, vegetable, or castor based racing oils. 73 Ll/os/m 10: .07 32chcooioeo Viscosity: Viscosity grade at 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. \ 4, tow-an 1uw-40 rau -2u 40 a 10 20 so no 50‘: -zu o 20 40 so no 100 120‘F 74 JASO T 903 standard he AS“ 9 3 standard is an index for engine oils for Aestroke 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> MA‘\<2> (1) ()ilcode (2) ()ilclas fication % 11/05/07 10; .14 32chcooiues 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 performed more frequently than specified in the maintenance schedule. Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed cont ner to your local recycling center or service station for reclalnation. Do not throw it in the trash or pour it on the ground or down a drain. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although thi unlikely unless you handle used oil on a d ly basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi- ble after handling used oil. /\ \1 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 telnperature and the motorcycle on its center stand to assure complete and rapid draining. 75 /\ \1 % «if \ 1 11/05/07 10:12:23 32chcooiuee 1. Placeadrain pan under the crankcase. 3. Check that the sealing washer on the 2. To drain the oil, remove the oil fill cap/ drain bolt is in good condition and install dipstick, oil drain bolt (1), and sealing the bolt. Replace the sealing washer washer (2). every other time the oil is changed, or each time if necessary. Engine oil drain bolt torque: 3O N-m13.0 kgf‘m , 22 Ibfrft) . Fill the crankcas with the recommended grade oil; approximately: 0.8 a (0.8 US qt , 0.7 Imp qt! Install the oil fill cap/ dipstick. Start the engine and let it idle for 3*5 minutes. 1,3 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. p “95-" (2) (1) (1) oil drain bolt (2) Sealing washer 76 a \ 1 Ll/ns/m 10:12:34 32chcooiue7 SPARK PLUG 1. Disconnect the spark plug cap (1) from Refer to the Safety Precautions on page 65 . the spark plug. 2. Clean any dirt from around the spark plug Recommended plugs: base. Standard: Remove the spark plug using a spark plug CPR7EA 7 9 lNGK) wrench (2) furnished in the tool kit (page For extended high speed riding: 69). CPREEAiS lNGK) Newer use a spark plug with an improper heat range. Severe engine damage could result. (1) Spark plug Cap (2) Spark plug wrench 77 /\ \1 % 7 l 11/05/07 10:12:47 32chcuuiuee 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. 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: 0.80m030 mm (0.031*0.035 in) P (3) Spark plug gap (4) Side electrode 73 /\ \l 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: I If the old plug is good: 1/8 turn after it seats. a If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 1/2 turn after it seats. l1) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats. 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. /\ \1 a \ 1 Ll/ns/m 10:12:57 32chcooiuee VALVE CLEARANCE 1. Remove the crankshaft hole cap (1) and Refer to the Safety Precautions on page 65 . timing hole cap (2). 2. Remove the bolts (3) and cylinder head Excessive valve clearance will cause noise cover bolts (4). and eventual engine damage. Little or no 3. Remove the cylinder head cover (5). 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. The checking or adjusting of the clearance should be performed while the engine is cold. The clearance will change as the engine temperature rises. <3) Bolts (4) Cylinder head cover buns (5) Cylinder head cover <1) Crankshafl hule cap (2) Timing hole 121) 79 /\ \1 *1 in/ns/m 10:13 i 02 32chc007090 4. Rotate the generator flywheel counter- clockwise 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 compressi n stroke. If they are tight and the val es re open, rotate the flywheel 360° and realign the T mark to the index mark. 80 /\ \l (6) T mark (7) Index mark r\ \/ *1 in/ns/m 10:13 i 10 32chc007091 m . 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) .11 it is necessary to make an adjustment, loosen the adju ng screw lock nut (10) and turn the adjusting screw so there is a slight resi ance when the Ieeler gauge is inserted. After completing the adjustment, tighten O 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 kgfam,10|bf>ft) 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. Install the remaining parts in the reverse order of removal. m .