vTéSOF IMPORTANT NOTICE 0 OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. Never exceed the maximum weight Capacity as shown on the tyre information label. 0 ON—ROAD USE This motorcycle is designed to be used only on the road. ' READ THIS OWNER‘S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: WARNWG Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. This manual should be considered a permanent part of the motorcycle and should remain wth the motorcycle when resold HONDA VT250F OWNER’S MANUAL All information in d1is publicatiun is based on the latest production infurmation available at the time of appro‘ml for printing. HONDA MOTOR CO., LTD. reserves the right to make changes at any time Without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. © Honda Motor Co., Ltd. 1988 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 oreride inspection and regular maintenance are essential to your Safety. Your reward is freedom. To meet the challenges eaiely, and to enjoy the adventure tnlly, you should become thoroughly familiar with this owner‘s manual BEFORE YOU RIDE THE MOTORCYCLE. When service is required, remember that your Honda dealer knows your motorcycle best. It you have the required mechanical “know-how” and tools, your dealer can supply you with an otiicial Honda Set» vice Manual to help you periorni many maintenance and repair tasks. Pleasant riding, and thank you tor choosing a Honda. OPERATION Rage 1 MOTORCYCLE SAFETY 1 Safe Riding Rules 2 Protective Apparel 3 Modifications 4 Loading and Accessories 7 PARTS LOCATION 10 Instmmenls and Indicators 14 MAJOR COMPONENTS (Infommtian you need to operate this motorcycle) 14 Suspension 17 Brakes 2 1 Clutch 23 Coolant 25 Fuel 29 EngineOil 30 Tubelesstyres 33 ESSENTIAL INDIVIDUAL COMPONENTS 33 Ignition Switch Page 34 Right Handlebar Controls 35 Left Handlebar Controls 36 FEATURES (Not required {or operation) 36 Steering Lock 37 Helmet Holder 33 Seat 39 Document Bag 40 OPERATION 4o Pre-ride Inspection 41 Starting the Engine 43 Running-in 44 Riding 46 Braking 47 Parking 48 Anti-theft Tips MAINTENANCE Page 49 MAINTENANCE 50 Maintenance Schedule 52 Tool Kit 53 Serial Numbers 54 Colour Label 54 Maintenance Precautions 55 Crankcase Breather 56 Engine Oil 60 Spark Plugs 62 Idle Speed 63 Drive Chain 68 Front and Rear Snspensmn Inspection 68 Side Stand 69 Wheel Removal 75 Brake Pad Wear 76 Brake Shoe Wear Page 77 Battery 79 Fuse Replacement 81 CLEANING 32 STORAGE GUIDE 32 Storage 83 Remoml from Storage 84 SPECIFICATIONS 88 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) 88 Tampering with Noise Control System Prohibited MOTORCYCLE SAFETY AWARNW ' Motorcycle riding requires special ef- forts on your part to ensure your safe- ty. Know these requirements before you ride: SAFE RIDING RULES 1, Always make a prefide inspection {page 40) beiore you Stan the engine. You may prevent an accident or equipment damage. 2. Many accidents involve inexperienced riders. Most countries require a special momrcycle riding test or licence. Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider. 3. Many automobile/motorcycle accidean hap- pen because the automobile driver does not “see” the motorcyclist Make yourself conspicuous to help avoid the accident that wasn’t your fault: 0 Wear bright or reflective clothing. ' Don‘t ride in another molorisl's “blind spot." 4, Obey all national and local laws and regulations. ' Excessive speed is a factor in many ac- cidents. Obey the speed limits, and NEVER travel faster than cond ons warrant. - Signal before you make a turn or lane change. Your size and maneuverability can surprise other mntorists. 5. Don't let other motorists surprise you. Use extra caution at intersections, parking lot en- trances and exits, and driveways. 6. Keep both hands on the handlebars and both feel on the footpegs while riding. A passenger should hold on to the motorcycle or the operator with both hands and keep both feet on the passenger footpegs. PROTECTIVE APPAREL 1. Most motorcycle accident fatalities are due to head injuries: ALWAYS wear a helmet. You should also Wear a face shield or goggles as well as boots, gloves, and protective clothing. A passenger needs the same protection. . The exhaust system becomes ho! during operation, and it remains hot for a while alter sLopping the engine. Be careful not to touch the exhaust system while it is hot. Wear clothing that hilly covers your legs. . Do not wear loose clothing which could catch on the control levers, tootpegs, drive chain or wheels. MODIFICATIONS AWARNW Modification of the motorcycle, or removal 01 original equipment, may render the vehicle unsafe or illegal. Obey all national and local equipment regulations. LOADING AND ACCESSORIES ~ mums ' To prevent an accident, use extreme care when adding and riding with ac» oessories and cargo. Addition of 34> eeseoriee and Cargo can reduce a motorcycle’s stability, periornience and safe operating speed. Never ride an accessory-equipped motorcycle 8! speeds above 130 km/h (80 mph). And remember that this 130 km/h (30 mph) limit may be reduced by installa- tion of non-Honda accessories, im- proper loading, worn tyres and overall motorcycle cond~ ion, poor road or weather conditions. These general guidelines may help you decide whether or how ‘0 equip your motorcycle. and how to load it safely. Loading The combined weight of the rider, passenger, cargo and additional accessories must not ex- ceed the maximum weight capacity: 170 kg (375 lbs) Cargo weight alone should not exceed: 9 kg (20 lbs) 1. Keep cargo and accessory weight low and close to the center of the motorcycle. Load weight equally on both sides to minimize im- balance. As weight is located further from the mowrcycle‘s center of gravity, handling is proponionally affected. 2. Adjust tyre pressure (page 30), front suspen» sion tpage 14) and rear suspension (page 15) to suit load weight and riding conditions. 3. Vehicle handling and stability can be adversely affected by loose cargo. Recheck cargo security and accessory mounts irequently. 4. Do not attach large or heavy items to the handlebars, front iorlrs, or lender. Unstable handling or slow steering response may result. Accessories Genuine Honda accessories have been specifical- ly designed {or and tested on this motorcycle. Because the factory cannot test all other ac» cessories, you are personally responsible tor pro per selection, installation, and use of non-Honda accessories. Always follow the guidelines under Loading, and these . Carefully inspect the accessory to make sure it does not obscure any lights reduce ground clearance and banking angle, or limit suspen- sion travel, steering travel or control operation. 2. Large fork-mounted (airings Dr Windshields. or poorly designed or improperly mounted iairings can produce aerodynamic ioroes that cause unsmble handling. Do not install fair- ings that decrease cooling air flow to the engine. . Accessories which alter your riding position by moving hands or ieet away irom controls may increase reaction time in an emergency. . Do not add electrical equipment that will eXr teed the motorcycle's electrical system capacity. A blown {use could cause a dangerous loss oi lights or engine power. . This motorcycle was not designed to pull a Sidecar or trailer. Handling may be seriously impaired it so equipped. . Any modification oi the cooling system may cause overheating and serious engine damage. Do not modify the radiator shrouds or install accessories which block or deflecL air away irom the radiator. PARTS LOCATION Rearview mirror Temperature Tachometer gauge Warning and indicator lights Reaview mirror Front brake fluid reservoir Speedometer Engine stop switch Headlight switch Throttle grip Passing light control switch Starter button . _ Ignition switch dlmmer SWltch Tum signal switch Horn button Fuel tank cap Passenger foolpeg Fuel cock Center stand Footpeg Side stand Helmet. holder Brake caliper INSTRUMENTS AND INDICATORS The indicators and warning lights are conmined in the instrument panel. Their functions are described in the tables on the following pages. (1) Speedometer (2) Odometer (3) Left turn signal indicator (4) Coolant temperature gauge (5) Right turn signal indicator (6) Tachometer i7) Tachometer red zone (8)1‘ripmeter (9) Oil pressure warning light (l0) High beam indicator (11> Neutral indicator (12) Tripmeter reset knob 10 be») u Rel. No. Description Function 1 Speedometer Shows ri ng' speed. 