09/09/05 17:20:31 32KTGC007001 ‘ Honda SH125/150CRF OWNER’S MANUAL 5:) (C) Honda Motor Co., Ltd. 2009 ‘ \1/ ‘ t 5 % «if \I 09/00/05 17:20:36 32KTGC007002 ‘ IMPORTANT INFORMATION - OPERATOR AND PASSENGER This scooter is designed to carry the operator and one passenger. . ON-ROAD USE This scooter is designed to be used only on the road. - READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual. These messages are fully explained in the “A Few Words About Safety" section which appears before the Contents page. , This manual should be considered a permanent part of the scooter and should remain with < V the scooter when resold. k ) % #43? 09/00/05 17:20:40 32KTGC007003 Honda SH125/150CRF OWNER’S MANUAL All information in this publication is based on the latest production information available at the tirne of approval for printing Honda Motor Co.,Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication rnay be reproduced without written permission. /\ \1 % (if \ 1 09/00/05 17:20:47 32KTGC007004 WELCOME The scooter presents you a challenge to master the machine, a challenge to adventure. You ride through the wind, linked to the road by a vehicle that responds to your commands as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a pre- ride inspection and regular maintenance are essential to your safety. Your reward is freedom. To meet the challenges safely, and to enjoy the adventure fully, you should become thoroughly familiar with this owner’s manual BEFORE YOU RIDE THE SCOOTER. As you read this manual, you will find information that is preceded by a N symbol. This information is intended to help you avoid damage to your scooter, other property, or the environment. When service is required, remember that your Honda dealer knows your scooter best. If you have the required mechanical “know-how" and tools, your dealer can supply you with an Official Honda Shop Manual to help you perform many maintenance and repair tasks. Pleasant riding, and thank you for choosing a Honda ! r\ \/ .51 32KTGC007005 i 09/08/05 17: o The following code in this manual indicates the country. IWI_ . The specifications may vary with each locale. % «if \ 1 09/00/05 17:20:56 32KTGC007006 A FEW WORDS ABOUT SAFETY Your safety, and the s ety of others, is very important. And operating this scooter safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a scooter. You must use your own good judgment. You will find important safety information in a variety of forms, including: - Safety Labels — on the scooter. . Safety Messages — preceded by a safety alert symbol A and one of three signal words: DANGER, WARNING, or CAUTION. These signal words mean: r\ \/ 09/09/05 17:21:02 32KTGC007007 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 Scooter Safety. - Instructions — how to use this scooter correctly and safely. This entire manual is filled with important safety information — please read it carefully. % /\ \I 09/00/05 17:21:14 32KTGC007008 OPERATION page page 1 SCOOTER SAFETY 37 ESSENTIAL INDIVIDUAL 1 IMPORTANT SAFETY COMPONENTS INFORMATION 37 IGNITION SWITCH 2 PROTECTIVE APPAREL 38 KEYS 5 LOADING AND ACCESSORIES 39 RIGHT HANDLEBAR CONTROLS 40 LEFT HANDLEBAR CONTROLS 10 PARTS LOCATION 13 INSTRUMENTS AND INDICATORS 1:) 21 MAJOR COMPONENTS (Information you need to operate this scooter) 21 SUSPENSION 22 BRAKES 25 COOLANT 27 FUEL 30 ENGINE OIL 31 TUBELESSTYRES r\ \/ % 09/00/05 17:21:26 32KTGC007009 page 41 FEATURES (Not required for operau'on) 41 STEERING LOCK 42 SEAT LOCK 43 HELMET HOLDER 44 DOCUMENT COMPARTMENT 45 CENTER COMPARTMENT 46 SHOPPING HOOK 47 FRONT COVER 4s HEADLIGHT AIM VERTICAL 4' \ ADJUSTMENT /\ \1 page 49 OPERATION 49 50 54 55 63 64 r\ \/ PRERIDE INSPECTION STARTING THE ENGINE RUNNING—IN RIDING PARKING ANTI-THEFT TIPS % 09/00/05 17:21:44 32KTGC007010 MAINTENANCE page 65 MAINTENANCE 65 THE IMPORTANCE OF MAINTENANCE 66 MAINTENANCE SAFETY 67 SAFETY PRECAUTIONS 68 MAINTENANCE SCHEDULE 71 TOOL KIT 72 SERIAL NUMBERS 73 AIR CLEANER 75 BELT CASE AIR CLEANER 4: ) 77 CRANKCASE BREATHER 78 ENGINE OIL 83 SPARK PLUG 86 COOLANT 87 THROTTLE OPERATION 88 FRONT AND REAR SUSPENSION INSPECTION 89 BRAKE PAD WEAR 91 BATTERY 93 FUSE REPLACEMENT 96 BULB REPLACEMENT /\ \l r\ \/ page 104 CLEANING 108 STORAGE GUIDE 108 STORAGE 110 REMOVAL FROM STORAGE 111 TAKING CARE OF THE UNEXPECI‘ED 112 SPECIFICATIONS 1 16 CATALYTIC CONVERTER % 09/03/05 17; .54 32KTGC007011 SCOUT ER SAFETY IMPORTANT SAFETY INFORMATION Your scooter can provide many years of serv e and pleasure 7 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 scooters because they are not looking for them. To make yourself more visible, wear bright reflective clothing, position yourself so other drivers can see you, signal before turning or changing lanes, and use your hom when it will help others notice you. Ride Within Your Limits Pushing the limits is another major cause of scooter crash s. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue and inattention can significantly reduce your ability to make good judgements and ride safely. /\ \1 09/08/05 17: .01 32KTGC007012 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 scooter before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by Honda for this scooter. See page 5 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. % 09/00/05 17; .os 32KTGC007013 Helmets and Eye Protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. A bright-coloured helmet can make you more noticeable in traffic, as can reflective strips. An open-face helmet offers some protection, but a full-face helmet offers more. Always wear a face shield or goggles to protect your eyes and help your vision. /\ \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 more noticeable in traffic. Be sure to avoid loose clothes that could get caught on any part of your scooter. r\ \/ % (if \ 1 09/08/05 17:22:12 32KTGC007014 ALWAYS wear a helmet. You should also wear a face shield or goggles. Clothes should be closefilling. Wear bright or reflective clothing. Shoes should be closefitting, have low heels and offer ankle protection. /\ \1 09/08/05 17: .19 32KTGC007015 LOADING AND ACCESSORIES Your scooter 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 scooter well-maintained, with good tyres and brakes, you can safely carry loads within the given guideline . However, excessive weight or carrying an unbalanced load can seriously affect your scooter‘s handling, braking and stability. Non-Honda accessories, improper modifications, and poor maintenance can also reduce your safety margin. The following pages give more specific inform ion on loading, accessories and niodificr tions. Loading How much weight you put on your scooter, and how you load it, are important to your safety. Anytime you ride with a pa enger or cargo you should be aware of the following iuioririatiou. AWARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed. Follow all loading guidelines in this manual. % «if \ 1 09/00/05 17:22:28 32KTGC007016 ‘ Putting too much weight in individual storage compartments can also affect stability and handling. So be sure to stay within the limits given below: Maximum weight: in center compartment: 10 kg 122 lb) shopping hook: 1.5 kg (3.3 lb) rear carrier: 3.0 kg (6.6 lb) Shopping hook: weight limit: 1.5 kg (3.3 lb) Rear carrier: weight limit: 3.0 kg [6.6 lb) Center compartment: weight limit: 10 kg (22 lb) % 09/09/05 17; .35 32KTGC007017 Loading Guidelines Your scooter 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 Honda dealer for adv’ ‘e, and be sure to read the information regarding accessories on page 8 . Improperly loading your scooter can affect its stability and handling. Even if your scooter is properly loaded, you should ride at reduced speeds whenever carrying cargo. /\ \1 Follow these guidelines whenever you carry a passenger or cargo: . Check that both tyres are properly inflated (page 31). . If you change your normal load, you may need to adjust the rear suspension (page 21 ). cTo prevent loose items from creating a hazard, make sure the center colnpartment is closed and that any other cargo is securely tied down before you ride away. I Place cargo weight as close to the center of the scooter as possible. . Balance cargo weight evenly on both sides. r\ \/ 09/08/05 17: .42 32KTGC007018 Accessories and Modifications Modifying your scooter or using non-Honda accessories can make your scooter unsafe. Before you consider making any modifications or adding an accessory, be sure to read the following informt ion. 