“ 9° 9 /\ \l /\ \1 If a torque wrench is not used for this installation, see your dealer as soon as possible to verily proper assembly. (10) (8) Feeler gauge (9) Adjusting screw (10) Adjusting screw luck nut 31 *1 Ll/ns/m 10:13:15 32chc007092 THROTTLE OPERATION /\ \1 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 r\ \/ % 11/05/07 10:13:23 32chc007093 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 slop-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 carbu- retor 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 1100 min" (rpml /\ \l <1) Tllruttle stup screw /\ \1 (A) Increase (B) Decrease 33 *1 Ll/ns/m 10:13 i 34 32chcooiuea 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 Pre ride Inspection (page 51). Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy are i, more frequent maintenance will be necessary. Inspection: fl urnt e engine off, place the motorcycle on its center stand, and shilt the transmis ion 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 (U.8*1.2 in) 84 /\ \l 5” Rotate the rear wheel. Stop. Check the drive chain slack. Repeat this procedure several times. Drive chain k should remain constant. If the chain lack only in certain sections, some links are kinked and binding. Binding and kinking can frequently be eliminated by lubrication. Ext. sslve chain slack may allow the drive chain to dalnage the engine cases. (1) Drive chain /\ \1 : Lugs/07 10:13:41 32chc007095 4. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Damaged Sprocket Worn Sprocket Teeth Teeth ....... (EEW 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 % 7 l 11/05/07 10:13 i so 32KVCC007096 Adjustment: lnve cfiain slack should be checked and adjusted, if necessary, every 1,000 km (600 miles). When operated at sustained high speeds or under conditions of frequent rapid acceleration, the chain may require more frequent adjustment. <1) Axle nut (2) Drive chain luck nut (3) Drive chain adjusting nut (4) Index mark (5) Drive chain adjuster 86 /\ \I 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 018* 1.2 in) /\ \1 *1 in/ns/m 10:13 i 59 32chc007097 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 rni aligned, turn the left or right drive chain adjusting nut until the marks correspond on the iront edge oi the drive chain adjusters and recheck chain slack. 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. 6. Tighten the rear axle nut to the specified torque. Rear axle nut torque: 68 N-m16.9 kgfam , 50 Ibfrft) If a torque wrench is not used for this installation, see your dealer as soon as possible to verily proper assembly. /\ \l 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 repo oning the rear wheel to adjust drive ch' n slack. Check rear brake pedal ireeplay and adjust as necessary (page 26). Damage to the bottom part of the frame may be caused by excessive drive chain slack of more than: 50 mm (2.0 inl 37 /\ \1 a \ 1 ln/ns/m 10:14:04 32chcooiuee Lubrication: ubncate 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 lubricants 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. hain: 428Hi120 83 r\ \/ % 11/05/07 10:14:15 32chc007099 Removal and Cleaning. When the drive cfiain 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 Ii ing links, or otherwise appears unserviceable. Never use petrol or low flash point solvents for cleaning the drive chain. A fire or explosion could result. 5” Inspect the sprocket teeth for possible wear or damage. Replace if necessary. /\ \I 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. P Lubricate the drive chain (page 88 ). (1) (1) Mflsiflr link retaining clip 89 /\ \1 d \ 1 Ll/ns/m 10:14:19 32chcuui1uu 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 oi the drive chain. Master links are reusable ii they remain in excellent condition but it is recommended that a new master link retaining ip he installed whenever the dnve chaini reassembled. 1:) Install the master link retaining clip so that the closed end of the clip will face the direction oi iorward wheel rotation. .Adjust the drive chain (page 86 > and rear brake pedal freeplay (page 26 ). m (1) Master link retaining clip 90 % 11/05/07 10:14:25 32KVCC007101 FRONT AND REAR SUSPENSION INSPECI‘ION Refer to the Safety Precautions on page 65 . . 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. .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. . Carefully inspect all front and rear suspension fasteners for tightness. N w r\ \/ /\ \l 91 % SIDE STAND Refer to the Safety Precautions on page 65 . Perform the following maintenance in accordance with the maintenance schedule. Functional Ch cCheck the e stand spring (1) for damage or loss of tension and the side stand ' ‘sembly for freedom of movement. oCheck the side stand ignition cut-off system: ()1 1. Si astride the motorcycle; put the side stand up and the transmission in neutral. 