2 Odometer Shaws accumulated mileage. Left tum signal in- . 3 dicamr (amber) Flashes when the left turn signal operates. 4 CW1“ tempmm’e Shows coolant temperature tsee page 13). gauge Right tum signal in- . . 5 dimer (MW Flashes when the right turn signal operates. 6 Tachometer Shows engine rpm. Never allow the tachometer needle to enter the red zone, even after the engine has been broken in. 7 Tachometer red zone “WW": ~ The red zone indicates the maximum limits at engine speed and running the engine in the red zone may adversely aflect its service lite. Ref. No. Description Function 8 Triprneter Shows mileage per trip. Lights when engine oil pressure is below normal operating range. Should light when ignition switch is ON and engine is not mnning. Should go out when engine starts, except 9 on pressure warning for occasional flickering at or near idling speed when light iredl engine is warm, cAunou: ‘ Running the engine with insufficient oil pressure may cause serious engine damage. 10 magneani “mm” Lights when the headlight is on high beam. 11 New“ “"d‘cam‘ Lights when the transmission is in neutral. 1green) 12 Triprneter reset knob Resets triprneter to zero (0» by pushing the knob. Coolant Temperature Gauge CAUTION: When the needle begins to move above the c ' Exceeding maximum operating tem- (Cold) mark, the engine is warm enough tor the venture may cause serious engine motorcycle to be ridden. The normal operating damage. temperature range is within the section between the H and C marks. It the needle reaches the H (Hon mark, stop the engine and check the reserve tank coolant level. Read pages 23—24 and do not ride the motorcycle until the problem has been corrected. ‘2"? 45 (1) Coolant temperature gauge 13 MAJOR COMPONENTS (Information you need to operate this motorcycle) AWARNW ‘ It the Preride Inspection (page 40) is not pertormed, severe personal injury or vehicle damage may result. SUSPENSION Front Suspension The from suspension or this motorcycle can pro- vide the desired ride under various rider/cargo weights and riding conditions Lhrough adjust- ment of the air pressure within the fork tubes. The recommended pressure under normal riding conditions is: 0—40 kPa (0—0.4 kg/crnz, 076 psi» Low air pressure settings provide a softer ride and are for light loads and smooth road condi- tions. High air pressure settings provide a firmer nde and are for heavy loads and rough road conditionsr 14 Check and adjust air pressure when the from iork tubes are cold before riding. 1. Raise the frontwheel oil the ground by using a jack under the engine. Do not use the side stand or you will get false pressure readings . Remove the from fork air valve caps (1), r Check the air pressure using a pressure gauge, um (1) Valve cap NOTE: " Some pressure will be lost when removing the gauge from me valve, Determine the amount oi loss and compensate accordingly. 4. Add all to the recommended pressure. CAUTION: ' Do not exceed 300 kPa (3.0 kg/cmz, 42 psi) or the air pressure gauge may be damaged. NOTE: — Do not exceed the recommended air pressure or the ride will be harsh and uncomfortable. Rear Suspension Spring prelozd: The rear suspension can provide the desired ride under various rider/passenger weight and riding conditions through adjustments oi the spring preload adjuster (1). The spring preload adjuster is located behind the leit side cover. Remove the leit side cover by tur- ning the screw (2) counterclockwise and pulling the cover (3) out carefully while hold the rear cowl (4t (2) Screw (3) Left side cover (4) Rear cowl (st Pin spanner 15 Use the pin spanner 15» and breaker har (6) pro vided to make adjustments. The spring preload adjuster (it has 7 spring preload positions {or diiierent load or riding Conditions. Remove the left side Cover (page 15). Use the Pin spanner (5) to adjust the rear shock. Posi~ tions 1 is tor a light loads and smooth road conditions. Positions 2 to 7 increase spring preload for a stir ier rear suspension and can be used when the (1) Spring preload adjuster <6) Breaker bar 16 motorcycle is more heavily loaded. Awamxllliu « The rear shock absorber assembly in- cludes a damper unit that contains high pressure nitrogen gas. The in- structions found in th' owner‘s manual are limited to adjustment of the shock assembly only. Do not at- tempt to disassemble, disconnect or service the damper unit; an explosion causing serious injury my resultr Puncture or exposure to flame may also result in an explosion, causing rious injury. Service or disposal should only be done by your authorized Honda dealer or a qualified mechanic, equipped with the proper tools, safety equip- ment and the official Honda Service Manual. BRAKES Front Brake This motorcycle has hydraulic disc iront brakes. As the brake pads wear, brake fluid level drops, automatically compensating tor wear. There are no adjustments to perform, but fluid level and pad wear must be inspected periodical» ly. The system must be inspected trequently to ensure there are no fluid leaks. it the control lever free travel becomes excessive and the brake pads are not wom beyond the recommend- ed limit (page 75), there is probably air in the brake system and it must he bled. See your authorized Honda dealer for this service. Brake Fluid Level: AWARNW » Brake fluid may cause irritation. Avoid Contact with skin or eyes. in case oi contact, flush thoroughly with water and call a doctor if your eyes were exposed. Check that the fluid level is above the IDWER level mark (I) with the motorcycle in an upright position, (I) LOWER level mark 17 Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark 11). Remove the screws 12)' \ “7 u ’ ;. \v (1) LOWER level mark 14) Diaphragm plate (2) Screws 5) Diaphragm (3) Resevoir cover 16) Upper level mark reocrvoir cover (3). diaphragm plate (4} and diaphragm (5t. Fill the reservoir with DOT 3 or DOT 4 BRAKE FLUID (mm a sealed container up to the upper level mark (6). Reinstall the diaphragm , disphragm plate and cover. Tighten the screws securely. CWTION: ' Handle brake fluid with cure because it can dam-ac plastic and minted surf-ml ‘ when Hiding brake fluid, be sure the reservoir is horizonul before the cap is removed or brake fluid my spill out. ' Use only DOT 3 or 4 brtke fluid from I sealed container. Never allow conuminmta such ”dirt or water to enter the brake fluid reservoir. Other Checks: Make sure mm are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. Rear Brake Adjustment: l. Place the motorcycle on its center stand. 