HONDA VTBOOC OWNER’S MANUAL I MANUEL DU CONDUCTEUR I I FAHRER-HANDBUCH © Honda Motor Co., Ltd. 1995 \ IMPORTANT NOTICE 0 OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passengerl 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: Indicates a strong possibility of severe personal iniury or death if instructions are not followed. CAUTION: . . , . . ‘ _ . Indicates a possubility of personal injury or equipment damage 1! Instructions are not followed. N 0T E: Gives helpful information This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold. HONDA W600C OWNER’S MANUAL All information in this publication is based on the latest production information available at the time of approval for printing. HONDA MOTOR C0.,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 pennission. WELCOME The motorcycle presents you a challenge to master the machine, a challenge to adventure. You ride through the wind, linked to the road by a vehicle that responds to your commands as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a pre—ride inspection and regular maintenance are essential to your safety. Your reward is freedom To meet the challenges safely, and to enioy the adventure fully, you should become thoroughly familiar with this owner’s manual BEFORE YOU RIDE THE MOTORCYCLE. When service is required, remember that your Honda dealer knows your motorcycle best. If you have the required mechanical “lmowhow” and tools, your dealer can supply you with an official Honda Service Manual to help you perform many maintenance and repair tasks. Pleasant riding, and thank you for choosing a Honda 1 0 Following codes in this manual indicate each country. E U lIlT France ED SW wi n Austria 11 P0 Ponu Italy (TYPE 11) F1 Finland Belgium G Germany Hetherlands Sweden Portugal Norway Denmark l] G Germany (l‘ype II) Italy U Australia 0 The specifications may vary with each locale. OPERATION Page 1 MOTORCYCLE SAFETY 1 Safe Riding Rules 2 Protective Apparel 2 Modifications 3 Loading and Accessories 6 PARTS LOCATION 9 Instruments and Indicators 12 MAJOR COMPONENTS (Information you need to operate this motorcycle) 12 Suspension 14 Brakes 18 Clutch 20 Coolant 22 Fuel 26 Engine Oil 27 Tyres 29 ESSENTIAL INDIVIDUAL COMPONENTS 29 Ignition Switch Page 30 Right Handlebar Controls 31 Left Handlebar Controls 32 FEATURES (Not required for operation) 32 Steering Lock 33 Helmet Holder 34 Side Cover 34 Document Compartment 35 OPERATION 35 Pro-ride Inspection 36 Starling the Engine 39 Running-in 40 Riding 41 Braking 42 Parking 43 Anti-theft Tips MAINTENANCE Page 44 MAINTENANCE 45 Maintenance Schedule 43 Tool Kit 49 Serial Numbers 49 Colour Label 50 Maintenance Precautions 51 Air Cleaner 52 Crankcase Breather 53 Engine Oil 57 Spark Plugs 59 Throttle Operation 60 Idle Speed 61 Drive Chain 67 Side Smnd 68 Brake Pad Wear 69 Brake Shoe Wear 70 Wheel Removal 75 Battery 77 Stoplight Switch Adjustment 78 Fuse Replacement 81 Bulb Replacement Page 86 CLEANING 88 STORAGE GUIDE 83 Storage 90 Removal from Storage 91 SPECIFICATIONS 95 NOISE CONTROL SYSTEM (AUSI‘RALIA ONLY) MOTORCYCLE SAFEI'Y AWAHNING ‘ Motorcycle riding requires special efforts on your part to ensure your safety. Know these requirements before you ride: SAFE RIDING RULES 1. Always make a preride inspection (page 35) before you start the engine. You may prevent an accident or equipment damage. 2. Many accidents involve inexperienced riders. Most ountries require a special motorcycle 1' test or license. Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider. 3, Many automobile/motorcycle accidents happen because the automobile driver does not “see" the motorcyclist. Make yourself conspicuous to help avoid the accident that wasn't your fault: - Wear bright or reflective clothing. I Don’t ride in another motorist‘s "blind spot." 4. Obey all national and local laws and regulations. 'Excessive speed is a factor in many accidents. Obey the speed limits, and NEVER travel faster than conditions warrant. - Signal before you make a tum or lane change. Your size and maneuvembility can surprise other motorists. 5. Don‘t let other motorists surprise you. Use extra caution at intersections, parking lot entrances and exits, and driveways. 6. Keep both hands on the handlebars and both feet 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 tootpegs. 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 2, The exhaust system becomes hol during operation. and it remains hot for a while alter stopping the engine, Be careful not to touch the exhaust system while it is hot. Wear clothing that fully covers your legs. 3. Do not wear loose clothing which Could catch on the control levers, footpegs or wheels. MODIFICATIONS AWARNING cModifimtion of the motorcycle, or removal of original equipment. my render the vehicle unsafe or illegal. Obey all national and local equipment regulations. LOADING AND ACCESSORIES - To prevent an accident, use extreme care when adding and riding with accessories and cargo. Addition of accessories and cargo can reduce a motorcycle’s stability, performance and sate operating speed. Never ride an accessory-equipped motorcycle at speeds above 130 kin/h (80 mph). And remember that this 130 km/h (80mph) limit may be reduced by installation of non-Honda accessories, improper loading, worn tyres and overall motorcycle condition, poor road or weather conditions. These general guidelines may help you decide whether or how to equip your motorcycle and how to load it safely. Loading The combined weight of the rider, passenger, cargo and additional accessories must not exceed the maximum weight capacity: 184 kg (406 lbs) (G. HG, SPl 174 kgl384 lbs) (E, F, ED, U, SW, AR, Fl. lIIT, lIPO) Cargo weight alone should not exceed: 20 kgl44 lbs) . Keep cargo and accessory weight low and close to the center of the motorcycle. Load weight equally on both sides to minimize imbalance, As weight is located further from the motorcycle‘s center 01 gravity. handling is proportionally affected. .Adjust tyre pressure (page 27) and rear suspension (page 12) to suit load weight and riding conditions. no 3, Vehicle handling and stability can be adversely affected by loose cargo. Recheck cargo security and accessory mounts frequently. 4. Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebars. fork, or fenderl Unstable handling or slow steering response may result. Accessories Genuine Honda accessories have been specifically designed for and tested on this motorcycle. Because the factory cannot test all other accessories, you are personally responsible for proper selection. installation. and use of non-Honda accessories. Always follow the guidelines under Loading, and these: 1. Carefully inspect the accessory to make sure it does not obscure any lights, reduce ground clearance and banking angle, or limit suspension travel, steering travel or control operation Large lork»mounted {airings or Windshields, or poorly designed or improperly mounted failings can produce aerodynamic forces that cause unstable handling. Do not install {airings that decrease cooling air flow to the engine .57 3. Accessories which alter your riding position by moving hands or feet away from controls may increase reaction time in an emergency. 4. Do not add electrical equipment that will exceed the motorcycle‘s electrical system capacity. A blown {use could cause a dangerous loss of lights or engine power. 5. This motorcycle was not designed to pull a sidecar or trailer, Handling may be seriously impaired if so equipped 6. Any modification of the cooling system may cause overheating and serious engine damage. Do not modify the radiator shrouds or install accessories which block or deflect air away from the radiator, PARTS LOCATION Speedometer Indicators “55"“? “‘3'“ 5mm“ Front brake fluid rtservoir Headlight Starter button Horn button Fuel rlll cap Battery Aircleaner Stomge compartment Steering lock Coolant reserve hank cap on filler cap/dipstick Passenger footpeg Ignition switch Fuel cock Helmet holder Passenger footpeg Side Maud Gear shin pedal INSTRUMENTS AND INDICATORS The indicators are located within and below the speedometer. Their functions are described in the iable on the following page. (1) Tfipmeler reset knob (2) Speedometer (3) Odometer (4) Tripmeter (5) Coolant temperamre indicalor (6) Turn signal indicator (7) Neutral indicator (3) High beam indicator (9) Low oil pressure indicator (10) Side stand indicator (Refl No.) Desa'ivtion Function (1) Tripmeter reset knob Resets Lripmeter to zero (0) l Turn knob in direction shown. (2) Speedometer Shows riding 5986d. (3) Odometer Shows aCCmfllalJMIEBEQ. (4) Tripmeter Shows MERE per trip, (5) Coolant tempemture indicator (red) Lights when the coolant is over the specified temperature. it the indicator goes on while riding. stop the engine and check the reserve tank coolant levell Read pages 20—21 and do not ride the motorcycle until the problem has been corrected. CAUTION: . Ex ‘ maximum running temperature may cause serious ermine damme. (6) Turn signal indicator Flashes when either turn signal is onerated. (7) Neul‘ml indicator (green) Light when the transmission is in neutral. (8) High beam indicator (blue) Light when the headlight is on hizh beam. 10 (Ref. No.) Description Function (9) Low oil pressure indicator (red) Lights when the engine oil pressure is below the normal operating range. Should light when ignition switch is ON and engine is not mnning. Should go out when the engine starts. except for occasional flickering at or near idling speed when engine is warm. CAUTION: ' Running the eny'ne with insufficient oil pressure may cause serious engine damage. (10) Side stand indicator (amber) Light when the side stand is put down. Before parking, check that the side stand is fully down; the light only indicates the side stand ignition cut-off system (page 36) is activated. 11 MAJOR COMPONENTS (Information you need to operate this motorcycle) - If the Pre-ride Inspection (page 35) is not performed. severe personal injury or vehicle damage may result. SUSPENSION Rear Suspension The spring preload adjuster (1) has 7 spring preload positions for different load or riding conditions. Remove the leit side cover (page 34), Use the pin spanner to adjust the rear shock. Position Us for light loads and smooth road conditions. Positions 2 w 7 increase spring preload for a stiffer rear suspension and can be used when the motorcycle is more heavily loadedl Standard position : 2 (1) Spring preload adjuster 12 AWARNWG *The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas. The instructions found in this owners manual are limited to adjustment of the shock assembly only. Do not attempt to disassemble. disconnect or service the damper unit; an explosion causing serious iniury may result. Puncture or exposure to flame may also result in an explosion, causing serious injury. Service or disposal should only be done by your authorized Honda dealer or a qualified mechanic. equipped with the proper tools. safety equipment and the official Honda Shop Manual. . u 13 BRAKES Front Brake TE]: motorcycle has a hydraulic front disc I) e. As the brake pads Wear. brake fluid level dropsi 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. II the control lever free travel becomes excessive and the brake pads are not worn beyond the recommended limit (page 67). there is probably air in the brake system and it must be bled. See your authorized Honda dealer for this service. 1‘ Brake Fluid Level: AWARNING * Brake fluid may cause irritation. Avoid Contact with skin or eyes. In Case of Contact. flush thoroughly with water and call a doctor if your eyes were exposed. ‘ EP OUl' 0F REACH OF CHIL— DREN. CAUTION: ' Handle brake fluid with care because it can damage plastic and painted surfaces. ' When adding brake fluid, be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out. * Use only DOT 4 brake fluid from a sealed container. . Never allow contaminants such as dirt or vvater to enter the brake fluid reservoir. Check that the fluid level is above the LOWER level mark (1) with the motorcycle in an upright position. (2) (3) " / <5) / (6) (1) LOWER level mark (4) Diaphragm plate (2) Screws (5) Diaphragm (3) Reservoir cover (5) Upper level mark Brake fluid must be added to the reservair whenever the fluid level begins to reach the LOWER level mark (1). Remove the screws (2), reservoir cover (3). diaphragm plate (4), and diaphragm (5). Fill the reservoir with DOT 4 BRAKE FLUID from a sealed container up to the upper level mark (6) Reinstall the diaphragm, diaphragm plate. and coverl Tighten the screws securelyl Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. 