2. Start the engine and with the utch 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 (if \ 1 11/05/07 10:14:33 32chcooi102 (1) Side stand spring 7 l + % 11/05/07 10:14:46 32chc007103 WHEEL REMOVAL Refer to the Safety Precautions on page 65 . Front Wheel Removal (Type 11) 1. Place the motorcycle on its center stand. Raise the front wheel off the ground by placing a support block under the engine. Remove the speedometer cable (1) by removing the screw (2). Remove the front axle nut cap (3). Remove the front axle nut (4). Remove the front axle shaft (5 ), front wheel and side collar. .N 95-"? 5” 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. /\ \l <1) Speedometer cable (2) Screw (3) Front axle nut cap /\ \1 (4) Front axle nut (5) Front axle shaft 93 % «lf \ 2 11/05/07 10:14:56 32chc007104 l (1371791) . 1Place the motorcycle on its center stand. 2. Raise the front wheel off the ground by placing a support block under the engine. 3. 4. Remove the speedometer cable (1) by (1) removmg the screw (2). 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 0 wheel and side collar. ( ) (8) \ (1) Speedometer cable (5) Brake ann (2) Screw (5) Front axle nut cap (3) Front brake (7) Front axle nut adjusting nut (5) Front axle shalt (4) Front brake cable 94 Tl + is *1 in/ns/m 10:15:09 32chc007105 Front Wheel Installation (pre 11) . I I I 1. Install the side collar into the nght side wheel hub. . 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. .To avoid damaging the brake pads while install' g the wheel, carefully fit the brake disc between the pads. Make sure that the lug (1) on the fork leg is located in the slot (2) on the speedometer gearbox (3). .Tighten the front axle nut to the specified torque. Front axle nut torque: 59 N-m16.0 kgf‘m , 44 Ibfrft) . 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. . Install the speedometer cable and tighten the screw securely. . Install the front axle nut cap. N w P m a mu /\ \I If a torque wrench is not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. <1) Lug (2) Slot (3) Speedometer gearbox 95 /\ \1 *1 in/ns/m 10:15:20 32KVCC007106 (pre I) . I I I 1. Install the side collar into the right side wheel hub. . 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. . Make sure that the lug (1) on the left fork leg is located in the slot (2) of the brake panel ( 3 ). .Tighten the front axle nut to the specified torque. Front axle nut torque: 59 N-m16.0 kgfam , 44 Ibfrft) Adjust the front brake (pages 23 7 25 ). 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. Install the speedometer cable and tighten the screw securely. Install the front axle nut cap. N w 95-" '5 9°.“ 96 /\ \I If a torque wrench is not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. (3) (1) <1) Lug (2) Slot (3) Brake panel /\ \1 % 11/05/07 10:15:31 32chc0071u7 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). (7) (8) (11) (9) (5) (2) (4) (1) Rearbnike (a) Stopperan'n nut adjusting nut (7) Drive chain lock (2) Brake rod nuts (3) Brake arm (8) Drive chain (4) Brake stopper arm adjusting nuts (5) Cotterpin (9) Rear axle nut /\ \l 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. Loosen the drive chain lock nuts (7) and drive chain adjusting nuts (8). Remove the rear axle nut (9). Remove the rear axle s all (10), drive chain adjusters (11) and side collars, then remove the drive chain (12) from the driven sprocket by pushing the rear wheel forward. Remove the rear wheel from the motorcycle. P 95-" .“ (11) (10) (1o) Rearaxl - aft (11) Drive chain adjusters (12) Drive chain 97 /\ \1 % 11/05/07 10:15:40 32KVCC007108 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-m16.9 kgfam , 50 Ibfrft) Brake stopper arm nut torque: 1O N-m11.0 kgfam , 7 Ibf-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. 93 r l L If a torque wrench is not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. % 11/05/07 10:15:47 32chc007109 BRAKE PAD WEAR (Type II) Reler to the Safety Precautions on page 65 . Brake pad wear depends upon the severity cl usage, the type at riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval (page es ). 