2. The stopper bolt (1D is provided to allow ad- justment of the pedal height. To adjust the pedal height, luosen the lock hut at and tum the stopper bolt. Tighten the lock nut. (l) Stopper bolt (2) Lock nut 3. Measure the distance the rear bmke pedal (3D moves before the brake starts to take hold Free play should be: 20730 mm (W4rl-1/4 in) (3’ Rear brake pedal 20—30 mm (3/4—1-1/4 in) Make free play adjustments by luming the adjusting wt (4) at the brake arm. NOTE- ‘ Make sure the cubout on the adjusting nut is seated on the brake arm pin (5» after making final free play adjustment. II proper adjustment cannot be obtained by this method, see your authorized Honda dealert 20 4. Apply brake several times and check for free wheel rotation when released, Other Checks: Make sure the brake rod, brake arm, spring and fasteners are in good condition. (43 Adjusting nut (51 Arm pin (A) Decrease free play ()3) Increase free play CLUTCH Clutch adjustment may be required it the motor- cycle stalls when shitting into gear nr tends to creep; or if me clutch slips. causing acceleration to lag behind engine speed. Minor adjustments can be made win: the clutch cable adjuster (4) at the lever (1). Normal clutch lever free play is: 10~20 mm (3/8—3/4 in) 10—20 mm (3/8—3/4 int 11) Clutch lever 1. Pull back the rubber dust cover (2t. Loosen the lock nut (3) and turn the adjuster (4t. Tighten the lock nut (3t and check the adjustment. 2. If the adjuster is threaded out near lts limit or if the correct free play Cannot be obtained. loosen the lock nut (3| and turn in the cable adjuster (4) completely. Tighten the lock nut (3) and pull on the dust Coven (2t Dust cover (A) Increase free play (3, Lock mu (5» Decrease tree play 14) Clutch cable adjuster 21 3. At the lower end of the cable, loosen the lock nut (6). Turn the adjusting nut (5) to obtain the specified tree play. Tighten the lock nut (6) and check the adjustment. 4. Start the engine, pull in the clutch lever and shift into gear. Make sure the engine does not stall and the motDrcycle does not creep. Gradually release the clutch lever and open the throttle. The motorcycle should start smoothly and accelerate gradually. Q (A) Increase free play 1B) Decrease free play 15) Adjusting nut (6) Lock nut 22 NOTE: ‘ Lt proper adjustment cannot be obtained or the clutch does not work correctly, see your authorized Honda dealer. Other Checks: Check the clutch cable tor kinks or signs at wear that could cause sticking or failure. Lubricate the clutch cable with 2 commercially awilable cable lubricant to prevent premature wear and corrosion. COOLANT Coolant Recommendation The owner must properly maintain the coolant to prevent lreezing, overheating, and corrosion. Use only high quality ethylene glycol antiireeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. (SEE ANTIFREEZE CONTAINER LABEL). CAUHON: . Use only low-mineral drinking water or distilled water as a part of the an- tifreeze solution. Water that is high in mineral content or salt may be harm- ful to the aluminum engine. The factory provides 2 50/50 solution of an- tifreeze and water in this motorcycle. This coolant solution is recommended for most operating temperatures and provides good cornr sion protection. A higher concentration or an» tilreeze decreases the cooling system perfor mance and is recommended only when addi» tional protection against freezing is needed. A concentration of less than 40/601400)» antifreeze) will not provide proper corrosion protection, During freezing temperatures, check the cooling system frequently and add higher concentrations of antifreeze (up to a maximum of 60% an- tifreeze) if required, 23 Inspection The reserve tank is behind the left side cover. Remove the lelt side cover (page 15) and check the coolant level in the reserve tank (1) while the engine Is at the normal operating temperature with the motorcycle in an upright position. It the coolant level is below the LOWER level mark 13), remove the reserve tank cap 14) and add (ll Reserve tank (2) UPPER level mark (4) Reserve tank can (3D LOWER level mark 24 coolant mixture until it reaches the UPPER level mark (2D. Do not remove the radiator cap. A ARNWG ' Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. ' Keep hands and clothing away from the cooling (an, as it starts auto~ matically. If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your authorip ed Honda dealer tor repair. FUEL Manual Fuel Cock The manual luel cock (1) is under the left side of the fuel tank in the left side Cover. Set it Lo ON for normal operation or RES when you start to run out of the main fuel supply. The OFF setting is only for long term storage or servicing oi fuel system componentsl Automatic Fuel ON-OFF With the fuel cock set to ON (or RES) fuel flows to the carburetors only when the engine is being started or is running. A diaphragm shuts off fuel flow when the engine is turned off. Reserve Fuel When the main fuel supply is gone, turn the fuel cock to RES. Refill the hank as soon as possible after switching to RES. then switch the cock back to ON. The reserve fuel supply is: 2.2 l (0.58 US gal, 0.48 Imp gal) To avoid running out of fuel that may result in a sudden stop, learn how to operate the fuel cock when riding the malorcycle. NOTE: Do not operate the motorcycle with the fuel cock in the RES position after refueling. You may run out 01 fuel with no reserve. OFF (1’ Fuel cock 25 Fuel Tank The fuel tank capacity. including reserve, is: 13 I (3.4 Us gal. 2.3 Imp gal) To open the fuel tank cap (1), open the tank cap cover 12). insert the ignition key (3) and turn it clockwise. The Cap will pop up and can be lifted 0“. To close the fuel tank cap, align the latch in the cap with the slot in the filler neck. Push cap into the filler neck until 1: snaps closed and locks. Remove the key and close the tank cap Cover. Use low-lead or unleaded petrol with an Octane number of 91 or higher. FOR AUSTRALIA ONLY: Use unleaded fuel with an research octane number of 91 or higher. CAUTION: ‘ It “spark knock“ at “pinking” occurs at a steady engine speed under normal load, change brands of petrol. n spark knock or pinking persists, consult your authorized Honda dealer. Failure to do so is considered misuse. and damage caused by misuse is not covered by Honda’s Limited War- ranty. 26 (1) Fuel tank cap (2) Tank cap cover (3) Ignition key (4) Filler neck ll MARNW ‘ Petrol is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is reinsletl or where petrol is stored. ‘ Do not overfill the tank (there should be no fuel in the filler neck 14)}. After refueling, make sure the fuel cap is closed securely. ‘ Be careful not to spill fuel when refueling. Spilletl fuel or fuel vapor may ignite. It any fuel is spilled, make sure the area is dry before starting the engine. ‘ Avoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDRENr Petrol Containing Alcohol It you decide to use a petrol containing alcohol (gasohol). be sure it‘s octane rating is at least as high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol, and the Other containing methanol. Do not use petrol that contains more than 10% ethanol. Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use petrol containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors. 27 N0 n 28 TE: Fuel system damage or engine performance problem resulting mm the use of fuels that contain alcohol is not covered under the war- ranty. Honda cannot endorse the use of fuels containing methanol since evidenoe 0f their suitability is as ye! incomplete, Before buying tuel tram an untamiliar sta- tion. try to find Out the fuel contains alcohol, it it does, continn me type and percentage of alcohol used. It you notice any undesirable operating symptoms while using a petrol that contains alcohol, or one that you think coir rains alcohol. switch to a petrol that you know does not contain alcohol. ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be mainmined between the upper (l) and lower l2l level marks in the inspection window (3), 1. Start the engine and let it idle for a few minutes. Make sure the red oil pressure war» ning light goes off. If me light remains on, stop the engine immediately. 