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 scooter. Because 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 «Make 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. uBe sure electrical equipment does not exceed the scooter’s electrical system capacity (page 115 ). A blown fuse can cause a loss of lights or engine power. % 09/00/05 17; .47 32KTGC007019 /\ \l o Do not pull a trailer or sidecar with your Modifications scooter. This scooter was not designed We strongly advise you not to remove any for these attachments, and their use can original equipment or modify your scooter seriously impair your scooter's handling. in any way that would change its design or operation. Such changes could seriously impair your scooter’s handling, stability and braking, making it unsafe to ride. Removing or modifying your lights, mufflers, emission control system or other equipment can also make your scooter illegal. r\ \/ % «if \ 1 09/00/05 17:22:52 32KTGC00702D PARTS LOCATION Rear brake fluid reservoir Speedometer Coulant temperature gauge Rearview mirrur Fuel gauge Rear brake lever Headlight dimmer switch Passing light cuntrul mite Turn signal switch Front brake fluid reservoir Rearview minur Front brake lever Throttle grip Headlight switch Start button Horn button lgnitiun switch 10 % (if \ 1 09/03/05 17:22:57 32KTGC007021 Helmet hnlrler Cemer compartment Shopping hook Fuel fill cap Document bag " Tool k“ ( ) Rear carrier Rear suavension spring preload adjuster on filler cap/dipsfick Spafi plug Passenger [notpeg 11 7 \ + LB/oe/os 17:22:02 32KTGC007022 Fuse box Ballery " Passenger Iootpeg Main [use 12 e Helmet-holder Center stand e Rear suspension spring prelnad adjuster " Air cleaner Belt case air cleaner Engine oil drain plug Engine oil strainer screen % (if \ 1 09/00/05 17:23:09 32KTGC007023 INSTRUMENTSAND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages. (1) Left turn signal indicator (2) High beam indicator (3) PGM-FI malfunction indicator lamp (MIL) (4) Oil change indicator (5) Right turn signal indicator (6) Fuel gauge (7) CLOCK/ OIL button (8) Speedometer (9) Digital clock (10) Odometer (11) Tripmeter (12) Tripmeter reset knob (13) Coolant temperature gauge (1) (2) l l (£1 ;r K. I L 13 09/08/05 17:23:21 32KTGC007024 memo.) Description Function (1) Left turn signal indicator (green) Flashes when the left turn signal operates. (2) High beam indicator (blue) Lights when the headlight is on high beam. (3) PGM-FI malfunction indicator lamp (MIL) (amber) Lights when there is any abnormality in the PGM-Fl (Programmed Fuel Injection) system. Should also light for a few seconds and then go off when the ignition switch is turned ON. If it comes on at any other time, reduce speed and take the scooter to your Honda dealer as soon as possible. (4) Oil change indicator (amber) Lights when specified maintenance interval for engine oil change is reached (page 19 ). (5) Right turn signal indicator (green) Flashes when the right turn signal operates. 14 09/08/05 17:23 : 35 32KTGC007025 memo.) Description Function (6) Fuel gauge Shows approximate fuel supply available (page 17 ). (7) CLOCK/OIL button This button is used to adjust the time (page 18 ). This button is also used to reset the oil change indicator (page 19 ). (8) Speedometer Shows riding speed. (9) Digital clock Shows hour and minute (page 18 ). (10) Odometer Shows accumulated mileage. (11) Tripmeter Shows mileage per trip. (12) Tripmeter reset knob Resets tripmeter to zero (0) by pushing the knob. (13) Coolant temperature gauge Shows coolant temperature (page 16 ). 15 % 09/00/05 17:23:41 32KTGC007026 Coolant Temperature Gauge The coolant temperature gauge (1) shows coolant temperature. When the needle begins to move above the C (Cold) mark (2), the engine is warm enough for the scooter to be ridden. The normal operating temperature range is within the section between the H and C marks. If the needle reaches the red band (3), stop the engine and check the reserve tank coolant level. Read pages 25 7 26 and do not ride the scooter until the problem has been corrected. Exceeding maximum running temperature may cause sen'ous engine damage. 16 /\ \l <1) Cuolant temperature gauge (2) c (Culrl) mark (3) Red band /\ \1 % (if \ 1 09/00/05 17:23:47 32KTGC007027 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: 2.0 D (0.53 US gal , 0.44 Imp gall (1) Fuel gauge needle (2) Red band /\ \/ 17 % 09/00/05 17:23 : 55 32KTGC007028 Digital Clock Shows hour and minute. To adjust the time. proceed as follows: 1. Turn the ignition switch ON. 2. Press and hold the CLOCK/OIL button (2) for more than 2 seconds. The clock will be set in the adjust mode with the display flashing. (1) Digital clock (2) CLOCK/OIL button 13 7 l /\ \l 3. Press the CLOCK/ OIL button until the desired time and AM/ PM are displayed. -The time is advanced by one minute. each time the button is pressed. n'l‘he time is advanced by ten minutes. when the button is pressed and held. ALTO end the adjustment, press the CLOCK/ OIL button 5 seconds after the last adjustment, or tum the ignition switch OFF. The clock will be reset AM 1:00 if the battery is disconnected. /\ \1 % 09/00/05 17:24 i 03 32KTGC007029 Oil Change Indicator The oil change indicator (1) lights when the mileage on your scooter approaches the oil change interval specified on the maintenance schedule (page 69 ). After changing the engine oil, reset the indicator as follows: 1. Turn the ignition switch OFF. 2. Press and hold the CLOCK/OIL button (2) while simultaneously turning the ignition switch to ON. 3. Continue to hold the CLOCK/OIL button for more than 2 seconds. The indicator will disappear. /\ \I If the oil is changed before the oil change indicator appears, he sure to reset the oil change indicator after changing the oil. The indicator will appear for 2 seconds, then disappear. This means the indicator is reset. <1) Oilchangeindiuatur <2) CLOCK/OILbutton 19 /\ \1 % «if \ 1 09/00/05 17:24:06 32KTGC007030 The first oil change is at 1,000 km (600 miles), but in this case the indicator should not be reset. The indicator will start blinking after the scooter has covered approximately 4,000 km (2,500 miles). Therefore, after the second engine oil change, as described in the maintenance schedule (page 69 ), remember to reset the oil change indicator (page 19 ). 20 % (if \ 1 09/00/05 17:24:12 32KTGC007031 i MAJOR COMPONENTS (Information you need to operate this scooter) SUSPENSION Each shock absorber (1) has 3 adjustment positions for different load or riding conditions. Use a handlebar (2) to adjust the rear shocks. Always adjust the shock absorber position in sequence (1-2-3 or 3-2-1). Attempting to adjust directly from 1 to 3 or 3 to 1 may damage the shock absorber. , Position 1 is for light loads and smooth road g) conditions. Positions 2 to 3 increase spring preload for a stiffer rear suspension, and can be used when the scooter is heavily loaded. Be certain to adjust both shock absorbers to the same position. Standard position: 1 (2) (1) Shock absorber <2) Handlebar 21 w + lat? % 09/09/05 17:24 i 17 32KTGC007032 BRAKES Combined Brake System (CBS) This scooter is equipped with a Combined Brake System. Operating the rear brake lever applies the rear brake and a portion of the front brake. For full braking etiectiveness, use both the front and rear brake lever simultaneously, as you would with a conventional scooter braking system. As with a conventional scooter braking system, excessively hard application of the brake controls may cause wheel lock reducing control of the scooter. For normal braking, apply both the front and rear brake lever to lnatch your road speed. For maximum braking, close the throttle and firmly apply the front and rear brake lever. 