15 Rear Brake Pedal He’ght Adjustment: The stopper bah (l) is provided to allow adjustment of the pedal height. To adjust the pedal height, loosen the lock nut (2) and turn the stopper bolt. Tighten the lock nut. (1) (2) / Q1) ll)” (3) (1) Stopper bolt (2) Lock nut 1 s (3) Rear brake pedal Brake Ad‘ustment: 1. Place the motorcycle on its side stand. 2. Measure the distance the rear brake Pedal (3) moves beiore the brake starts to take hold‘ Free play should be: 20*30 mm (03-12 in) If adjustment is necessary, turn the rear brake adjusting nut (4). (4) Adjusting mu (5) Ann pin (A) Decrease free play (B) Increase free play 3. Apply the brake several times and check for free wheel rotation after the brake 981121 is released. NOTE: I Make sure the cutout on the adjusting nut is seated on the brake arm pin (5) after making final free play adjustment. 0 If proper acfiustment cannot be obtained by this method see your authorized Honda dealer. (4) Adjusting nut ‘ (5) Arm pin (A) Decrease free play (B) Increase tree play Other Checks: Make sure the bmke arm, brake rod, spring and fasteners are in good condition. 17 CLUTCH Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep; or it the clutch slips, causing acceleration to lag behind engine speed. Minor adjustments can be made with the clutch cable adjuster (4) at the lever (1). Normal clutch lever free play is: 10-20 mm (0.4703 in) (1) MD (1) Clutch lever 18 rPull back the rubber dust cover (2). Loosen the lock nut (3) and turn the adjuster (4), Tighten the lock nut (3) and check the adjustment. 2,1! the adjuster is threaded out near its limit or it the conect free play cannot be obtained. loosen the lock nut (3) and turn in the cable adjuster (4) completelya Tighten the lock nut (3) and install the dust cover. (3) <4) (2) \ . / \ (”0%) (B) 5 (2) Dust cover (3) Lock nut (4) Clutch cable adjuster (A) Increase (ree play (B) Decrease free play 3. Loosen the lock nut (5) at the lower end of the cable. Turn the adjusting nut (6) to obtain the specified free play. Tighten the lock nut (5) 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 motorcycle does not creep. Gradually release the clutch lever and open the throttle, The motorcycle should begin to move smoothly and accelerate gradually. NOTE: 1: If proper adjustment cannot be obtained or the clutch does not work correctly. see your authorized Honda dealer. Other Chet Check the clutch cable for kinks or signs of wear that could cause sticking or failure. Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion. (5) Lock nut (6) Adjusting nut (A) Increase free play (B) Decrease free play 19 COOLANT Coolant Recommendation The owner must properly maintain the coolant to prevent freezing. overheating, and corrosion, Use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. (SEE ANT IF REEZE CONTAINER LABEL). CAUTION: t Use only low-mineral drinking water or distilled water as a part of the antifreae solution. Water that is high in mineral content or salt may be harmful to the aluminium engine. 20 The factory provides a 50/50 solution of antifreeze and distilled water in this motorcycle. This coolant solution s recommended for most operating temperatures and provides good Conosion protection. A higher concentration of antifreeze decreases the cooling system performance and is recommended only when additional protection against freezing is needed. A concentration of less than 40/ 60 (40% antifreeze) will not provide proper corrosion protection. During freezing temperatures. check the cooling system lrequently and add higher concentrations of antifreeze (up to a maximum of 60% antifreeze) if required Inspection The reserve tank is behind the right side cover. 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, If the coolant level is below the LOWER level mark (2), remove the right side cover (page 34) and the reserve tank cap (3) Add coolant mixture until it reaches the UPPER level mark (4). Do not remove the radiator cap. AWARNING ~ Do not remove the radiator up when the engine is hot. The coolant is under pressure and could scald you. ' Keep hands and clothing away from the cooling fan, as it starts automatically. H the reserve tank is empty» or if coolant loss is excessive. check for leaks and see your authorized Honda dealer for repair. (3) (1) Reserve tank (2) LOWER level mark (3) Reserve tank cap (4) UPPER level mark 21 FUEL Manual Fuel Cock The manual fuel cock (1) is under the left side of the fuel tank. Set it to 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 of fuel system components. Automatic Fuel 0N -0F F 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 tank as soon as possible after switching to RES. then switch the cock back to ON. The reserve fuel supply is: 3.4 010.90 us ga|,0.75 Imp gal) AWARNI 0 To avoid running out of fuel that may result in a sudden stop, learn how to operate the fuel cock when riding the motorcycle. N 0T E: ' Remember to check that the fuel cock is in the ON position each time you refuel. If the cock is left in the RES position, you may run out of fuel with no reserve, 0N OFF RES v FUEL vrutL Viuu as (l) (1) Fuel cock Fuel Tank The fuel tank capacity including the reserve supplyis: 11.0 9 (2.91 US gal, 2.42 Imp gal) To open the fuel fill cap (1), insert the ignition key (2) and turn it clockwise. The fuel fill cap will pop up and can be lifted off. After refueling, to close the fuel till cap, align the latch in the cap with the slot in the filler neck. Push the fuel fill cap into the tiller neck until it snaps closed and locks. Remove the key. Use unleaded or low-lead petrol with a research octane number of 91 or higher. We recommend that you use unleaded