2. Stop die engine and put the motorcycle on its Center stand on level ground 3. Check that the oil level is maintained be- tween the upper (ll and lower (2) level marks in the inspection window (3). It the window is dirty, clean it by turning the wiper (4) with a screwdriverl 4. It required. remove the oil filler cap 15) and add the specified oil up to the upper level mark (See page 56). Do not overfillv 5. Reinsmll the oil filler cap. Check for oil leaks, CAUTION: ‘ Running the engine with insufficient oil can cause serious engine damage. (1) Upper level mark (4) Wiper (2’ Lower level mark (5) Filler cap (3) Inspection window 29 TUBELESS TYRES This motoreyele is equipped with tubeless tyre, valves, and wheel n'rns. Use only tyres marked ”TUBELESS" and lubeless Valves on rims marked “TUBELESS TYRE APPLICABLE." Proper air pressure will provide maximum stability, riding comfort and tyre life. Check tyre pressure frequently and adjust if necessary. NOTE: * Tyre pressure should be checked before you ride while the tyres are “cold". Tubeless tyres have some degree of senseal- lng ability if they are punctured, and leakage ls olten very slow, lnsneet very closely for punctures, espeolally if the tyre is not fully inflated. 30 Front Rear . 110/9046 120/sm7 Ty” 5'“ 545 615 Cold tyre Driveron- 225 225 pressures ly (225,331 (225,33) kPa D» (kg/6mg afivzge 225 250 psi) passenger (2,25, 33) (2.50, 35) Tyre brand TUBELESS ONLY G539 (3540 BRIDGESTONE Check the tyres for cuts, imbedded nails or other sharp objects. Check the rims for dents or defor- mation. If there is any damage, see your authorized Honda dealer for repair, replace» ment, and balancing. mer improper tyre inflation will cause ab- normal trend wear and create a safety hazard. Underinflation may result in the tyre slipping on, or coming ott of the rim causing tyre deflation that may result in a loss of vehicle control. Operation with excessively worn tyres is hazardous and will adversely affect traction and handling. Replace tyres heiore tread depth at the center oi the tyre reaches the following limit: Minimum tread depth Front: 1.5 mm (1/16 int Rear: 2.0 mm (3/32 in) Tyre Repair/Replacement: See your authorized Honda Dealer. AWARNWG ' The use of tyres other than those listed on the tyre infurmation label may adversely affect handling. ‘ Do not install tube-type tyres on tubeless rims. The heads may not seat and the tyres could slip on the rims, causing tyre deflation that may result in a loss of vehicle control. ' Do not install a tube inside a tubeless tyre. Excessive heat build-up may cause the tube to burst resulting in rapid tyre deflation that may result in a loss of vehicle control. 31 AWARNW ‘ Proper wheel balance is necessary for safe, stable handling of the motorcy- cle. Do not remove or change any wheel balance weights. When wheel balancing is required, see your au- thorized Honda dealer. Wheel balanc- ing is required after tyre repair or replacement. « To avoid possible repair failure and tyre deflation that may result in a loss of vehicle control, do not exceed 30 km/ll 150 mph] for the first 24 hours‘ or 130 km/h 180 mph} at any time, aiier tyre repair. ' Replace the tyre ii the sidewall is punctured or damaged. sidewall flex- lng may cause repair failure and tyre deflation that may result in a loss of vehicle control. 32 CAUTION: ’ Do not try to remove tubeless tyres without special tools and rim protec- tors. You may damage the rim sealing surface or disligure the rim. ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (I) is below the indicator Panel, (1’ Ignition Switch Key Position Function Key Removal LOCK . , . Key can be (“wing lock) Steenng ls locked. Engme and was cannot be operated. removed For parking the molorcyclc near traffic, The millight and pan. K6 can be P (parking) lion light are on. but all other lights are all. The engine cannot V d be started, remove . V Key can be OFF Engme and lush: cannot be opmled, removed . Key cannot be ON Engine and lights can be operaml. removed 33 RIGHT HANDLEBAR CONTROLS Engine Stop Switch The engine stop switch m is next to the throttle grip. When the switch is in the RUN position, the engine will operate. When the switch is in the OFF position, the engine will not operate. This switch is intended primarily as a safety or emergency switch and should normally remain in the RUN position. Headlight Switch The headlight switch (3) has three positions. “H" “P" and “OFF" marked by a dot to the right of “P". H: Headlight, taillight. position light and meter lights on. P: Position light, taillight and meter lights on. OFF (dot): Headlight, taillight, and meter lights off. position light 34 Starter Button The starter button (2) is below the headlight switch (It When you press in the button the starter cranks the engine See pages 41—42 for “Starting Procedure.” (1) Engine stop switch (2) Starter button (3) Headlight switch LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch {1) Push the dimmer switch to “H1” to select high beam or to “L0" to select low bezml Passing Light Control Switch (2) When this switch is pressed, the headlight flashes on to signal approaching cats or when passing. Turn Signal Switch 13) Move to L to signal a left tum, R to signal a right turn. Press to tum signal of: Horn Button 14} Press the button to sound the ham (1) Headlight dimmer switch (2) Passing light control switch (St Turn signal switch (4} Horn button 35 FEATURES (Not required for operation) STEERING LOCK To lock the steering. turn the handlebars all the Way to the left or right. tum the key (1) to P or LOCK while pushing in. Remove the key. WARM , ~ Do not turn the key to P or LOCK while riding the motorcycle; loss of vehicle control may result. 36 (1t Ignition key (A) Push in (BD Tum to P or LOCK HELMET HOLDER The helmet holder (1) is on the left side below the seat. insert the ignition key (2) and turn it clockwise to unlock the holder. Hang your helmet on the holder pin (3), Turn the key counterclockwise to lock the holder and then remove the key wwv The helmet holder is designed for helmet security while parked. Do not ride with a helmet attached to the holder; the helmet may interfere with safe operation and result in lose or control. (D Helmet holder [2} Ignition key (3] Holder pin 37 Passenger‘s Helmet Holder The passenger's helmet holder is located below the seat. Remove the seal. Hang the helmet on the holder hook (4b. Install the seat, Turn the key counterclockwise to lock the seat then remove the key. (4) Holder hook 38 SEAT To remove the seat (1», insert the ignition key (2) into the helmet holder (3), turn it clockwise and pull the seat lock lever 14) downward. Pull the seat back and up (ll Seal. (3) Helmet holder To install the seat, insert the seat tab under the frame cross member and push down on the rear of the seat. Tum the key counterclockwise to lock the seat, then remove the key, Lift the seat to make sure it is locked securely in position. To install the seats, reverse the removal procedure. (2) Ignition key (3) Helmet holder (4) Seat lock lever DOCUMENT BAG The document bag m is under the seat. This owner's manual and other documean should be stored in the document bag. When washing your motorcycle, be careful not to flood this area with water. (l) Document bag 39 OPERATION PRBRIDE INSPECTION it www ‘ If the Pre-ride Inspection is not per- torined, severe personal injury or vehicle damage may result Inspect your motorcycle every day helore you ride it. The items listed here will only take a few minutes to inspect, and in the long run they can save time, expense, and possibly your lile. 1. Engine oil level—add engine oil it required (page 29b. Check for leaks. 2. Fuel level—fill fuel tank when necessary (page 26). Check for leaks. 3. Coolant level—add coolant if required. Check for leaks (pages 2344). 