22 /\ \1 Front/ Rear Brake Both the front and rear brakes are the hydraulic disc types. As the brake pads wear, the brake fluid level drops. There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks. If the control lever free travel becomes excessive and the brake pads are not worn beyond the recomlnended limit (page 89 ), there is probably air in the brake system and it must be bled. See your Honda dealer for this service. /\ \1 % «if \ 1 09/00/05 17:24:24 32KTGC007033 l Front Brake Fluid Level: W'h—h—M t e scooter m 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 89 ). Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda 4:) DOT 3 or DOT 4 brake fluid from a sealed container, or an equivalent. Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. (1) LOWER level mark 23 w + w? % 09/00/05 17:24 : 30 32KTGC007034 Rear Brake Fluid Lev With the scooter 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 90 ). 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. Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. 24 /\ \l (1) LOWER level mark /\ \1 % 09/00/05 17:24 : 36 32KTGC007035 COOIANT Coolant Recommendation Use only genuine HONDA PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminum engines when adding or replacing the coolant. Genuine HONDA PREMIX COOLANT is excellent at preventing corrosion and overheating. The effects last for up to 2 years. The coolant should be inspected and repl' ed properly by following the maintenance schedule (page 69 ). /\ \I Use any genuine HONDA PRE-MIX COOLANT without diluting with water. Do not use non-ethylene glycol coolant, tap water, nor mineral water when adding or replacing the coolant. Use of improper coolant may cause damage, such as corrosions in the engine, blockage of the cooling passage or radiator and premature wear of the water pump seal. 25 r\ \/ % «if \ 1 09/00/05 17:24:44 32KTGC007036 l Inspection If the reserve tank IS empty or if coolant The reserve tank (1) is behind the front loss' IS excessive check for leaks and see cover (2). your Honda dealer for repair. Check the coolant level in the reserve tank while the engine is at the normal operating temperature with the scooter in an upright position. If the coolant level is below the LOWER level mark (3), remove the front cover (page 47 ) and reserve tank cap (4), and add coolant mixture until it reaches the UPPER level mark (5). Always add coolant to the reserve tank. Do 0 not attempt to add coolant by removing the C > radiator cap. (2) (4) Reserve tank cap (1) (5) UPPER level mark (1) Reserve tank (3) LOWER level mark (2) Front cover 26 w + lea 09/08/05 17:24 : 52 32KTGC00703’7 FUEL Fuel Tank The fuel tank is located under the seat. Fuel tank capacity is: 7.5 B (1.98 US gal , 1.65 Imp gall To open the fuel fill cap (1), unlock and lift up the seat (page 42 ), then remove the fuel fill cap by turning it counterclockwise. AWARNING Petrol is highly llammable and explosive. You can be burned or seriously injured when handling fuel. - Stop the engine and keep heat. sparks, and flame away. - Reluel only outdoors. - Wipe up spills immediately. (3) <2) \7 , (1) Fuel fill cap (2) Fillei neck (3) An uw marks 27 % 09/00/05 17:24 : 57 32KTGC007038 Do not overfill the tank. There should be no fuel in the filler neck (2). After refueling, be sure to tighten the fuel fill cap firmly by turning it clockwise. Make sure that the arrow marks (3) on the fuel fill cap and fuel tank are aligned. Close the seat. 23 /\ \I Use unleaded petrol with a research octane number of 91 or higher. The use of leaded petrol will cause premature damage to the catalytic converter. If spar knock" or “pinking” occurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinking persists, consult your Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda‘s Limited Warranty. r\ \/ % 09/00/05 17; .02 32KTGC007039 Petrol Containing Alcohol If you decide to use a petrol containing alcohol (gasohol), be sure it's octane rating is at le 't high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol, and the other containing methanol. Do not use petrol that contains more than 10 96 ethanol. Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use petrol containing more than S 96 methanol, even if it has cosolvents and corrosion inhibitors. /\ \l The use of petrol containing more than 10 % ethanol (or more than 5 % methanol) may: . Damage the painting of the fuel tank. . Damage the rubber tubes of the fuel line. . Cause corrosion of the fuel tank. 0 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. 29 r\ \/ % 09/00/05 17:25:12 32KTGC007040 ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the scooter. The level must be maintained between the upper (1) and lower (2) level marks on the oil filler cap/ dipstick (3). 1. Start the engine and let it idle for 375 minutes. 2. Stop the engine and put the scooter on its center stand on level ground. 3. After 273 minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the oil filler cap/dipstick without screwing it in. Remove the oil filler cap/ dipstick. The oil level should be between the upper and lower level marks on the oil filler cap/ dipstick. 4. If required, add the specified oil (see page 78 ) up to the upper level mark. Do not overfill. 30 e i L 5. Reinstall the oil filler cap/ dipstick. Check for oil leaks. Running the engine with insufficient oil pressure may cause serious engine damage. (1) Upper level mark (2) Lewerieveiinark (3) oil filler cap/dipstick + i at? 09/08/05 17: .18 32KTGC007041 TUBELESS TYRES To safely operate your scooter, your tyres must be the proper type and size, in good condition with adequate tread and correctly inflated for the load you are carrying. The following pages give more detailed informa- tion on how and when to check your air pressure, how to inspect your tyres for damage, and what to do when your tyres need to be repaired or replaced. AWARNING Using tyres that are excessively worn or Improperly inilated can cause a crash in which you can be seriously him or killed. Follow all instructions In this owner's manual regarding tyre inilation and maintenance. Air Pressure Keeping your tyres properly inflated provides 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. Overinflated tyres make your scooter n'de harshly, are more prone to damage from road hazards, and wear unevenly. We recommend that you visually check your tyres before every ride and use a gauge to measure air pressure at least once a month or any time you think the tyres might be low. Tubeless tyres have some self-sealing ability if they are punctured. However, because leakage is often very slow, you should look closely for punctures whenever a tyre is not fully inflated. 