petrol because it produces fewer engine and spark plug deposits and extends the life of exhaust system components. CAUTION: ‘ l.f “spark knock” or “pinking” occurs at a steady engine speed under normal load, change brands of petrol. If spark knack of 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 Warranty. (1) Fuel nu cap (2) Ignition key 23 AWARNING ' Petrol is extremely flammable and is explosive under certain conditions. Refuel In a well-ventilated area with thle en e stopped Do not smoke or James or sparks in the area where petrol is stored or where the fuel tank is refueled. ’ Do not overfill the tank (there should be no fuel in the filler neck (3)). After refueling, make sure the fuel fill cap is closed securely. - Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignitel If any fuel is spilled, make sure the area is dry before starting the engine. tAvoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN. 24 (3) Filler neck Petrol Containing Alcohol If you decide to use a petrol containing alcohol (gasohol), be sure it‘s octane rating is at least as high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol. and the other con- taining methanol. Do not use petrol that contains more than 1% ethanol Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors [or methanol Never use petrol containing more than 5% methanol, even it it has cosolvents and corrosion inhibitors. NOTE: ¢ Fuel system damage or engine performa- nce problems resulting from the use of fuels that contain alcohol is not covered under the warranty Honda cannot endorse the use oi fuels containing methanol since evidence of their suitability is as yet incomplete. Before buying fuel from an uniamiliar station, try to [ind out if the fuel contains alcohol. If it does, confirm the type and percentage oi alcohol used‘ It 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. a 25 ENGINE OIL Engine Oil Level Check Check the engine oil level each day beiore riding the motorcycle. The level must be mainmined between the upper (l) and lower (2) level marks on the dipstick (3). 1. Stan the engine and let it idle for 2 few minutes. Make sure the low oil pressure indicator goes off, If the light remains on, stop the engine immediately. 2. Stop the engine and hold the motorcycle in an upright position on firm, level ground. 3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the dipstick without screwing it in. Remove the dipstick. The oil level should be between the upper and lower marks on the dipstick. 26 4. If required, add the specified oil (see page 53) up to the upper level mark. Do not overlill. 5. Reinstall the oil filler cap/dipstick, Check [or oil leaks. CAUTION: t Running the engine with insufficient oil can cause serious engine damage. — (1) 7 <2) (1) Upper level mark (2) Lower level mark (3) on filler cap/dipstick TYRE Proper air pressure will provide maximum stability, riding comfort and tyre life. Check tyre pressure frequently and adjust it neccessary. N 0T E: t Tyre pressure should be checked before you ride while the tyres are “cold". On- road tyres are standard on this model. Select the right replacement tyres in accordance with the following specifications Check the tyres for cuts, embedded nails. or other sharp objects. See your authorized Honda dealer for replacement of damaged tyres or punctured inner tubes. Front Rear Tyre Size 100/907 19 170130—15 57S M/C 77S Rider only 200 200 Cold tyre 12.00 , 29) (2‘00 , 29) pressures pa Rider and 200 250 (kg/cmi p50 one 12.00 , 29) (2.5a , 36) pamnger Tyre brand BRIDGlETONl-Z L309 GSAS DUNLOP F24 K555 27 “WARNING 'Do not attempt to patch a damaged tyre or inner tube. Wheel balance and tyre reliability may be impaired. itIlnproper tyre inflation will cause abnormal tread wear and create a safety hazard. Underinflalion may result in the tyre slipping on, or coming off of the rim causing tyre deflation that may result in a loss of vehicle control. t Operation with excessively worn tyres is hmrdous and will adversely aifect traction and handling. *The use of tyres other than those listed on the tyre information label may adversely affect handling. 23 Replace tyres before tread depth at the center of the tyre reaches the following limit: Minimum tread depth 15 mm (0.06 in) Front : Rea NOTE: < For Germany> * German law prohibits use of tyres whose tread depth is less than 1.6 mm. ESSENTIAL INDIVIDUAL COMPONENTS IGNlTION SWITCH The ignition switCh (I) is on front of left side cover. (1) Ignition switch p Key Position Function Key Removal P (parking) For parking the motorcycle near traffic. (AR type only) The taillight is on. but all other lights are off. Key can be removed The engine cannot be staned. O F F Engine and lights cannot be operated. Key can be removed 0 N Engine and light can be operated Key cannot be removed 29 RIGHT HANDLEBAR CONTROLS Engine Stop Switch The engine stop switch (1) is next to the throttle grip. When the switch is in the RUN position, the engine will operate. When the switch is in the OFF position, the engine will not opemte. This switch is intended primarily as a satety or emergency switch and should normally remain in the RUN position. Headlight Switch < Except U type> The headlight switch (2) has tree positions; “H". “P" and “OFF" marked by a red dot to the left of “P”. H: Headlight, taillight, position light and meter lights on. P: Position light, taillight and meter light on. OFF(dot) : Headlight. taillight, position light and meter lights off. 30 Starter Button The starter button (3) is below the headlight switch (2) When the starter button is pressed. the starter motor cranks the engine. See page 37 [or the starting procedure. (1) Engine stop switch (2) Headlight switch (3) Starter button LEI-‘1‘ HANDLEBAR CONTROLS Headlight Dimmer Switch (1) Select HI for beam, L0 for low beam. Turn Signal Switch (2) Move to L to signal a left turn, R to signal a right turn. Press to turn signal off. (ExceptAR type> (1) Headlight dimmer switch (2) Turn signal switch Horn Button(3) Press the button to sound the horn. Passing Light Control Switch (4) < AR type on1y> When this