4. Front and rear bakes—check operation; make sure there is no brake fluid leakage, Adjust {roe play if necessary (Pages 17—18). 5. Tyresichcck condition and pressure (pages 30—31D 6. Drive char check condition and slack (pages 63-67). Adjust and lubricate it necessary. 40 7. Throttle—check lor smooth opening and closing in all steering positions. 3. Liglns and homicheck that headlight. tail/stoplight, tum signals, indicators and horn function properly. 9. Engine stop switch—check (or proper {unc- lion(page 341 10. Battery electmlyterclleck the level and add if necessary (page 77). Correct any discrepancy belore you ride. Con- tact your authorized Honda dealer for assistance if you cannot correct the problem. STARTING THE ENGINE NOTE: The electric system is designed to prevent electric starting it the transmission is in gear, unless the clutch is disengaged. However, it is recommended that the transmission be placed in neutral before attempting to start the engine. ‘ Do not use the electric starter for more than 5 seconds at a time. Release the starter button {or approximately 10 seconds before pressing it again. « Never run the engine in a closed urea. The exhaust contains poisonous car- bon monoxide gas that can cause loss oi consciousness and may lead to death. Preparation . Make sure the transmission is in neutral and the fuel cock is ON 2. Insert the key in the ignition switch and turn to ON. The neutral indicator (green) and oil pressure warning light (red) should go on. 3. Make sure the engine stop switch is in RUN Starting Procedure 1 Pull the choke lever (1) back all the way to the fully open position (B). it the engine is cold 2. Press the starter button, leaving the throttle closed. 3. Warm up the engine by opening and closing the throttle until it runs smoothly, with the choke closed. V-\ 52s @73 (I) Choke lever {A} Fully Closed (8) Fully Open 41 NOTE: ‘ Do not open the throttle when starting the engine with the choke open. This will lean the mixture, resulting in hard starting. CAUTION: . The red oil pressure warning light should go off a few seconds after the engine starts. 11 the light stays on, stop the engine immediately and check engine oil level. Operating the engine with insufficient oil pressure can cause serious engine damage. (2) on pressure waming light 42 Flooded Engine II the engine fails to scan after repeated at- tempts, it may be flooded with excess fuel. To clear a flooded engine. turn the engine stop switch OFF and push the choke lever forward to Fully Closed (A). Open the throttle iuuy and crank the engine {or 5 seconds. Wait 10 seconds, then tum the engine stop switch 0N and follow the Starting Procedure (page 41). RUNNING-IN During initial running-in. newly machined sur- faces will be in contact with each other and these surfaces will wear in quickly. Runningin maintenance at 1,000 km (500 miles) is designed to compensate for this initial minor wear. Timely performance oi running-in maintenance will en» sure opu‘nium service life and pertormance from the engine. The general rules are as tollows: 1. Never labour the engine with {I111 throttle at low engine speeds. This rule is applicable not only during running-in but at all times. 2. Maximum continuous engine speed during the first 1,000 km (600 miles» must not ex ceed 6,000 min" (rpm). 3. Increase the maximum continuous engine speed by 4,000 min" (rpm) between odom- eter readings of 1,000 km (600 miles) and 1,600 km (1,000 miles). Drive briskly, vary speeds frequently and use full throttle for short bursts only. Do not exceed 10,000 min-l (rpm). 4. Upon reaching an odometer reading ot 1,600 km (1,000 milesb, you can subject the motor- cycle to iull throttle operation. However, do not exceed 13,500 min" (rpm at any time iteaehometer RED ZONE limit). cwnou: - The red zone indicates the maximum limits at engine speed and running the engine in the red zone will adversely affect its service lite. 43 RIDING ‘ Review Motorcycle Safety (pages 1—6) betare you ride. ’ Make sure die 5 e stand is inlly retracted before riding the motor- cycle. NOTE: ~ Make sure the function of the side stand mechanism.1See MAINTENANCE SCHED- ULE on page 50 and explanation tor 51m: STAND on page 68) . Warm up the engine. . With the engine idling, squeeze the clutch lever and shilt into low (1st) by depressing the gear shiit pedal. 3, Slowly release the Clutch lever while gradual- 1y picking up speed. Coordination of these two operations will assure a smooth start. 4. When the motorcycle attains smooth forward motion, slow down Lhe engine, squeeze the clutch again and shiit into 2nd by raising the shift-pedal. Do the same tor the other gears. m.— 44 5. Coordinate the throttle and brakes for smooth deceleration. 6. Both front and rear brakes should be used a! me same time and should not be appliesd strongly enough to lock the wheel, or braking effectiveness may be greatly reduced and control of the motorcycle be difficult. 432 65 Shiftlng pattern AWARNI i * Do not downshifl when traveling at a speed that would torce the engine to overrev in the next lower gear: the rear wheel may lose traction, resulting in a possible loss at vehicle control. CAUTION: * Do not shift gears without disengag- ing the clutch and closing the throttle. The engine and drive train could be damaged by overspeed and shock. ’ Do not tow the motorcycle or coast for long distances while the engine is off. The transmission will not be properly lubricated and damage may result. ' Do not exceed 13,500 min" (rpm! when running the engine without a load. Serious engine damage may result. NOTE: ‘ The battery will not charge while the engine speed is below 1,500 min" (rpml. Avoid idl- ing for prolonged periods, or continuous operation below 1,500 min" {rpm}. Be carelul when revving the engine or ac» oelemting in 15: or 2nd gear as the engine will easily enter the tachometer red zone. 45 High Altitude Riding When operating this motorcycle at high altitude the air-fuel mixture becomes overly rich. Above 2.000 m (6,500 feet) driveabillty and perfor- mance may be reduced and luel consumption in- creased See your authorized Honda dealer tor high altitude adjustment. 46 BRAKING 1. For normal braking. gradually apply both front and rear brakes while downshifting to suit your road speed. 2 For maximum deceleration. close the throttle and apply the front and rear brakes firmly. Disengage the clutch before the motorcycle slopsl ARNlAG ‘ Independent use of only (he tron! or rear brake reduces stopping pertor- mance. Extreme braking may cause either wheel to lock, reducing control of the motorcycle. » When possible, reduce speed or brake betore entering a turn: closing the throttle or braking in mid-turn may cause wheel slip. Wheel slip will reduce control of the motorcycle. ‘ When riding in wet or rainy condi- tions. or on loose surfaces, the ability to maneuver and stop will he reduced. All oi your aetions should be smooth under these conditions. Sudden ac- celeration, bulking or turning may cause loss at control. For your satety. exercise extreme caution when brak- ing, accelerating or turning. * When descending a long, steep grade. use engine compression braking by downshifting, with intermittent use of both brakes. Continuous brake ap- plication can overheat the brakes and reduce their eflectiveness. ‘ Riding with your foot resting on the brake pedal or your hand on the brake lever may actuate the brakelight. giv- ing a false indication to other drivers. It may also overheat the brake, reduc- ing eflectiveness. PARKING 1. After stopping the motorcycle. shift the transmission into neutral. turn the luel cock OFF, turn the handlebar fully to the left. turn the ignition switch OFF and remove the key. 2, Use the side stand to support the motorcycle while parked. CAUTION: ‘ Park the motorcycle on firm, level ground to prevent it trorn tolling over. ' If you park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility ot rolling off the side stand or overturning. 