31 % 09/00/05 17:25:26 32KTGC007042 Always (R) to signal a right turn. Press to tum signaloff. Horn Button (4) Press the button to Sound the horn. <2) Passing light control switch (3) Turn signal switch (4) Hombuflun 40 7‘ + lea % (if \ 1 09/00/05 17:26:30 32KTGC007051 i FEATURES (N at required for operation) STEERING LOCK To lock the steering, turn the handlebars all the way to the left, turn the key (1) to LOCK while pushing in. Remove the key. To unlock the steering, turn the key to OFF while pushing in. Do not turn the ignition switch to LOCK while riding the scooter; loss of vehicle control will result. (A) To unlock (1) Ignition key (A) Push in (B) Turn tu LOCK (C) Turn tu OFF 41 + l éltiij % «if \ 1 09/00/05 17:26:36 32KTGC007052 SEAT LOCK The seat lock is in the ignition switch. To open the seat, insert the ignition key (1) and turn it to the OFF position while pushing in, then turn it counterclockwise to unlock. Pull the seat up. To look the seat, lower and push down on it until it locks. Make sure the seat is secure before riding. (1) Ignition key 42 7 l + 09/00/05 17:26:42 32KTGC007053 HELMET HOLDER The helmet holders (1) are on the left and right side below the seat. The helmet holders are designed to secure your helmet while parked. Open the seat (page 42 ). Hang your helmet on the hooks at the seat hinge and lower the seat to lock. To remove a helmet, unlock the seat. Lift the helmet off the holder and lower the seat, making sure it securely locked before riding. AWARNING Riding With a helmet attached to the holder can interfere with the rearwheel or suspension and could cause a crash in which you can be seriously hurtor killed. Use the helmet holder only while parked. Do not ride with a helmet secured by the holder. (1) Helmet holders 43 % «4}» \ 1 09/08/05 17:26:49 zzkrccooiusa ‘ DOCUMENT COMPAKI‘MENT The document bag (1) is in the document compartment (2), located under the seat. Open the seat (page 42 ). This owner’s manual and other documents should be stored in this compartment. When washing your scooter, be careful not to flood this area with water. (1) Doulment bag (2) Doulment Compartment 44 w + lat? % 09/00/05 17:26 : 56 32KTGC007055 CENTER COMPAKI‘MENT The center compartment (1) is below the seat. Opening and closing: See “SEAT LOCK" (page 42 ). MAXIMUM WEIGHT LIMIT: 10 kg (22 lb) Never exceed the maximum weight limit; handling and stability may be severely affected. The center compartment may become heated by the engine. Do not store food and other articles which are flammable or susceptible to heat damage in this compartment. Do not direct water under pressure against the center compartment as water will be forced into the compartment. not l L (1) Center compartment 45 + l at? % (if \ 1 09/00/05 17:27:02 32KTGC007056 SHOPPING HOOK The shopping hook (1) is provided below the handlebar. MAXIMUM WEIGHT LIMIT: 1.5 kg (3.3 lb) Do not attach large luggage to the hookthat would hang out from the scooter and/or interfere with the movement of your feet. (1) (1) Shopping huok 46 o \ 1 LB/oe/os 17:27:11 32KTGC007057 FRONT COVER The from cover (1) must be removed to service the coolant and fuse. Removal: 1. Remove the screws (2). 2. Release the hooks (3), then remove the from cover. Insmllati : uInslallalion can be done in the reverse 1’ ‘1 order of removal. (1) Front cover (2) Screws 7 \ + (3) Hooks 47 % ll“ \ 1 09/00/05 17:27:16 32KTGC007058 HEADLIGHT AIM VERTICAL ADJUSTMENT Vertical adjustment can be made by tumlng the screw (1) in or out as necessary. Obey local laws and regulations. (1) Screw (A) Up (B) Down 43 09/00/05 17:27:28 32KTGC007059 OPERATION PRE-RIDE INSPECTION For your safety, i is very imponant to take a few moments before each ride to walk around your scooter and check its condition. If you detect any problem, be sure you take care of it, or have it corrected by your Honda dealer. AWARNING Improperly malntalning this scooter or failing to correct a problem before ridlng can cause a crash in whlch you can be seriously hurt or kllled. Always penorm a pre-ride inspection belore every nde and correct any problems. . Engine oil level7add engine oil if required (page 78 ). Check for leaks. Fuel level7fill fuel tank when necessary (page 27 ). Check for leaks. Coolant level7add coolant if required. Check for leaks (pages 25 7 26). Front and rear brakes7check operation; make sure there is no brake fluid leakage (pages 22 7 24 ). 5. Tyres7check condition and pressure (pages 31 7 36 ). .Throttle7check for smooth opening and full closing in all steering positions. 7. Lights and horn7check that headlight, brake/tail light, position light, license light, turn signals, indicators and horn function properly. P99.” a 49 % 09/00/05 17; .33 32KTGC007060 STARTING THE ENGINE Always follow the proper starting procedure described below. This scooter has an automatic fuel valve. To protect the catalytic converter in your scooter‘s exhaust system, avoid extending idling and the use of leaded petrol. 50 /\ \1 Your scooter‘s exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. Do not run the engine with the garage door closed. Even with the door open, run the engine only long enough to move your scooter 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. r\ \/ % «if \ 1 09/00/05 17:27:39 32KTGC007061 This scooter has a fuel-injected engine with an automatic choke. Follow the procedure indicated below. 1. Place the scooter on its center stand. 2. Squeeze the rear brake lever (l). The electric starter will only work when the rear brake lever is pulled in. (1) Rear brake lever 51 7 l + % «if \ 1 09/00/05 17:27:40 32KTGC007062 3. Turn the ignition switch (2) to ON. 4. With the throttle completely closed, press the start button (3). Confirm the following: n’l‘he PGM-FI malfunction indicator lamp The engine will not start if the throttle is (MIL) is OFF. fully open (because the electronic control module cuts off the fuel supply). (2) 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. (2) Ignition switch (3) Stan button 52 7 l + % «if \ 1 09/00/05 17:27:56 32KTGC007063 5. Be sure to keep the throttle closed and Flooded Engine the rear brake lever applied while starting If the engine fails to start after repeated and warming up the engine. attempts, it may be flooded. 6. Allow the engine to warm up before 1. Open the throttle fully. riding (See “RIDING”, page 55 ). 2. Press the start button for 5 seconds. 3. Follow the normal starting procedure. Do not “BLIP" the throttle (open and close 4. If the engine starts with unstable idle, rapidly) as the scooter will move forward open the throttle slightly. suddenly, causing possible loss of control. If the engine does not start, wait for 10 Do not leave the scooter unattended while seconds, then follow steps 173 again. the engine is warming up. CLOSED 53 A _<{>» % 09/00/05 17:20 : 01 32KTGC007064 Ignition Cut on Your scooter is designed to automatically stop the engine and fuel pump if the scooter is o er-turnecl (a banking sensor cuts off the ign on system). Before restarting the engine, you must turn the ignition switch to the OFF position and then back to ON. 54 /\ \l RUNNING-IN Help assure your scooter‘s future reliability and performance by paying extra attention to how you ride during the first 500 km (300 miles). During this period, avoid full-throttle starts and rapid acceleration. r\ \/ % 09/00/05 17:20 : 00 32KTGC007065 RIDING Review Scooter Safety (pages 1 7 9) before you ride. 1. Make sure the throttle is closed and the rear brake is applied before moving the scooter off the center stand. The rear wheel must be locked when moving the scooter off the center stand or loss of control may result. 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 scooter. /\ \l (1) Rear brake lever /\ \1 *1 LB/oe/os 17:28:14 zzkrccooioss (l) 2. Stand on the left side of the scooter /\ \l and push it forward and off the center stand. 3. Mount the scooter from the left side keeping at least one foot on the ground to steady the scooter. 56 r\ \/ % 09/00/05 17:28:20 32KTGC007067 4. Unlock the rear wheel by releasing the rear brake lever (1). (1) Rear brake lever /\ \l 5. Before starting off, indicate your direction with the turn signals, and check ior safe traffic condiu'ons. Grasp the handlebars firmly with both hands. Never attempt onehanded operation; loss of vehicle control could result. 