switch is pressed, the headlight flashes on to signal approaching cars or when passing (1) (3} (3) Horn button (4) Passing light control switch 31 FEATURES (Not required for operation) STEERING LOCK The steering lock (1) is on the steering stem. To Lock: Turn the handlebar all the my to the left or right, and insert the key into the lock. turn the key clockwise and remove it. (1) (1) Steering lock 32 < G, 11 G,Fl Wpe> The steering lock (1) is on the steering column. To lock the steering. turn the handlebar all the way to the left, insert the steering key into the lock, turn the key counterclockwise as far as possible. Then, press the lock all the way in, turn the key hack to the original position, and remove the key. To unlock the steering, perform the lacking sequence in the reverse order. (1) Steering lock (G, I] (3.1“1'3’0e> HELMET HOLDER (1) The helmet holder (1) is on the left side below the seat Insert the ignition key (2) and turn it counterclockwise to unlock. Hang your helmet on the holder pin (3) and push it in to lock. Remove the key. “WARNING “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 loss of control. (3) (2) /1 (l) Helmet holder (3) Holder pin (2) Ignition key 33 SIDE COVER DOCUMENT COMPARI'Mm To remove the right and left side covers (1), The document compamnent (1) behind the pull out the prongs (2) and then genfly pu“ right side cover. the side cover dawn to release the tabs (3). This owner‘s manual and other documents should be stored in this compartment, When washing your motorcycle. be careful not to flood this area with water. (1) Side cover (3) Tabs (1) Document compartment (2) From 34 OPERATION PRE-RIDE INSPECI‘ION AWARNING ‘ If the Pre-ride Inspection is not per‘onned, severe personal injury or vehicle damage may result. Inspect your motorcycle every day before you ride it. The items listed here will only take a few minutes to inspect, and in the long run they can save time. expense, and possibly your life. 1, Engine oil leveleadd engine oil it required (page 26). Check for leaks. 2. Fuel levelifill fuel tank when necessary (page 23). Check for leaks. 3i Coolant level-add coolant if required. Check for leaks (page 20—21). 4, Front and rear brakes*check operation; make sure there is no brake fluid leakage. Adjust free play if necessary (page 14* 17). 5. Tyres* check condition and pressure (page 27 7 28). 6. Drive chain—check condition and slack (page 61 ). Adjust and lubricate if necessary. 7,Throttle4check for smooth opening and lull closing in all steering positions. 8. Lights and ham-check that headlight. tail/brake light, turn signals. indicators and horn function properly, 9, Engine stop switcl-rcheck for proper lunction (page 30). 10, Side stand ignition cut—off systemvcheck for proper function (page 67). Correct any discrepancy before you ride. Contact your authorized Honda dealer for assistance it you cannot correct the problem. 35 STARTING THE ENGlNE This motorcycle is equipped with a side stand ignition cut—oft system. The engine cannot be started ii the side stand is down unless the transmission is in neutral. If the side stand is up, the engine can be started in neutral or in gear with the clutch lever pulled in. After starting with the side stand down, the engine will shut off it the transmission is put in gear before raising the side stand I Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and lead to death. NOTE: 4 Do not use the electric starter for more than 5 seconds at a time. Release the starter button for approximately 10 seconds before pressing it again. 36 Preparation Before starting, insert the key. turn the ignition switch ON and confirm the following: IThe transmission is in NEUTRAL (neutral indicator light ON), 0 The engine stop switch is at RUN, o The red low oil pressure indicator is ON. 0 The fuel cock is ON. Startingl’rocedure To restart a warm engine, follow the procedure for “High Air Temperature,” Normal Air Tempgrature 10° i35°C 50° *95‘1 1. Pull the chock knob ( 1 ) up all the way to Fully ON (A) . if the engine is cold. 2. Start the engine. leaving the throttle closed. NOTE: ~ Do not open the throttle when starting the engine with the choke ON. This will lean the mixture, resulting in hard starting. \Qx\ (A) Fully ON (B) Fully OFF (1) Choke knob 3.1mmedialely after the engine starts» operate the choke knob (1) to keep last idle. 4. About a hall minute after the engine starts, push the choke knob (1) down all the way to Fully OFF (B). 5.1( idling is unstable, open the throttle slightly. CAUTlON: t'l‘he red low oil pressure indicator should go off a few seconds after the engine starts. 1! 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) e e G (2) Low oil pressure indicator 37 High Air Temgmture 35°C 95°F or above 1. Do not use the choke. 2‘ Open the throttle slightly. 3. Start the engine. Low Air Tempgrature 10° 50°F or below 1. Follow steps 1 7 2 under “Normal Air Temperature.” 2. When engine speed begins to pick up, operate the choke knob to keep fast idle. 3. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob (l) is at Fully OFF (B). 38 Flooded Engine Ii the engine fails to start alter repeated attempts, it may be flooded with excess fuel. To clear a flooded engine, turn the engine stop switch to OFF and push the choke lever forward to Fully OFF (B). Open the throttle fully and crank the engine for 5 seconds. Wait 10 seconds, then turn the engine stop switch to RUN and follow the Starting Procedure (page 37 ). RUNNING-IN During the first 1,000 km (600 miles), avoid lull throttle use and never labour the engine, Do not operate at any one speed for prolonged periods. During initial ninning-in newly machined surfaces will be in contact with each other and these surfaces will wear in quickly. Runningrin maintenance at 1.0001011 (600 miles) designed to compensate for this initial minor wear, Timely performance of the running maintenance will ensure optimum servme life and perlormance from the engine. 