3. Lock the steering ta help prevent their (page 33). NOTE: ' When stopping for a short time near traffic at night, the ignition switch may be turned to P and the key removed, This will turn on the taillight to make the motorcycle more visible to traffic The battery will discharge it the ig- nition switch is left at P for too long 47 ANTI-THEFT TIPS l. Always lock the steering and never leave the key in the ignition switch‘ This sounds sim- ple but people do forget 2, Be sure the registration information for your motorcycle is accurate and tune)“. 3. Park your motorcycle in a locked gzmge whenever possible, 4. Use an additional anti»the{t device of good quality. 5. Put your name, address, and phone number in this Owner’s Manual and keep it on your motorcycle at ail times. Many times stolen motorcycles are identified by infomaiion in the Owner’s Manuals that are still with them. NAME: ADDRESS: PHONE N0.: 48 MAINTENANCE - When service is required, remember that your authorized Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it. The scheduled maintenance may also be per» formed by a qualified service facility that normally does mis kind of work; or you may perform most of the work yourself if you are mechanically qualified and have the proper tools and service data. 0 These insn'uctions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty condi~ tions, will require more frequent service than specified in the MAINTENANCE SCHEDULE. Con- sult your authorized Honda dealer for recommendations applirable to your individual needs and use. 49 MAINTENANCE SCHEDULE The following items require some mechanical knowledge. Certain items {particularly those marked ‘ and "‘) may require more technical information and tools. Consult Your authorized Honda Dealer. Perform the Prefide Inspection at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE FREQUENCY BgfiI-gEVER . DDDMEIER READING [NOTE III] “R T A Low Inn 1 e 12 18 24 an 36 ”'3“ NOTE MDNTI-I s 12 Is 24 so as To PAGE ' FUEL LINE I I I — - FUEL sTRAINER SCREEN c C c c c c — - THROTTLE OPERATION I I I W - CARBURETOR CHOKE I I I — - AIR CLEANER INOTE 2; R R 7 CRANKCASE EREATIIER lNOfl'E 3] c c c c c c 55 SPARK PLUG I R I R I R so . VALVE CLEARANCE I I I I — ENGINE on R R R R 29 ENGINE oIL FILTER R R R R 56 - CARBURETOR SYNcI-IRoNIzATIuN I I I I # - CARBURTOR IDLE SPEED I I I I I I I 62 RADIATOR cooLANT IN)“: N I I R 23 ‘ COOLING SYSTEM I I I — 50 FREQUENCY EvoI-IIJ‘CEISIEVEK n ODOMETER READLNG [Norm 11)] m T x mm) km I 5 I2 18 24 so 36 x 1,000 m. 0's 4 a 12 Is 20 2e REFER ”EM NoTE MONTH 5 I2 Is 2‘ an as To PAGE DRIVE CHAIN I,L EVERY Leno km 1500 m» 63767 BATTERY I I I I I I 77 BRAKE FLUID INo-IE A) I I R I I K 17 BRAKE SHOE/PAD WEAR I I I I I I 75, 7s BRAKE SYSTEM I I I I 17—19 - BRAKE LIGHT SWITCH I I I — - HEADLIGHT AIM I I I — CLUTCH SYSTEM I I I I I I I 21722 SIDE STAND I I I 53 - SUSPENSION I I I N - NUTS, BOLTS, FASTENERS I I I I — u WHEELS/TYRES I I I a " STEERING HEAD BEARINGS I I I I 7 Should be serviced by an amhmlzed HONDA deem, unless :h: owner has proper um um service clan and us mechamcally qu ‘ EeIerrozI-eomeru HONDA servroe manualv glmIESme inreresr of 5.1er, we recommend “Its: Ilms be sen'lced ONLY by an aurmrrzea H0NDA dealer I AI Irryrer odometer reading, repeal m are Irequency Intzrval esmhhshed rm 2, Serra: more Ireqrrenuy when ndm in umuaIIy weI or dumy areas. 3. Semoe mule Irequeme when rid rrg u. raw or :2 ml meme 4 chhc: every 2 years, or m Indi ted odomeIer interval‘ whmhever cums hm Replaoemen: req Im mechamcal skill. 51 TOOL KIT The tool kit up is in the too! compartment behind the left side cover. Some roadside repairs, minor adjustments and pans replacement can be per- formed with the tools contained in the kit, 0 s x 12 mm open end wrench ‘ 10 x 14 mm open end wrench 0 14 x 17 mm open end wrench 0 24 mm box end Wrench ‘ 5 mm hex wrench - Spark plug wrench 0 No. 2 Screwdriver 0 No. 2 Phillips Screwdriver ‘ No. 3 Phillips Screwdriver Screwdriver handle Screwdriver T-handle Pliers . Tool bag 52 (1’ Tool kit SERIAL NUMBERS The frame number (I) is stamped on the right The frame and engine serial numbers are re- Side 0‘ ”.‘e 5‘99““3 head: . quired when registenng your motorcycle, They The engine number (2’ IS stamped 0“ “'9 "2‘“ may also be required by your dealer when order Side of the crankcase- ing replacement parts Record the numbers here for your reference. ENGINE N0~ FRAME N0. (2) Engine number (1) Frame number 53 COLOUR LABEL The color label III is attached to the rear fender below the seat (See page SM It is helpful when ordering replacement parts. Record the colour and code here for your reierente. COLOUR CODE (1) Colour label 54 MAINTENANCE PRECAUTIONS “. The service hie ot the drive chain is dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprockets, The drive chain should be checked and lubricated as part of the Prerride Inspection (page 38). Under severe usage, or when the motorcycle is ridden in unusually dusty areas. more frequent maintenance will be necessary. inspection : 1. Turn the engine off, place are motorcycle on its center stand, and shilt the transmission in- to nemmL 2. Check slack in the lower drive chain run mid» way between the sprockets. Drive chain slacir should be adjusted to allow the following vertical movement by hand: 15—25 mm (5/8—1 in) Rotate the rear wheel and check drive chain slack as the wheel turns. Drive chain slack should remain constant as the wheel rotates. If the chain is slack only in certain sections, some links are kinked and binding. Binding can lrequently be elim» mated by lubrication. 15—25 mm (5/8—1-1 in) 3: “’92: c a unease: (1) Drive chain 63 3- $531333; 3:35;? 3:22;”? 3;: named sphere Ten ‘ wom sphere. ream following conditions: \ DRIVE CHAIN - Damaged Rollers Replace ) Replace " Loose Pins l ‘ Dry or Rusted Links ' Kinked or Binding Links ' EXCGSSWQ W?“ Normal Sprocket Teeth ' Improper Adjustment ‘ Missing O-rings GOOD SPROCKETS ‘ Excessively Worn Teerh " Broken or Damaged Teeth A drive chain with damaged rollers, loose pins, or missing O-rings must he replacedi A chain which appears dry, or shows Slgns of rust, re quires supplementary lubrication. Kinked or bin- ding links should be thoroughly lubncaled and worked free. If links cannot be freed, me chain must be replaced. 64 Adjustment: Drive chain slack should be checked and ad» justed, it 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 adjust- ment. (1) Axle nut (4) Index mark (2) Lock nut (5) Rear edge oi l3l Dn've chain adjusting slot adjusdng nut it the drive chain requires adjustment. the pros cedure is as follows; 1. Place the motorcycle on its center stand with the transmission in neutral and the ignition switch off. e Loosen the axle nut (1). . Loosen the lock nuts (2) on both adjusting nuts (3t. 4. Turn both adjusting nuts an equal number of tums until the correct drive chain slack is ob» tained. Turn the adjusting nuts clockwise to tighten the chain. or counterclockwise to pro- vide 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: 15—25 mm {5/871 in) 5. Check rear axle alignment by making sure the chain adjuster index marks (4) align with the rear edge (5) at the adjusting slots. are 65 Both left and right marks should tonespond. If the axle is misaligned, tum the left or right adjusting nut until the marks correspond oh the rear edge of the adjusting slots and recheck chain slack, 6. Tighten the axle nut to: 90 Nm (9.0 kg»m, 65 ft-lbl 7V Tighten the adjusting nuts lightly, then tighten the lock