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. /\ \l (1) Wear indicator marks /\ \1 99 % 11/05/07 10:15:56 32chc007110 BRAKE SHOE WEAR Refer to the Safety Precautions on page 65 . (have I) , The front and rear brakes are equipped with brake wear indicators. (Tynan) 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 4:) 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. 100 /\ \l /\ \/ (Type I) (> (2)4 (2) (1) Arrow (2) Brake arm (3) Reference mark (4) Brake panel Ll/us/m 10:16 : 04 32KVCC007111 BATI‘ERY 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 maintenancefree (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), contact your dealer. ry 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. An mproperly disposed of battery can be harmful to the environment and human health. Alw confirm local regulations for battery disposal. AWARNING The battery gives off explosive hydrogen gas during normal operation. 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. *1 Ll/ns/m 10:16:14 32chc007112 Removal: . Make sure the ignition switch is OFF. . Remove the right side cover (page 49 ). . Remove the fuse holder (1) from the one battery holder (2). e (4) m the bolts (5). 6. Pull out the battery from the battery box. Installation: . Reinsta in the reverse order of removal. .Disconnect the negative (7) terminal lead (3) from the battery first, then disconnect the positive (+) terminal lead .Remove the battery holder by removing r l L Be sure to connect the positive (+) terminal first. then the negative (7) terminal. 2. Check all bolts and other fasteners are secure. 102 (1) Fuse holder (2) Battery holder (3) Negative (7) terminal lead (4) Positive (H terminal lead (5) Bolts + l alte- % FUSE REPLACEMENT Refer to the Safety Precautions on page 65 . 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 0 electrical system or a fire may result, causing a dangerous loss of lights or engine power. «if \ 1 11/05/07 10:16:20 32chc007113 Blown fuse E 103 *1 in/ns/m 10:16 : 30 32chc007114 Fuse Holder: he fuse ho ders (1) are located behind the left side cover. The specified fuses are: 1 0A, 1 5A Remove the left side cover (page 48 ). Remove the fuse holder from the fuse holder cover (2). Open the fuse holder and lift out the old fuse (3) with the clips (4). Slide the old fuse out of the clips and discard it. 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. . Close the fuse holder and install it in the fuse holder cover. . Install the left side cover. S-"PS’JN!" \lm 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 /\ \l (1) Fuse holders (2) Fuse holdercover (3) 01d fuse (4) Clips (5) Spare fuse /\ \1 *1 in/ns/m 10:16:42 32chc007115 Main Fuse: he maln fuse (1) is located behind the right side cover. The specified fuse is: 20A Remove the right side cover (page 49 ). Remove the fuse holder (2) from the battery holder (3). Open the fuse holder and lift out the main fuse with the clips (4). Slide the main fuse out of the clips and discard it. 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. N!" WP.“ 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. /\ \l (1) Main tuse <2) Fuse holder (3) Battery holder (4) Clips (5) Spare main fuse /\ \1 105 % 11/05/07 10:16:49 32KVCC007116 INSTALIATION (1) Push in <1) Fuse holder (3) Clips (2) Fuse 106 7 l /\ \I If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating. ep acml, a fuse with one that has a higher rating greatly increases the chances of damaging the electrical system. 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. r\ \/ u \ 1 Ll/ns/m 10:16:55 32chc007117 BRAKELIGHT SWITCH ADJUSTMENT Refer to the Safety Precautions on page 65 . Check the operation of the brakelight switch (1) at the right side behind the engine from time to time. Adjustment is done by luming the adjusu'ng nut (2). Turn the nut in the direction (A) if the switch operates [00 late and in direction (B) if the switch operates too soon. <1) Brakeiight switch (2) Adjusting nut 7 i + *1 in/ns/m 10:17:04 32chcooine 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, Ill‘U) 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 /\ \I .Be sure to turn the ignition switch )8 (OFF) when replacing the bulb. - Do not use bulbs other than those specified. a After installing a new bulb, check that the light operates properly. r\ \/ % (l) 7 i «if \ 1 11/05/07 10:17:15 32chc007119 Headlight Bull) 3. Pull out the socket (4) without turning. U, Ill‘ 4. Remove the seat rubber (5). 1. Remove the bolts (1) from the front cowl 5. Remove the headlight bulb (6) while 2 . pressing down on the pin (7). 2. Disconnect the connector (3). 