39 RIDING WARNING - Review Motorcycle Safety (pages 1 7 5 ) before you ride. * Make sure the side stand is fully re- tracted before riding the motorcycle. NOTE: C Make sure you understand the function of the side stand mechanism. (See MAIN- TENANCE SCHEDULE on page 46 and explanation for SIDE STAND on page 67 ) 1.Atter the engine has been warmed up, the motorcycle is ready for riding. 2. While the engine is idling, pull in the clutch lever and depress the gearshift pedal to shift into 1st (low) gear. 3. Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start. 4. When the motorcycle attains a moderate speed. close the throttle, pull in the clutch lever and shift to 2nd gear by raising the gearshift pedal. This sequence is repeated to progressive- ly shift to 3rd, 4th and 5th (top) gears. 5. Coordinate the throttle and brakes for smooth deceleration. 6. Both front and rear brakes should be used at the same time and should not be applied strongly enough to lock the wheel, or bmking effectiveness will be reduced and control of the motorcycle be difficult. < Except sw type> < sw type > 954 5 93¢ \ BRAKING 1. For normal braking, gradually apply both the from and rear brakes while tWhen riding in wet or rainy condi- downshifting to suit your road speed. tions. or on loose surfaces, the ability 2, For maximum deceleration, close the to maneuver and stop will he reduced. throttle and apply the front and rear All of your actions should be smooth brakes firmly. Pull in the clutch lever under these conditions. Rapid accel- before coming to a complete stop to eratinn, braking or turning may cause prevent stalling the engine. loss of control. For youthsafety, exer- cise extreme caution w en hrakin' g, accelerating or turning. t Independent use of only the front or t When descending a long, steep grade, rear brake reduces stopping use engine compression braking by performance. Extreme braking may downshifting, with intermittent use of cause either wheel to lock, reducing both brakes. Continuous brake control of the motorcycle. application can overheat the brakes ~When possible. reduce speed or and reduce their effectiveness. brake before entering a turn; closing ' Riding with your foot resting on the the throttle or braking in mid-tum brake pedal or your hands on the may cause wheel slip. Wheel slip will brake lever may actuate the reduce control of the motorcycle. brakeligit, giving a false indication to other drivers. It may also overheat the brake, reducing effectiveness. 41 PARKING LAtter stopping the motorcycle, shift the transmission into neutral. turn the fuel 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 film, level ground to prevent it from falling over. ' If you must park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility of rolling off the side stand or overturning. 5" Lock the steering to help prevent theft (page 32). 42 NOTEI -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 ignition switch is left at P for too long a time. ANTI-THEFT TIPS 1. Always lock the steering and never leave the key in the steering lock This sounds simple but people do forget. 2. Be sure the registration infomlation for your motorcycle is accumte and current. 3. Park your motorcycle in a locked garage whenever possible. 4. Use an additional antitheft device oi good quality. 5. Put your name. address. and hone number in this Owner‘s Manual and) keep it on your motorcycle at all times. Many times stolen motorcycles are identified by information in the Owner‘s Manuals that are still with them. NAME : ADDRESS : PHQNE NO: MAINTENANCE 0 The Required Maintenance Schedule specifies how often you should have your motorcycle served. and what things need attention. It is essential that your motorcycle be served as scheduled to retain its high level 0! safety. dependability. and emission control performance. -These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose, Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the MAINTENANCE SCHEDULE. Consult your authorized Honda dealer for recommendations applicable to your individual needs and use. u MAINTENANCE SCHEDULE The following Maintenance Schedule specifies all malnlelwnce required to lmep your motorcycle in peak openling condition Maintemnce work should be perIormed in accordance with sundnrds and specifications oI Honda by properly trained and equipped Iechniclans Your aulhorlzed Honda dealer wheels all M these requiremenls, Pefloml Ihe mfide Inspection (page 35) al each scheduled maintenance period I: INSPECT AND CLEAN. ADJUST, LUBRICATE OR REPLACE IF NECESSARY C~CLEAN RIREPLACE AzADJUSl‘ LLUBRICATE FREQUENCY WHICHEVER a DDOME' ER READING [NC/FE (1)] COMES xlooolm 1 6 12 18 24 30 36 FIRST lxwmm‘l 0.6 4 s 12 Is 20 24 REFER ITEM NOTE MONTH B 12 18 24 30 36 TO PAGE u FUEL LINE I I I A 0 THROTTLE OPERATION I l l 59 L CARBURETOR CHOKE I I I - AIR CLEANER (NOTE 2) R R 51 ¥ CRANKCA BREATl-LER (NOTE 3) C C C C C C 52 SPARK PLUG I R I R I R 57 — 58 . VALVE CLEARANCE I I I I 7 ¥ ENGINE OIL R R R R 26 53*56 ENGINE OIL FILTER R R R R 5A 7 56 t CAREURETOR SYNCHRONIZATION I l l I r t ENGINE IDLE SPEED l l l I I I I 50 RADIATOR COOLANT (NOTE A) I I R 20 — 21 a COOLING SYSTEM I I I r a SECONDARV AIR SUPPLY SYSI‘EM (NOTE 5? l I I - 45 rrEM D BRAKE FLUID BRAKE SHOE AD B er RAKE GHT SWITCH LlG CLUT SYSI‘EM SlDESrAND SION BOL F HEAD 46 0 SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED, REFER TO THE OFFICIAL HONDA SHOP MANUAL n [N THE INTEREST OF SAFETY, WE RECOMMEND THESE n‘EMS BE SERVICED ONLY BY YOUR AUTHORIZED HONDA DEALER. Honda recommends am your amhoriztd Honda dealer should road test your molomycle aller each periodic maintenance 15 carried out. NUTES: 1 A. higher odometer mum repeal at the frequency lnlerval esmbllshcd here. 2‘ Servitc more lrequemly when rldlng in unusually wel or dusty areas 3. Service mom frequently when ridlng in rim or at lull throttle. 4. Replace every 2 years, or at lndicated odometer interval, whichever comes first. Replacement requires mechania] skill. 5‘ Swilurland Iype only. 47 TOOL KIT The tool kit (1) is in the tool box behind the left side cover. Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. 