57 r\ \/ % «if \ 1 09/00/05 17:28:26 32KTGC007068 6. To accelerate, open the throttle (2) gradually; the scooter will move forward. Do not “BLIP" the throttle (open and close rapidly) as the scooter will move CLOSE OPEN forward suddenly, causing possible loss \ RR f t 1. A A“ 0 con ro V\§ 7. To decelerate, close the throttle. (2) Throttle 53 7 i + % «4}» \ 1 09/00/05 17:28:32 32KTGC007069 ‘ 8. When slowing down the scooter, coordination of the throttle (2) and front and rear brakes (3) is most important. Both front and rear brakes should be applied together. Independent use of only the front or rear brake reduces stopping performance. Excessive brake application may cause either wheel to lock, reducing control of the scooter. x),- 40 ’\ (l) (2) \ \ (3) (3) C <3) mm and rear brakes (2) Throttle 59 w + we? % 7 \ 09/00/05 17:28 : 38 32KTGC00707D 9. When approaching a corner or turn, close the throttle (2) inlly, and slow the scooter down by applying both from and rear brakes (3) at the same time. (3) (2) Throttle (a) From and rear brakes so /\ \l 10. After completing the turn, open the throttle gradually to accelerate the scooter. % 7 \ «if \ 1 09/08/05 17:28:44 zzkrccooiuu 11. When descending a steep grade, close Avoid continuous use of the brakes, which the Lhrotfle (2) fully and apply both may result in overheating and reduction of brakes (3) to slow the scooter. braking efficiency. (2) Thmme (3) From and rear brakes 61 r\ \/ % H 1:“ l . 50 32KTGC007072 09/00/05 17; 12. When riding on wet or loose surfaces, be especially cautious. When riding in wet or rainy conditions or on loose surfaces, the ability to maneuver and stop will be reduced. For your safety: I Exercise extreme caution when braking, accelerating or turning. 0 Ride at slower speeds and allow for extra stopping distance. I Keep the scooter as upright as possible. 0 . Use extreme aution when riding over : ) slippery surfaces such as railroad tracks, iron plates, manhole covers, painted lines, etc. 62 % 09/00/05 17:20 i 50 32KTGC007073 PARKmG 1.After stopping the scooter turn the ignition switch to the “OFF" position and remove the key. 2. Use the center stand to support the scooter while parked. Park the scooter on firm, level ground to prevent it from falling over. If you must park on a slight incline, aim the front of the scooter uphill to reduce the poss ility of rolling off the center stand or overturning. /\ \l 3. Lock the steering to help prevent theft (page 41 ). The exhaust pipe and muffler become very hot during operation and remain sufficiently hot to inflict burns if touched even after shutting pti the engine. Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking your scooter. HOW TO USE CENTER STAND 63 % 7 i 09/00/05 17:29:04 32KTGC007074 ANT I»THEF1‘ TIPS 1. Always look 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 scooter is accurate and current. 3. Park your scooter in a locked garage whenever possible. 4. Use an ' ditional anti-theft device of good quality. 5. Put your name, address, and phone number in this Owner's Manual and keep it on your scooters at all times. Many times stolen scooters are identified by information in the Owner's Manuals that are still with them. NAME: ADDRESS: PHONE N0: 54 /\ \l LOCK STEERING (1) Ignition key /\ \1 (A) Push in (B) Tum m lotk 09/08/05 17: .11 32KTGC0070’75 MAINTENANCE THE IMPORTANCE OF MAINTENANCE A well-maintained scooter is essential for safe, economical and troublefree riding. It will also help reduce air pollution]. To help you properly care for your scooter, the following pages include a Maintenance Schedule and a Maintenance Record for regularly scheduled maintenance. These instructions are based on the assumption that the scooter will be used exclusively for its designed purpose. Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the Maintenance Schedule. Consult your Hond‘ dealer for recommendations appli able to your individual needs and use. If your scooter overturns or becomes involved in a crash be sure your Honda dealer inspects all major pans even if you are able to make some repairs. AWARNING Improperly maintaining this scooter or failing to correct a problem belore 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. 65 09/08/05 17: .16 32KTGC0070’76 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. 66 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. % 09/03/05 17; .22 32KTGC007077 SAFEI'Y PRECAUTIONS . Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: . Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine. . Burns from hot parts. Let the engine and exhaust system cool before touching. ( ) . Injury from moving parts. Do not run the engine unless instructed to do so. I Read the instructions before you begin, and make sure you have the tools and skills required. oTo help prevent the scooter from falling over, park it on a firm, level surface, using the center 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 pans. Remember that your Honda dealer knows your scooter 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. 67 /\ \1 % «if \ 1 09/08/05 17:29:31 zzkrccooiom MAINTENANCE SCHEDULE Pertonn the Preride lnspectinn (page 49 ) at each scheduled maintenance periud. l lNSEEcr AND CLEAN‘ ADJUST, LUBRICATE OR REPLACE IF NECEseAlzv c CLEAN R: REPLACE A ADJUST L: LUBRICATE The tnllnwingttems require some mechanical knuwledge. Certain ttenis (particularly thnse marked * and a as ) may require more technical intonnation and tools. Consult ynur l-lnnda dealer . Should he seryiced by your Hand-d dealer, unless the uwner has prnper tnols and sennce data and is mechanically qualified. Reter tn the Uflicial Honda Shnp Manual s a ln the interest oi satety, we recnnnnend these items be serviced only by your l-lnnda dealer Hand-d recommends that ynur l-lnnda dealer shnuld road test your sconter atter each periodic maintenance is camed uut. Nn'rEs. (1) At higher ndorneter readings, repeat at the trequency imenrd] established here (2) Serytce at every 8,000 km (5,000 mi) nr nurre irequently when riding in unusually wet or dusty areas (cleaning is prohibited). (3) Sery ~e more irequently when riding in rain ur at iull throttle (4) Replace every 2 years. Replacement requires mechanical skill. 53 r\ \/ 09/08/05 17:29:39 32KTGC007079 ‘ FREQUENC‘ 2%?» ER oDoMETER READING [NOTE (1)] FIRST x mm km I .1 a 12 Reler L x mm m (A G 2 5 7,5 m ITEM NOTE MONTI-I 5 12 12: page . FUEL LINE I I I r x THROTTLE OPERATION I I I 87 AIR CLEANER NOTE (2) EVERY x mmuunsmm R 73 CRANKCASE EREATHER NOTE (:5) C c C 77 SPARK PLL'G I R I xx . VALVE CLEARANCE I I I I r ENGINE OIL R R R R 78 / \‘ : ENGINE OIL S’I‘RAINER SCREEN C 80 , ) \ / - ENGINE IDLE SPEED I I I I x RADIATOR COOLANT NOTE (1) I . COOLING SYSTEM I r . SECONDARY AIR SUPPLY SYSTEM I r 69 09/08/05 17:29:46 32KTGC007080 ‘ FREQUENC‘ Egg“ ER ODOMETER READING INOTE (17] FIRST x mm km I .1 R 12 Reler L x mm Im (A G 2 5 7,5 m ITEM ,7 NOTE MONTH Is 12 12: page x DRIVE BELT u RY {mm (3 0001\le I r EVERY . {mm 0; 00mm) R BELT CASE AIR CLEANER C c C 75 v FINAL DRIVE OIL NOTE (1) BRAKE ELLIID NOTE (1) I I I 1 BRAKE PADS WEAR I I I 89, 90 BRAKE SYSTEM I I I I 22 x 90 / \‘ 9: BRAKELIGHT SWITCH I I I , ) \ , - HEADLIGHT AIM I I I 18 x u CLUTCH SHOES WEAR I r - SUSPENSION I I I xx 9; NUTS BOLTS, FASTENERS I I r u WHEELS/TYR S I I I I r u STEERING HEAD BEARINGS I I r 70 % ll“ \ 1 09/00/05 17:29:57 32KTGC007081 TOOL KIT The tool kit (1) is in the center compartment (2 ). Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. a 8 X 12 mm Open end wrench o 10 X 14 mm Open end wrench . 4 mm Hex wrench . Spark plug wre 'h a Standard/ Phillips screwdriver 4: ) . Screwdriver handle 9 Handlebar . Fuse 30A . Fuse puller . Tool bag (1) Tuol kit (2) Center compartment (1) 71 % 7 \ «if \ 1 09/08/05 17:30:05 32KTGC007082 SERIAL NUMBERS The frame and engine serial numbers are The frame number (1) is stamped on the required when registering your scooter. right side of the frame body. 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 72 /’\ \1 % «if \ 1 09/00/05 17:30:14 32KTGC007083 AIR CLEANER Refer to the Safety Precautions on page 67 . 2. Take out the air cleaner element (3). 3. Thoroughly clean the inside of the air The air cleaner should be serviced at cleaner housing (4). regular intervals (page 69). Service more frequently when riding in unusually wet or dusty areas. 