6. Install a new bulb in the reverse order of removal. (4) (7) <1) Bolts (3) Connemur (4) Socket (5) Headlightbulh <2) Frontcowl (5) Seat rubber (7) Pin 109 /\ \1 «if \ 1 11/05/07 10:17:26 32chc00712u ‘ % (U, IIU) 5. Slightly press the headlight bulb (6) and 1. Remove the screws (1) from the turn it counterclockwise. headlight case. 6. Install a new bulb in the reverse order of 2. Gently pull the lower end of the headlight removal. (2) forward and remove the headlight. 0 Install the dust cover with its ”TOP“ 3. Remove the seat rubber (3). mark ( 7 ) facing up. 4. Remove the socket (4) while pressing (6) (4) down on the pin (5). (1) Screws (3) Seat rubber (a) Headliglitbulb (2) Headlight (4) Socket (7) "row mark (5) m 110 w + lea % Posiflon Light Bulb , Ill‘ 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. (1) Socket (2) Bulbs ll“ \ 1 11/05/07 10:17:38 32chc007121 (UV HU) 1. Remove the headlight (1) (page 110). Pull the position light socket (2) and remove it. Pull out the bulb (3) without turning. Install a new bulb in the reverse order of removal. P99.” (1) Headlight (2) Socket (3) Bulb w + 1% % (if \ 1 11/05/07 10:17:44 32chc007122 Brake/T ail 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. (1) Taillight lens (2) Screws 1 12 /\ \1 (1) (3) Bulb (2) % Ill“ \ 1 11/05/07 10:17:53 32chc007123 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. (1‘ U, Ifl‘U) - Use only the amber bulb. <1) ScrewA (4) ScrewsB <2) Reflector (5) Bulb (3) Tum signal lens 113 7 \ + *1 Ll/ns/m 10:18 : 00 32chc007124 License Light Bulb 1. Remove the screws (1). 2. Remove the license light cover (2). 3. Pull out the bulb (3) without luming. 4. Install a new bulb in the reverse order of removal. 114 /\ \l <1) Screws (2) License 1;qu cover (3) Bulb r\ \/ *1 in/ns/m 10:18 i 10 32chc007125 CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect for damage, wear, and oil or brake fluid leakage. Avo'd 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 coin- operated car washes). High pressure water (or air) can damage certain parts of the motorcycle. /\ \1 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. 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. 5” 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 /\ \1 % 11/05/07 10; .22 32KVCC007126 ALAIter cleaning, rinse the lnotorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. 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. .Lubricate the drive chain immediately after washing and drying the motorcycle. 5-" \. Braking efficiency may be temporarily impaired immediately after washing the motorcycle. Anticipate longer stopping distance to avoid a possible accident. 116 /\ \1 Finishing Touches After washing your motorcycle, consider using a commercially-available spray cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abra ive polish or wax lnade 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. /\ \1 u 1/05/07 10; .32 32chc007127 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. 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 yollr dealer. /\ \l Painted Aluminum Wheel Maintenance Aluminum may corrode from contact with dirt, mild, or road salt. Clean the wheels after riding through ally of these substances. Use a wet sponge and lnild detergent. Avoid stiff brushes, steel wool, or cleaners containing abrasives or chemical compounds. After washing, rinse with plenty of water and dry with a clean cloth. Clean the Matt Colour Painted Surface Using plenty of water, clean the lnat colour painted surface with a soft cloth or sponge. Dry with a soft, clean cloth. Use neutral detergent to clean lnat colour painted surface. Do not use waxes containing colnpounds. 117 /\ \1 in/us/m 10:18:40 32KVCC007128 i STORAGE GUIDE Extended storage, such as for winter, AWARNING requires that you take cer 111 steps to reduce the effects of deterioration fr_om non-use of the motorcycle. In addition, Petrol is highly llammable and necessary repairs should be made BEFORE explosive. You can be burned or storing the motorcycle; otherwise, these seriouslylnjured when handling luel. repairs may be forgotten by the time the motorcycle is removedfrom storage. .Stop the engine and keep heat, sparks, and flame away. STORAGE . Reluel only outdoors. 1. Change the engine oil. . Wipe up spills Immediately. 