0 10 x 12 mm open end wrench 0 14 x 17 mm open end wrench o Pliers 0 5 mm hex wrench - 6 mm hex wrench 0 No. 2 screwdriver o No. 2 Phillips screwdriver 0 Screwdriver grip 0 8 mm open end wrench 0 17 mm box end wrench 0 24 mm box end wrench 0 Hook spanner o Breaker bar 0 Spark plug wrench 0 Tool bag ‘8 (1) Tool kit SERIAL NUMBERS The frame and engine serial numbers are required when registering your motorcycle. They may also be required by your dealer when ordering replacement parts. Record the numbers here for your reference. The frame number (1) is stamped on the right side of the steering head. The engine number (2) is stamped on the right side of the crankcase. FRAME NO. ENGINE N0. (Z) 3? (2) Engine number (1) Frame number COLOUR IABEL The colour label (1) is attached to the frame under the front seat. It is helpful when ordering replacement parts. Record the colour and wde here far your reference COLOUR CODE (1) Colour label 49 MAINTENANCE PRECAUTIONS ‘ Use new, genuine Honda parts or 0 If your motorcycle is overturned or their equivalent for maintenance and involvedinaoollision, inspect control repair. Parts which are not of levers, cables, brake hoses, calipers, equivalent quality may impair the accessories, and other vital parts for safety of your motorcycle. damage. Do not ride the motorcycle if damage impairs safe operation. Have your authorized Honda dealer inspect the major components, including flame, suspension and steering parts, for misalignment and damage that you may not be able to detect. ' Stop the eng'ne and support the motorcycle securely on a firm, level surface before performing any maintenance. 50 AIR CLEANER (Refer to the maintenance precautions on page 50). The air cleaner should be serviced at regular intervals (page 44). Service more frequently when riding in unusually wet or dusty areas. 1. Remove the bolt (1) and the air cleaner housing cover (2). 2, Remove the air cleaner stay (3) by removing the screws (4) (2) (l) / (1) Bolt (2) Air cleaner housing Cover 3. Take out the air cleaner (5) and discard it. 4. lnsmll the new air cleaner. Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model. Using the wrong Honda air cleaner or a nonvl‘londa air cleaner which is not 01 equiwlent quality may cause premature engine wear or performance problems. 5. Install the removed parts in the reverse order of removal. (3) Stay (4) Screws CRANKCASE BREATHER (Reter to the maintenance precautions on page 50). 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, NOTE: t Service more frequently when riding in rain, at full throttle, or after the motorcycle is washed or overturned Service if the deposit level can be seen in the transparent section of the drain tube. (1) Crankcase breather tube plug 52 ENGINE OIL (Refer to the maintenance precautions on page 50), . e Good engine oil has many desirable qualities. Use only high detergent, quality motor oil certified on the container to meet or exceed requirements for API Service Classification SE, SF or 56. Viscosity: Viscosity grade of engine oil should be based on average atmospheric temperature in your riding area. The following provides a guide to the selection 01 the proper grade or viscosity of oil to be used at various atmospheric temperatures. (1) Single grade (2) Multigmde Engine Oil and Filter Engine oil quality is the chief factor affecting engine service life Change the engine oil as specified in the maintenance schedule (page 45). Changing the oil filter requires a special oil filter tool and a torque wrench, If you do not have these tools and the necessary skill. we recommend that you have your authorized Honda dealer perform this service. If a torque wrench is not used [or this installation, see your authorized Honda dealer as soon as possible to verify proper ‘ Change the engine oil with the engine at normal operating temperature and the motorcycle on its side stand to assure complete and rapid draining. CAUTION: ‘ To prevent oil leaks and filter damage, rever support the engine on the oil iter. 54 ].To drain the oil, remove the oil filler cap agd oil drain plug (1) and sealing washer AWARNlNG ‘ A wanned—up engine and the oil in it are hot; be careful not to burn yoursell'. >\ (1) N: {7 f (2) / a (1) Oil drain plug (2) Sealing washer 2. Remove the oil filter (3) with a filter 4. Applyathin coat of engine oil to the new wrench and let the remaining oil drain out. oil filter mbber seal (4). Discard the oil filter. 5. Using a special tool and a torque wrench, 3. Check that the new oil filter rubber seal install the new oil filter and tighten to a is in good condition. torque of: 10 N4" (10 kg-m , 7 lbfl) (3) Use only the Honda genuine ail filter or a filter of equivalent quality specified for your model. Using the wrong Honda filter or a non—Honda filter which is not of equivalent quality may cause engine damage. ‘ (3) Oil filter ‘ (4) Oil filter rubber seal 6. Check that the sealing washer on the drain plug is in good condition and install the plug. Replace the sealing washer every other time the oil is Changed, or each time it necessary. Oil Drain Plug Torque: 35 N-m (3.5 kg-m , 25 lb-ft) 7. Fill the crankcase with the recommended grade oil; approximately: 2.25 M238 US qt,1i98 lmpqt) 8, Install the oil filler cap. 9, Start the engine and let it idle for 2*3 minutes. 10, Stop the engine and check that the oil level is at the upper level mark on the dipstick with the motorcycle upright on firm, level ground, Make sure there are no oil leaks. NOTE: th-ien running in very dusty conditions, oil changes should be perfomed more frequently than specified in the maintenance schedule. 