nuts by holding the adjusting nuts with a spannerv 8' Rear brake pedal free play is affected when repositioning the rear wheel to adjust drive chain slack. Check rear brake pedal free play and adjust as necessary. Wear inspection: Check the chain wear label when adjusting the chain. If the red zone (6) on the label aligns with the arrow mark (7) on the chain adjuster plates after the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced. The proper slack is: 1545 mm (518—1 in) 66 CAUTION: ' Damage to the bottom pan of the frame may be caused by excessive drive chain slack of more than: 50 mm {2 in) 16) Red zone (7» Arrow mark Lubrication and cleaning: Lubricate every 1,000 km (600 miles) or sooner if chain appears dry. The O-rings in this chain can be damaged by steam cleaning, high pressure washers, and Cer- min solvents. Clean the chain with high flash point solvent, such as parzfin. Wipe dry and lubricate only with SAE 80 or 90 gear oil. Com- mercial chain lubricans may contain solvents which could damage the rubber O~rings. Replacement chain: DIDSZDVA or RKSZOSMD CAUTION: ‘ The drive chain on this motorcycle is equipped with small O-rings between the link plates. These O-rings retain grease inside the chain to improve its service life. However, special precau- \ions must be taken when adjusting, lubricating. washing, and replacing the chain. 67 FRONT AND REAR SUSPENSION INSPECTION (Refer to the maintenance precautions on page 54), 1. Check the front 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 2. Swingarm bearings should be checked by pushing hard against the side or the rear wheel while the motorcycle is on the center stand. Free play indicates worn bearings. 3. Carefully inspect all front and rear suspen- sion fasteners {or tightness 68 SIDE STAND lRefer to the maintenance precautions on page 54). Check the mbber pad {or deterioration and wear. Replace if wear extends to Lhe wear line {See (1) in the picturel. Check the side stand assembly for freedom of movement If parts must be replaced, please Contact an authorized HONDA dealer. REPLACE (1) Wire line WHEEL REMOVAL (Refer to Maintenance Precautions on page 54), Front Wheel Removal ll Raise the (mm. wheel oit the ground by plac- ing a padded block centered under me engine. 2 Disconnect the speedometer cable from the speedometer gearbox by removing the cable set screw (1?. 3. Remove the fixing bolLs (3) and remove the right brake caliper (2p. CAUTION: ~ Support the caliper assembly so that (1) Cable set screw it doesn't hang on the brake hose. Do not twist the brake hose 4. Remove the axle holder (4) by removing the axle holder nuts (5}. NOTE: - Do not depress the brake lever when the wheel is on the motorcycle. The caliper pistons will be forced out of the cylinders with subsequent loss of brake fluidl If this oc~ curs, servicing ol the brake system will be neoessary. See your authorized Honda dealer ior this service. 5, Remove Lhe from wheell (2) Brake caliper f3? Fixing bolts (4) Axle holder (5) Axle holder nuts 69 Instalation Not Position the front wheel between the fork legs. CAUTION: ‘ When installing the wheel, {it the left brake disc caremlly between the brake pads to avoid damaging the pads. (6) Tangs 70 Position the tang on the speedometer gearbox against the tang (6} on the right fork leg. Install the right axle holder facing the arrow mark to the from and tighten the forward nut first and the rear nut to the specified torques. Axle holder nut: 22 N-m (2,2 kg-nl, 16 {1-11)}. Insmll the left axle holder facing the arrow mark to the front Fit the right caliper over the disc taking care not Lo damage the brake pads. Install the caliper mounting bolts and tighten to: 27 N-m (2V7 kg-m, 19 (i-lb). A ARNWG ' It a torque wrench was not used for in- stallation. see your authorized Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. Measure the clearance (7) between each surface of the lell brake disc (8) and Lhe left caliper holder (9) with a 0.7 mm (0.023 in) {eeler gauge (10) (see sketch). If the gauge inserts easily, tighten the left axle holder nu's 15) to the specified torque. Axle holder nut torque: 22 N-m (2.2 kg-m, 16 {t-lb) 17) Clearance (8) Left brake disc (9) Left Caliper holder AWARNW « It a torque wrench was not used for in- stallation, see your authorized Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capability. (10} Feeler gauge 71 if the feeler gauge manner be inserted easily, pull the left fork outward or push inward until the gauge can be inserted and tighten the axle holder nuts with the gauge inserted. After tightening, remove the gauge. After installing the wheel, apply the brakes several nmes, then recheck both discs for caliper holder to disc clearance. Do not operate the motorcycle without adequate clearance, W/XF we ‘ Failure to provide adequate disc to caliper holder clearance may damage the brake discs and impair braking efficiency. 72 Rear Wheel Removal (Refer to the maintenance precautions on page 54). 1. Place the motorcycle on the center stand. 2. Remove the rear brake adjusting nut (1). Disconnect the brake rod (2) from the brake arm (3). . Loosen the drive chain adjusting nut lock nuts (4) and adjusting nuts (5». . Remove the rear axle nut (6). . Remove the drive chain {7) from the driven sprocket by pushing the rear Wheel forward. . Remove the axle shaft (8), and rear wheel from the swingann. (1’ Brake adjusting nut (4’ Lock nuts (2) Brake rod (5) Chain adjusting nuts (3) Brake arm (6) Axle nut (7D Drive chain (8) Axle shalt 73 Installation Note: To install the rear wheel, reverse the removal procedure. Make sure that the lug on the swingarm is located in the slot in the brake Panel. Adjust the drive chain {page fits—est and the rear brake (page 19—20D. Tighten the drive chain adjusting nut lightly, then hold the adjusting nut with a wrench. Secure the lock nut on each side of swingarm. Torque the axle nut to the specified torque. Axle nut torque: 90 N~m (9.0 kg—m, 55 ftrlb) After installing the wheel, apply the bake several times and men check if the wheel rotates freely. Recheck the Wheel if the brake drags or if the wheel does not rotate treely, WAHNlNG " If a torque wrench was not used for in- stallation. see your authorized Honda dealer as soon as possible to verity proper assembly. Impmper assembly may lead to loss of braking capability. 74 BRAKE PAD WEAR (Refer to the maintenance precautions on page 54). Brake pad wear will depend upon the severity of usage, type of riding and condition oi the roads. The pads will wear faster on dirty and wet roads. Inspect the pads visually during all regular ser~ vioe intervals to determine the par] wear. If either pad wears to the bottom of the groove (1), both pads must be replaced as a set. Other checks: Make sure there are no fluid leaks. Check for deterioration or eracks in the hoses and fittings NOTE: ‘ Use only genuine Honda replacement friction pads offered by authorized Honda dealers. When brake service is necessary consult Your Honda dealer. (1) Groove {2) Brake disk 75 BRAKE SHOE WEAR (Refer to the maintenance precautions on page 54?. The rear brake is equipped with brake wear indicator. When the brake is applied, an arrow (1) attached to the brake arm (2) moves toward a reference mark (3) on the brake panel 14). It the arrow aligns with the reference mark on full application 01 the brake. the brake shoes must he replaced NOTE: * When the brake service is necessary, see your authorized Honda dealer, Use only ge~ <1) Arrow (3) Reterence rnark nuine Honda parts or its equivalent. <2) Brake arm (4) Brake panel 76 BATTERY (Refer to the maintenance precautions on page If the motorcycle is operated with insufficient battery electrolyte, sulfation and battery plate damage will