2. Empty the fuel tank into an approved Q; petrol container using a commercially C) available hand siphon or an equivalent method. Spray the i 'ide 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 % 11/05/07 10; .47 32chc007129 3. To prevent rusting in the cylinder, perform the following: a Remove the spark plug cap from the spark plug. Using tape or string, secure the cap to any convenient pla tic 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. I Crank the engine several times to distribute the oil. a Reinstall the spark plug and spark plug cap. /\ \l P m 5‘? 9° r\ \/ Remove the battery. Store in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month. .Wash and dry the motorcycle. Wax all painted surfaces. Coat chrome with rustinhibiting oil. Lubricate the drive chain (page 88 ). Inflate the tyres to their recommended pressures. Place the motorcycle on blocks to raise both tyres off the ground. 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 \mriation. Do not store the motorcycle in direct sunlight. 119 *1 Ll/ns/m 10:18 : 53 32chc007130 REMOVAL FROM STORAGE 5,: Nt—t p m . Uncover and clean the motorcycle. .Change the engine oil if more than 4 months have passed since the start of storage. Charge the battery as required. Install the battery. .Drain any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol. .Perform all Pre-ride Inspection checks (page 51 ). Test ride the motorcycle at low speeds in a safe riding area away from traffic. 120 r\ \/ /\ \l % 11/05/07 10:18 i so 32chc007131 /\ \l TAKING CARE OF THE UNEXPECT ED IFYOU 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 lor emergency assistance if needed. Also follow applicable laws and regulations if another person or vehicle is involved in the 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. 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. r\ \/ 11/05/07 10:19:10 32chcuui132 SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase CAPACITIES Engine all After draining After disassembly Fuel tank Fuel reserve Passenger capacity Maximum weight capacity 122 2,048 mm (80.61nl 766 mm (30.2 in)...Type || 752 mm129.6in) .Typel 1,084 mm (42.7 inl .TU, IITU 1,067 mm (42.0 inl .HU 1,048 mm (41.31nl...U 1,299 mm (51.1 inl B 210.8 US qt , 0.7 Imp qt) 0 E 11.1 US qt , 0.9 Imp qt) 3.5 B (3.57 US gal , 2.97 Imp gall .0 1110.53 US gal ,0.44 Imp gall Operator and one passenger 150 kg 1331 Ibl 0 1 1 2 % 11/05/07 10:19:16 32chc007133 ENGINE Bore and stroke Compression ratio Displacement Spark plug Standard For extended high speed riding Spark plug gap Idle speed 4 1 Valve clearance /\ \I 52.4 X 57.8 mm (2.06 X 2.28 in! 9.2:1 124.7 cm317.61 cu-in) CPR7EA791NGK) CPRBEAiS INGK) 0.80* 0.90 mm (0.031 *0.035 in) 1,400 i 100 min" (rpml Intake Exhaust r\ \/ 0.08 mm 10.003 in) 0.12 mm 10.005 in) 123 11/05/07 10:19:26 32KVCC007134 CHASSIS AND SUSPENSION Caster Trail Tyre size, Front Tyre size, Rear Tyre type / POWER TRANSMISSION Primary reduction Gear ratio, 151 2nd 3rd 41h 51h Final reduction 124 2630' 100.0 mm (3.94 in) BO/100i18M/C 47F KENDA K2911: 90/90 *18M/C 51F 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 32chc007135 ELECFRICAL Battery Generator LIGHTS Headlight Brake/ Tail light Turn signal light Front Rear Position light License light Instrument light Neutral indicator Turn sign‘ indicator High beam indicator Gear position indicator FUSE Main {use Other fuses /\ \l YTX7L7 BS 12Vi6Ah (10HR) 0.22 kW/5,0IJO min" (rpm) 12Vi35/35W 12V721/5W 12Vi1lJW X 2 12Vi1lJW X 2 12V75W ...U,l|U 12V75W >< 2...TU,IlTU 12Vi5W LED 12Vi1.7W 12Vi3.4W>< Z 12Vi1.7W LED 20A 10A, 15A /\ \1 125 u 1/05/07 10; .46 32KVCC007136 CATALYTIC CONVERTERS (1‘ U, Ill‘U) 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, C0, and NOX. Replacement parts must be original Honda parts or their equivalents. The catalytic converters must operate at a high temperature for the chemical reactions to take place. They can set on fire any combustible materials that come near them. Park your motorcycle away from high grasses, dry leaves, or other flammables. 126 /\ \l Defective Catalytic converters contribute to air pollution and can impair your engines performance. Follow these guidelines to protect your motorcycle’s catalytic Converters. - Always use unleaded petrol. Even a small amount of leaded petrol can contaminate the catalyst metals, making the catalytic converters ineffective. cKeep the engine in good running condition. A poorly mnning engine can cause the catalytic converter to overheat causing damage to the converter or the motorcycle. .lt your engine is mi firing backfiring, stalling or otherwise not running properly, stop riding and turn off the engine. Have your motorcycle serviced as soon as possible. /\ \1