1. Remove the air cleaner housing cover (1) by removing the screws (2). (a) Air cleaner (4) Air deaner element housing (1) Air cleaner (2) Screws housing cover 73 /\ \1 % 09/00/05 4. 5-" 74 17; (if \ 1 .19 32KTGC007084 Install the new air cleaner element. This scooter is equipped with a viscous type Use the Honda Genuine air cleaner air cleaner element. element or an equivalent air cleaner Air blow cleaning or any other cleaning can element specified for your model. Using degrade the viscous element performance the wrong Honda air cleaner element or a and cause the intake of dust. non-Honda air cleaner element which is Do not perform the maintenance. not of equivalent quality may cause premature engine wear or performance problems. Install the removed parts in the reverse order of removal. r\ \/ % 7 \ «if \ 1 09/00/05 17:30:29 32KTGC007085 BELT CASE AIR CLEANER Refer to the Safety Precautions on page 67 . 1. Remove the screws (1) and release the hook(2)l 2. Dlseonnecl Ihe drnln tube (3). 3. Remove the belt case air cleaner assembly (4) by removing the bolts (5). <4) Belt case air cleaner assembly (5) Bolts <1) Screws (3) Drain mbe <2) Houk /\ \/ 75 % ll“ \ 1 09/08/05 17:30:39 zzkrccooiuee 4. Remove the element cover (6) by 6. Wash the element in clean, nonflammable releasing the tab (7). or high flash point solvent and let it dry 5. Remove the element (8). thoroughly. - Never use petrol or low flash point solvents for cleaning the air cleaner. A (7) fire or explosion could result. .Allow the element to dry thoroughly before installation. 0 Do not apply oil to the element; damage to the drive belt will occur. 7. Installation can be done in the reverse order of removal. (6) Element cover (8) Element (7) Tab 76 A _<{>» % «if \ 1 09/08/05 17:30:46 zzkrccooium CRANKCASE BREATHER Refer to the Safety Precautions on page 67 . 1. Remove the crankcase breather tube plug (1) from the tube and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. Service more frequently when riding in rain, at full throttle, or after the scooter is washed or overturned. Service if the deposit 0 level can be seen in the transparent section of the drain tube. <1) Crankcase breather tube plug 7 l + 09/08/05 17:30:59 32KTGC007088 ENGINE OIL Refer to the Safety Precautions on page 67 . Oil Recommendation API SG or higher except classification oils labeled as energy conserving on the circular API service label Viscosity SAE low-30 JASO T 903 MB standard Suggested Oil ENGINE OIL" or equivalent. HONDA “Al-STROKE GASOLINE 78 Your scooter does not need oil additives. Use the recommended oil. Do not use API SH or higher oils displaying a circlllar API energy conserving service label on the container. They may affect lubrication and clutch performance. NOT RECOMMENDED Do not use non-detergent, vegetable, or castor based racing oils. 09/08/05 17: .07 32KTGC007089 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. low-30 low-4o ran an -10 a 1o 20 30 An su‘c i_l_l_l_l_l_l_l 720 n 20 40 so no 100 1zo'F 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 MB class ication. ./ (1) '\ (2) FWDUCT NEEYWG mo r Em comm soanamzwo Wis ME rsnrummcr (1) Code numbel of the sales company cf the oil (2) ()il classification 79 % 09/00/05 17; .14 32KTGC007090 Engine Oil/ Oil Strainer Screen Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the lnaintenance schedule (page 69). 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 reclamation. Do not throw it in the trash or pour it on the ground or down a drain. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although thi unlikely unless you handle used oil on a d 1y basis it is still advisable to thoroughly wash your hands with soap and water as soon as possi- ble after handling used oil. 80 /\ \1 Changing the oil requires a torque wrench. If you do not have it and the necessary skill we recommend that you have your Honda dealer perform this service. If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly. Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. /\ \1 % (l) «if \ 1 09/08/05 17:31:22 32KTGC007091 1. Place a drain pan under the crankcase. 3. Clean the oil strainer screen. 2. To drain the oil, remove the oil filler cap/ 4. Check that the oil strainer screen, sealing dipstick (1), oil drain plug (2), O-ring rubber and drain plug O-ring are in good (3), spring (4) and oil strainer screen condition. (5)- KKT’j/K (2) (1) on filler rap/dipstick (2) on drain plug (4) Spring (3) Oring (5) on strainer sueen 81 /’\ \1 % (if \ 1 09/00/05 17:31:27 32KTGC007092 m . Install the oil strainer screen, spring and drain plug. Oil drain plug torque: 20 N-m12.0 kgf‘m,14|bf>ft) . Fill the crankcase with the recommended grade oil; approximately: 0.9 E (1.0 US qt , 0.8 Imp qt! Install the oil filler cap/ dipstick. Start the engine and let it idle for 3*5 minutes. [12,3 minutes after stopping the engine, check that the oil level is at the upper 4:) level mark on the oil filler cap/dipstick with the scooter upright on firm, level ground. Make sure there are no oil leaks. m 9°.“ 82 % «if \ 1 09/00/05 17:31:40 32KTGC007093 SPARK PLUG Refer to the Safety Precautions on page 67 . Recommended plugs: Standard: CR8EH-9 lNGK) or U24FER9 (DENSO) For extended high speed riding: CRSEH-S lNGK) or U27FER9 (DENSO) 4:) Newer use a spark plug with an improper heat range. Severe engine damage could result. 1. Open the seat (page 42 ). 2. Remove the screws (1). 3. Release the tabs (2), then remove the maintenance lid (3). <1) Screws (3) Maintenance lid (2) Tabs 7 l + 33 % «if \ 1 09/08/05 17:31:51 32KTGC007094 4. Disconnect the spark plug cap (4) from 7. Inspect the electrodes and center the spark plug. porcelain for deposits, erosion or carbon 5. Clean any dirt from around the spark plug fouling. If the erosion or deposit is heavy, base. replace the plug. Clean a carbon or wet- Remove the spark plug using a spark plug fouled plug with a plug cleaner, otherwise wrench furnished in the tool kit. use a wire brush. 9° Check the spark plug gap ( 5) using a wire-type feeler gauge. If adjustment is necessary, bend the side electrode (6) carefully. The gap should be: 0.80i0.90 mm (0.031 *0.035 in) 6. Discard the spark plug. (6) (4) Spark plug Cap (5) Spark plug gap (6) Side electrude 84 7 l + % 09/09/05 17:31:58 32KTGC007095 9. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 10. Tighten the spark plug: 0 If the old plug is good: 1/8 turn after it seats. /\ \l 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. 0 If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 1/2 turn after it seats. DENSO: 1 turn after it seats. b) Then loosen the plug. ( ) c) Next, tighten the plug again: 1/8 turn after it seats. 11. Reinstall the spark plug Cap and maintenance lid. Take care to avoid pinching any cables or wires. 35 r\ \/ 09/08/05 17:32 : 04 32KTGC007096 COOLANT Refer to the Safety Precautions on page 67 . Coolant Replacement Coolant should be replaced by a Honda dealer, unless the owner has proper tools and service data and - mechanically qualified. Refer to an official l-londa Shop Manual. Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. 36 AWARNING Removlng the radlator cap while the englne ls not can cause the coolant to spray out, seriously scaldlng you. Always let the englne and radiator cool down belore removing the radlator cap. % 09/09/05 17:32 : 12 32KTGC007097 THRUITLE OPERATION Refer to the Safety Precautions on page 67 . 1. Check for smooth rotation of the throttle gn‘p from the fully open to the fully closed position at both full steering positions. 