occur. If rapid loss of electrolyte is experienced. or if your battery seems to be weak, causing slow sn-ming or other electrical pmblems. see yaur authorized Honda dealer. Battery electrolyte: The battery (h is behind the right side cover. Remove the right side cover. Check the elec- trolyle level with the motorcycle in an upright position on level ground. The electrolyte level must be maintained between the UPPER (2) and LOWER (3) LEVEL marks on the side of the battery. It the electrolyte level is low, remove the battery filler cap (4) Carefully add distilled water to the UPPER LEVEL mark. using a small syringe or plastic tunnel. (1) Battery (3) LOWER LEVEL 12] UPPER LEVEL mark mark (4) Filler caps 77 CAUTION: ' When checking the battery electrolyte level, or adding distilled water, make sure the breather tube is connected to the battery breather outlet. Use only distilled water in the battery. Tap water will shorten the service life oi the battery. ‘ Filling the battery above the UPPER LEVEL line may cause the electrolyte to overflow, resulting in corrosion to engine or nearby parts. Immediately wash off any spilled electrolyte. - The battery breather tube must be routed as shown on the label. Do not bend or twist the breather tube. A bent or kinked breather tube may pressurize the battery and damage its case. 78 In ARNVNG The battery gives off explosive uses; keep sparks, times, and cigarettes away. Provide adequate ventilation when charging or using the batteries in an enclosed space. ’ The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. — lt electrolyte gets on your skin. flush with water. — li electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. ’ Electrolyte is poisonous. — If swallowed, drink large quan‘ titles of water or milk and follow with milk of magnesia or vegetable oil and call a physician. ‘ KEEP OUT OF REACH OF CHIL- DREN. FUSE REPLACEMENT (Refer to maintenance precauu'ons on page 54). The main fuse (1}, located near the battery, is 30 A The spare main [use (2) is located under the starter magnetic switch. The hise box (4) is located between the handlebars. The specified {uses are 10 A and 15 A. When frequent {use failure occurs, it usually in- (1) Main fuse (2) Spare main {use (3} Connector dicates a shon eirenit or an overload in the elec- triczl system. See your authorized Honda dealer for repai CAUTION: - Turn the ignition switch OFF before checking or replacing tnees to prevent accidental short-circuiting. To replace the main tnse (1), remove the right side cover, disconnect the wire connectar (3) or the Slater magnetic switch and pull out the old fuse. Install a new tnse and reconnect the connector. 79 To replace any fuses in the fuse box (4), remove the fuse box cover (5) by removing the screws16) that secure it. Spare fuses (7) are located in the fuse box. Pull the old {use out of the clips with the fuse remover (8). Push a new fuse into the clips and install the fuse box cover. Tighten the screws. (4) Fuse box (7) Spare fuses (5) Fuse box cover (8) Fuse remover (G) Screws 80 AWARMNG Never use a [use with a different rating from that specified. Serious damage to the electicul system or a fire may result, causing a dangerous loss of lights or engine power. - MHIIHINIIII Il'Alllllllllllll (3) Fuse remover (9) Blown {use CLEANING Clean your motorcycle regularly to protect the surtace finishes and inspect {or damage, wear, and oil, coolant or hydraulic fluid seepage. spraying high pressure water ttypical in coil-operated car washesl at the following areas: Wheel Hubs Brake Master Carburetors Cylinder instruments Muffler Outlets Under Seat. Under Fuel Tank Drive Chain Handlebar Switches Ignition Switch 1. After cleaning, rinse the motorcycle thoroughly with plenty ofclean water. Strong demgent residue can corrode alloy parts. 2. Dry the motorcycle. start the engine, and let it run for several minutes. ML mum, » Braking efficiency may be temporar- ily impaired immediately utter wash- ing the motorcycle. Anticipate longer stopping distance tn avoid a possible accident. 3. Test the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking performance. 4. Lubricate the drive chain immediately after washing the motorcycle. Aluminum Wheel Maintenance Aluminum corrode: when it comes in contact with dust. mud, road salt, etc. After riding, clean the wheels with a wet sponge and mild detergent, then rinse well with water and wipe dry with a clean Cloth. CAUTION: ' Do not use steel wool or a cleaner con- taining abrasives or compounds to clean the wheels, as they can cause damage. ‘ Do not ride over a curb or rub the wheel against an obstacle, as wheel damage my result. Bl STORAGE GUIDE STORAGE Extended storage, such as tor winter, requires that you take certain steps to reduce the effects at deterioration from non-use ot the motorcycle, In addition, necessary repairs should he made BEFORE storing the motorcycle; otherwise, these repairs may be {orgotten by the time the motorcycle is removed from storage. 1. Change the engine oil and filter. 2. Lubricate the drive chain. 3. Make sure the cooling system is filled with a 50/50% antifreeze solution. 4, Drain the fuel milk and carburetors. Spray the inside of the tank with an aerosol rust- inhibiting oil, Reinstall the fuel cap on the tank. NOTE: ’ 1! storage will last more than one month, can buretor draining is very important, to assure proper perlorinance alter storage. 82 ' Petrol is flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks near the equipment while draining fuel. 5. Remove the spark plugs and pour a table» spoon (15720 cm of clean engine oil into each cylinder. Crank the engine several times to distribute the oil, then reinstall the spark plugs. NOTE: ~ When turning the engine over, the Engine Stop Switch should be OFF and each spark plug placed in is cable cap and grounded to prevent damage to the ignition system, . Remove the battery. Store in an area pm- tected from freezing temperatures and direct sunlight. Check the electrolyte level and slow charge me battery once a month . Wash and dry the motorcycle. Wax all surfaces. Coat chrome with rust- ng oil . 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 plastlc or other coated materials) and store in an unheated area. free at dampness with a minimum of daily temperature variation. Do not store the motorcycle in direct sunlight. REMOVAL FROM STORAGE 1. Uncover and clean the motorcycle. Change the engine all if more than 4 months have passed since the start of storage. 2. Check the battery eleetrolyte level and charge the battery as required. Install the battery, 3. Drain any excess aerosol rust~inhibltlng oil from the fuel tank. Fill the fuel tank with fresh petrol. 4. Perform all Pre-ride Inspection checks (page 40). Test ride the motorcycle at low speeds in a safe riding area away from traffic. 33 SPECIFICATIONS DIMENSIONS Overall length Ovemll width Overall height Wheelbase Ground clearance WEIGHT Dry weight CAPACITIES Engine oil Fuel tank Fuel reserve Cooling system capacity Passenger capacity load Maximum weight capacity 34 2,030 mm (79.9 in) 715 mm (28.1 in) 1.140 mm (44.9 in) 1,370 mm (53.9 in) 140 mm (5.5 in) 149 kg (328.8 lbs) 2.5 I (2.6 US qt, 2.2 Imp qt) After disassembly 2.0 I (2.1 US qt, 1.3 Imp qt) After draining and oil filter change 1.3 I (1.9 US qt, I.6 Imp qt) After draining 13.0 I (3.4 US gal, 2.9 Imp gal) 22 I (0.6 US gal, 0.5 Imp gal) 1.4 I (1.5 US qt, 1.2 Imp qty Operator and one passenger 170 kg (375 lb) ENGINE Bore and stroke Compression ratio Displacement Spark plug Standard For extended high speed riding Spark plug gap Valve clearance (cold) Idle speed 60.0 x 44.2 mm (2.36 x 1.74 in) “.0 : 1 249.6 cm3 (152 min) DPRSEA-Q (NGKD X24EPR-U9 (ND) DPRSEA-9 1NGK) X27EPR-U9