2. Measure the throttle grip freeplay at the throttle grip flange. The standard freeplay should be approximately: 2* 10 mm [0.08*0.39 in) To adjust the Ireeplay, slide the throttle cable boot (1), then loosen the lock nut (2) and turn the adjuster (3). After adjustment, tighten the lock nut and return the throttle cable boot securely. /\ \l <1) Throttle cable bunt (2) Lock nut /\ \1 <3) Adjuster % «If \ 1 09/00/05 17:32:16 32KTGC007098 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page 67 . . Check the lront fork assembly by locking the from brake and pumping the fork up and down vigorously. Suspension action should be smooth and there must be no oil leakage. Engine hanger bushingithis can be checked by pushing hard against the side of the rear wheel while the scooter is on o the center stand and feeling lor looseness of the engine hanger bushings. .Carefully inspect all front and rear suspension fasteners for tightness. N w 83 $2? +«~ 09/08/05 17:32:22 32KTGC007099 ‘ BRAKE PAD WEAR Refer to the Safety Precautions on page 67 . Brake pad wear depends upon the severity cl usage, the type cl riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval (page 70). Front Brake Check the wear indicator marks (1) on 4: ) each pad. If either pad is worn to the wear indicator mark, replace both pads as a set. See your Honda dealer for this service. (1) Wear indicator marks 39 Tl + lea % (if \ 1 09/00/05 17:32:26 32KTGC007100 Rear Brake Check the wear indicator grooves (2) in each pad. If either pad is worn to the bottom of the grooves, replace both pads as a set. See your Honda dealer for this service. (2) Wear indicator grooves 90 7 \ + 09/08/05 17:32:31 32KTGC007101 ‘ BATI‘ERY Refer to the Safety Precautions on page 67 . A WAR N I N G It is not necessary to check the battery electrolyte level or add distilled water as the The battery gives 0" explosive battery is a maintenancefree (sealed) type. hydrogen gas during normal operation. If your battery seems weak and/or is leaking electrolyte (causing hard starting or A spark or ilame can cause the battery other electrical troubles), contact your to explode With enough force to kill or Honda dealer. seriously hurt you. Wear protective clothing and a face I ) shield, or have a skilled mechanic do i: ) ry is a maintenance-free type and the battery maintenance. can be permanently damaged if the cap strip is removed. 91 % 09/08/05 17:32:42 32KTGC007102 Removal: . N aRe sure the ignition switch is OFF. 2. Remove the maintenance lid (page 83 ). 3. Remove the battery holder (1) by removing the screws (2). 4. Disconnect the negative (7) terminal lead (3) from the battery first, then disconnect the positive (+) terminal lead ( )- 5. Remove the battery. Installation: . Reinsta in the reverse order of removal. Be sure to connect the positive (+) terminal first, then the negative (7) terminal. 2. Check all bolts and other fasteners are secure. 92 a l L (1) Battery holder (2) Screws (3) Negative (7) terminal lead (4) Positive (H terminal lead + l ele- $2? +«~ 09/08/05 17:32:49 32KTGC007103 ‘ FUSE REPLACEMENT Refer to the Safety Precautions on page 67 . When frequent fuse iailure occurs, it Blownfuse usually indicates a short circuit or an overload in the electrical system. See your l-londa dealer for repair. HIHIHIHMHHH . ‘ L i. r; Never use a fuse with a different rating F from that specified. Serious damage to the IE 3 E 0 electrical system or a fire may result, . C) causing a dangerous loss of lights or engine power. i 93 % (if \ 1 09/00/05 17:32:58 32KTGC007104 Fuse Box: The fuse box is located behind the front cover. The specified fuses are: 1 5A, 1 DA 1. Remove the front cover (page 47 ). 2. Open the fuse box cover (1). 3. Pull out the fuse with the fuse puller furnished in the tool kit (page 71 ). If the fuse is blown, install a new fuse. The spare fuses (2) are located in the fuse box. 4: ) 4. Close the fuse box cover and install the front cover. (1) Fuse bux cover (2) Spare fuses 94 7 l + % #43? 09/00/05 17:33 : o7 32KTGC007105 Main Fu' : The main fuse (1) is located near the battery. The specified fuse is: 30A 1. Remove the maintenance lid (page 83 ). 2. Disconnect the wire connector (2) of the starter magnetic switch (3). Pull the {use out. If the main fuse is blown, install a new main fuse. The spare main {use is in the tool bag. Reconnect the wire connector and install <’ ‘i the maintenance lid. 5” P (1) Main fuse (3) Starter magnetic (2) Wire connectur switch 95 7 l + % «if \ 1 09/00/05 17:33:15 32KTGC007106 BULB REPLACEMENT Refer to the Safety Precautions on page 67 . 0 Be sure to turn the ignition switch OFF when replacing the bulb. The light bulb becomes very hot while the a Do not use bulbs other than those light is ON, and remains hot for a while specified. after it is turned OFF. Be sure to let it cool - After installing a new bulb, check that the down before servicing. light operates properly. 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. C) If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. 96 % 09/08/05 17:33:24 32KTGC007107 /\ \l Headlight Bulb 1. Pull up the dust covers (1). 5. Remove the right and left handle covers 2. Loosen the lock nuts (2) until they will (5) by removing the screwsA (6). no longer turn. P.” (1) Dust cuvers (4) Mirror adapters <2) Locknuts (5) Right and 1m (3) Rearview minors handle covers (6) ScrewsA 6. Remove the screws B (7). Loosen the rearview mirrors (3) and 7. Remove the front handle cover (8). remove them. Loosen the mirror adapters (4) and remove them. (8) <7) Screws B <3) mm handle cover 97 /\ \1 % (if \ 1 09/03/05 17:33:31 32KTGC007108 8. Remove the dust cover (9). 9. Disconnect the connector (10). 10.Turn the bulb holder (11) counterclockwise and remove the bulb (10) (12). 11. Install a new bulb in the reverse order of removal. C 3‘ (11) (12) (9) Dust cover (11) Bulb hulrler (1o) Connector (12) Bulb 93 7 l + % ll“ \1 09/03/05 17:33:39 32KTGC007109 Posiflon Light Bulb 1. Remove the front cover (page 47 ). 2. Remove the socket (1). 3. Pull out the position light bulb (2) without turning. 4. Install a new bulb in the reverse order of removal. (1) Socket /\ \1 (2) Bulb 99 % 09/00/05 17:33:45 32KTGC007110 Brake/Tail Light Bulb /\ \l 1.Remove the taillight lens (1) by removing the screws (2). 2. Slightly press the bulb (3) and turn it (1) counterclockwise. removal. 100 3. Install a new bulb in the reverse order of / \ V; (1) Taillight lens (2) Screws /\ \/ (3) Bulb % «4}» \ 1 09/00/05 17:33:52 32KTGC007111 ‘ Front Turn Signal Bulb The right and left turn signal bulbs replacement can be done in the same way. 1. Remove the socket (1) by turning it clockwise. 2. Slightly press the bulb (2) and turn it counterclockwise. 3. Install a new bulb in the reverse order of removal. . Use only the amber bulb. (2) (1) Socket (2) Bulb 101 w + mg? % (if \ 1 09/00/05 17:34:01 32KTGC007112 Rear Turn Signal Bulb The right and left turn signal bulbs replacement can be done in the same way. , / 1. Remove the taillight lens (pagelOO). 2. Remove the rear turn signal lens (1) by removing the screw (2). 3. Slightly press the bulb (3) and turn it counterclockwise. 4. Install a new bulb in the reverse order of removal. . Use only the amber bulb. (1) (2) (1) Rear turn signal lens (2) Screw 102 /\ \/ (3] Bulb % ll“ \ 1 09/08/05 17:34:09 32KTGC007113 License Light Bulb 1. Remove the license light cover (1) by P9.” removing the screw (2). Pull out the socket (3). Pull out the bulb (4) without lumlng. Install a new bulb in the reverse order of removal. \2 ”l (1) (2) x. (4) (3) ea 0‘} (1) License 1;qu cover (2) Screw /\ \1 <3) Suckel (4) Bull] 103 % 09/00/05 17:34:19 32KTGC007114 CLEANING Clean your scooter regularly to protect the surface finishes and inspect for damage wear and oil coolant or brake fluid leakage. Avoid cleaning products that are not specifically designed for scooter or automobile surfaces. They may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your scooter. If your scooter is still warm froln recent operation give the engine and exhaust systeln 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 scooter. 104 /\ \1 Washing the scooter 1. Rinse the scooter thoroughly with cool water to remove loose dirt. 2. Clean the scooter 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 dalnpened 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 scooter. They will dalnage the plastic and painted surfaces. 0: The inside of the headlight lens lnay be clouded immediately after washing the scooter. Moisture cond nsation inside the headlight lens will d' pear gradually by lighting the headlight in high beam. Run the engine while keeping the headlight on. /\ \1 % 09/08/05 17:34:27 32KTGC007115 /\ \l 4. After cleaning, rinse the scooter 6. Test the brakes before riding the scooter. thoroughly with plenty oi clean water. Several applications may be necessary to Strong detergent residue can corrode restore nonnalbrakingperformance. alloy parts. 5. Drylhe scooter, startlhe engine and let it Braking etiiciency may be temporarily impaired immediately after washing the scooter. Anticipate longer stopping distance to avoid a possible accident. run for several minutes. 105 r\ \/ % 09/09/05 17; .34 32KTGC007116 Finishing Touches After washing your scooter, consider using a commercially-available spray cleaner/ polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instructions on the container. 106 /\ \l Removing Road Salt Seawater can be found on the road near the seaside. The salt in seawater causes rust. Wash your scooter as follows after it has run through salty water. 1. Clean the scooter using cool water (page 104 ). Do not use warm water. This worsens the effect of the salt. 2. Dry the scooter and the surface of the metal is protected with the wax. r\ \/ % «if \ 1 .30 32KTGC007117 09/00/05 17; Painted Aluminum Wheel Maintenance Clean the Mat Painted Surface Aluminum may corrode from contact with Using plenty of water, clean the mat painted dirt, mud, or road salt. Clean the wheels surface with a soft cloth or sponge. Dry after riding through any of these withasoft,cleancloth. substances. Use a wet sponge and mild detergent. Avoid stiff brushes, steel wool, or Use neutral detergent to clean mat painted cleaners containing abrasives or chemical surface. compounds. Do not use waxes ontaining compounds. Alter was ing, rinse with plenty of water and dry with a clean cloth. r\ \/ 107 09/08/05 17:34:46 32KTGC007118 i STORAGE GUIDE Extended storage, requires that you take certain step.- m mum are effects of AWARNING deterioration from non-use of the scooter. In addition, necessary repairs should be Petrol is highly llammable and made BEFORE storing the scooter; explosive. You can be burned or otherwise, these repairs may be forgotten seriously injured when handling luel. by the time the scooter is removed from 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. Make sure the cooling system is filled : 41‘ with a HONDA PREMIX COOLANT. i: ) 3. Empty the fuel tank into an approved petrol container using a commercially available hand siphon or an equivalent method. Spray the inside of the tank with an aerosol rust-inhib ing oil. Reinstall the fuel fill cap on the tank. 108 % 09/09/05 17; 4. To prevent rusting in the cylinder, perform the following: I 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. 0 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. 0 Pour a tablespoon (15*20 cm“) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth. a Crank the engine several times to distribute the oil. a Reinstall the spark plug and spark plug cap. (if \ 1 .52 32KTGC007119 5-" Remove the battery. Store in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month. 6. Wash and dry the scooter. Wax all painted surfaces. Coat chrome with rustinhibiting oil. Inflate the tyres to their recommended pressures. Place the scooter on blocks to raise both tyres off the ground. Cover the scooter (don‘t use plastic or other coated materials) and store in an unheated area, free of dampness with a minimum of daily temperature \mr tion. Do not store the scooter in direct sunlight. .“ 9° 109 r\ \/ % 09/00/05 17:34 : 58 32KTGC00712D REMOVAL FROM STORAGE 5,: Nb—t p m . Uncover and clean the scooter. .Change the engine oil if more than 4 months have passed since the start of storage. Charge the battery as required. Install the battery. .Draln any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol. .Perform all Pre-rlde Inspection checks (page 49 ). Test ride the scooter at low speeds in a safe riding area away from traffic. 110 r\ \/ /\ \l % 09/00/05 17:35:04 32KTGC007121 /\ \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 scooter. 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, n'de slowly and cautiously. Sometimes, crash damage is hidden or not immediately apparent, so you should have your scooter thoroughly checked at a qualified service lacility as soon as possible. Also, be sure to have your l-londa dealer check the lrame and suspension after any serious crash. r\ \/ 09/08/05 17:35:15 32KTGC007122 SPECIFICATIONS DIMENSIONS Overall length Overall witlth Overall height Wheelbase CAPACITIES Engine oil After draining After disassemhly Fuel tank _ Transmission oil After draining :gi After dis sembly Cooling system capacity Passenger capacity Maximum weight capacity 112 2,025 mm (79.7 in) 726 mm 128.6inI 1,230 mm (48.4in) 1,335 mm (52.6in) 1D Sqt, 0.8 Imp qt) 1.1 S,qt 0.9 Imp qt) 1.9 8US gal, 1.65 Imp gal) (D. 20 US qt, 0. 17 Imp th (D. 23 US qt, 0. 19 Imp th 51m. 00 US qt, D.84|mpth Operator and one passenger 180 kg (397 lb) % 09/00/05 17:35:23 32KTGC007123 ENGINE Bore and stroke Compression ratio Displacement Spark plug Standard For extended high speed riding ‘ / Spark plug gap Idle speed /\ \l 52.4 X 57.8 mm (2.06 X 2.2 ' . SH125CRF 58.0 X 57.8 mm (2.28 X 2.28 inl... SH150CRF 11.0 :1 124.6 cm117.60 cu-in)...SH125CRF 152.7 cm“19.31cu-in)...SH150CRF CR8EH-91NGK) or UZAFERB (DENSO) CRSEH-S (NGK) or U27FER9 (DENSO) 0.807 0.90 mm (003170.035 in) 1500:100 min" (rpm! r\ \/ 113 09/00/05 17:35:32 32KTGC007124 ‘ CHASSIS AND SUSPENSION Caster 27DOD' Trail 85.0 mm (3.35 in) Tyre size, from 100/80 *16M/C 50F DUNLOP D451 IRC SS *53DF Tyre size, rear 120/80i16M/C SOP DUNLOP D451 IRC SS *53DR Tyre type biasiply, tubeless POWER TRANSMISSION Primary reduction V , Belt Final reduction 11.423 SH125CRF 10.544 SH15IJCRF 114 % 09/00/05 17:35:43 32KTGC007125 ELECFRICAL Battery Generator LIGHTS Headlight Brake/ Tail light Turn signal light Front Rear Position light Speedometer lights Turn signal indicator High beam indicator License light PGM-FI malfunction indicator lamp (MIL) Oil change indicator FUSE Main {use Other fuses a l L 12V , 6Ah 0.30kW/5,00IJ min" (rpm! avian/55w 1zv721/5w 1zv721w x 2 1zv721w x 2 1zv75w 1zv71.7wx 3 1zv73w x 2 f) 1zv71.7w 1zv75w LED LED 30A 15A, 10A 115 %l% % 09/09/05 17; .50 32KTGC007126 CATALYTIC CONVERTER This scooter is equipped with a catalytic converter. The catalytic converter contains precious metals that serve as catalysts, promoting chemical reactions to convert the exhaust gasses without affecting the metals. The catalytic converter acts on HC, C0, and NOX. A replacement unit must be an original Honda part or its equivalent. The catalytic converter lnust operate at a high temperature for the chemical reactions to take place. It can set on fire any combustible materials that come near it. Park your scooter away from high grasses. dry leaves, or other flammables. 116 /\ \l A defective catalytic converter contributes to air pollution and can impair your engine s performance. Follow these guidelines to protect your scooter‘s catalytic converter. 0 Always use unleaded petrol. Even a small amount of leaded petrol can contaminate the catalyst metals, making the catalytic converter ineffective. nKeep the engine in good running condition. A poorly running engine can cause the catalytic converter to overheat causing damage to the converter or the scooter. .If your engine is misfiring, backfiring, stalling or otherwise not running properly, stop riding and turn off the engine Have your scooter serviced as soon as possible r\ \/