56 NOTE: 0 Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the rubbish or pour it on the ground or down a drain. CAUTION: ~Used engine oil may cause skin can» cer if repeatedly left in Contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as solon as possible after handling used or . SPARK PLUGS (Refer to the maintenance precautions on page 50h Recommended plugs: Standard: DPRSEAi 9 (NGK) or XZAEPR , U9 (NIPPONDENSO) For cold Climate: (Below 5°C. 41° F) DPR7EA‘ 9 (NGK) or XZZEF‘R — U9 (NIFPONDENSO) For extended high speed riding: DPR9EA* 9 (NGK) or XZ7EPR , U9 (NIPPONDENSO) 1. Disconnect the spark plug caps from the spark plugs 2‘ Clean any dirt from around the spark plug bases. Remove the spark plugs using the plug wrench furnished in the tool kit. 3. Inspect the electrodes and center porcelain for deposits, erosion or cabon fouling, If the erosion or deposit is heavy, replace the plug, Clean a carbon or wet- {ouled plug with a plug cleaner, otherwise use a wire brush 4. Check the spark plug gap (1) using a Wire-type feeler gauge. If adjustment is necessary, bend the side electrode (2) carefully. The gap should be: 030*030 mmi0.031*0l035 in) Make Sure the plug washer is in good condition (1) Spark plug gap (2) Side electrode 57 5.Witl1 the plug washer attached, thread the spark plug in by hand to prevent cross-flireading. 6. Tighmn a new spark plug 1/2 turn with a spark plug wrench to compress the washer. If you are reusing a plug, it should only take 1/8~ 1/4 [um after the plug seats 7. Reinstall the spark plug caps. CAUTION: ‘The spark plug must be securely fiyltened. An improperly tightened ping can become very hot and possibly damage the engine. 4’Never use a spark plug with an im- proper lleat range. Severe engine damage could result. 58 THROTTLE OPERATION (Refer to the maintenance precautions on page 50 ). 1, Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. 2. Measure the throttle grip free play at the throttle grip flange. The standard free play should be approx: 276 mm {0.08—0.24 in) To adjust the free play, loosen the lock nut (1) and turn the adjuster (Z). (1) (2) ¥ (1) Lock nut (Z) Abjuster 59 IDLE SPEED (Reier to the maintenance precautions on page 50 The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-and-go riding is sufficient. NOTE: t Do not attempt to compensate for faults in other systems by adjusting idle speed See your authorized Honda dealer for regularly scheduled carburetor adjustments, including individual carburetor adjustment and synchronization. 1. Warm up the engine, shilt to neutral and place the motorcycle on it side stand. 2. Connect a tachometer to the engine. 3. Adjust idle speed with the throttle stop screw (1). Idle Speed (E,G,F,ED,U.SP.AR,F[, HG, 1] rr, lIPO type): 1,100 + 100 min“. (rpmttln neutral) Idle Speed (SWty 1,200 i 50 mimpe‘ermHIn neutral) (I) Throttle stop screw (A) Increase (B) Decrease DRIVE CHAIN (Refer to the maintenance precautions on Page 50 ). The service life at 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 Pre-ride Inspection (page 35). Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas. more frequent maintenance will be necessary. Inspeetl n: 1. Turn the engine off. place the motorcycle on its side stand and shift the transmission into neutral. 2. Check slack in the lower drive chain run midway between the sprockets. Drive chain slack should be adjusted to allow the following vertical movement by hand: 20’30 mm (08* 1.2 in) 3. Rotate the rear wheel. Stop. Check the drive chain slack Repeat this procedure several times. Drive chain slack should remain constant. If the chain is slack only in certain sections. some links are kinked and binding. Binding and kinking can frequently be eliminated by lubrication. (1) Drive chain 61 4. Rotate the rear wheel slowly and inspect the drive chain and sprockets for any of the [allowingRIV conditions: CHAIN ‘DamageRNd Rollers ‘Loose Pins *Dry or Rusted Links *anked or Binding Links “Excessive Wear *lmproper Adjustment 'Missing O-rings SPROCKETS 'Excessively Worn Teeth ‘Broken or Damaged Teeth A drive chain with damaged rollers, loose pins, or missing O-rings must be replaced. A chain which appears dry, or shows signs of mst, requires supplementary lu- brication, Kinked or binding links should be thoroughly lubricated and worked free. If links cannot be freed. the chain must be replaced. 62 Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE REPIACE Normal Sprocket Teeth GOOD Ad’ustmeng Drive chain slack should be checked and adjusted. if necessary, every 1,000 km (600 miles). When operated at sustained high speeds or under conditions of frequent rapid acceleration, the chain may require more frequent adjustment. (1) Axle nut (4) Index mark (2) Lock mix (5) Corresponding stale (3) Drive chain adjusting bolt If the drive chain requires adjustment, the procedure is as follows: 1, Place the motorcycle on its side stand with the transmission in neutral and the ignition switch on. 2. Loosen the axle nut (1), 3. Loosen the lock nuts (2) on both adjusting bolts (3). 4.Tum both adjusting bolts an equal number of turns until the correct drive chain slack is obtained. Turn the adjusting bolls clockwise to tighten the chain‘ or counterclockwise to provide more slack. Adjust the chain slack at a point midway between the drive sprocket and the rear wheel sprocket. Rotate the rear wheel and recheck slack at other sections of the chain. Chain slack should be: 20-30 mm (0i8*1.2 in) 5. Align the chain adjuster index marks (4) with the corresponding scale (5) graduations on both sides of the swing arm. Both left and right marks should correspond. If the axle is misaligned» turn the left or right adjusting bolt until the marks correspond on the scale graduation on the swingarm and recheck chain slack. 6. Tighten the axle nut to: 90 Nrm (9.0 kg-m , 65 Ib-ft) 7. Tighten the adjusting bolts lightly, then tighten the lock nuts by holding the adjusting bolts with a spanner. 8. Recheck drive chain slack. 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 (page 16). CAUTION: ‘Damage to the bottom part of the frame may be caused by excessive drive chain slack of more than: 50 mm [2.0 In) Wear inspection: Check the chain wear label when adjusting the chain. If the red zone (6) on the label aligns with the arrow mark (4) 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: 20*30 mm10.8—1i2inl Replacement Chain: DID525V8 or RKEZSSMS This motorcycle has a staked master link drive chain which requires a special tool for cutting and staking. Do not use an ordinary master link with this chain. See your authorized Honda dealer. (4) Index mark (6) Red zone Lubrication and cleaning: LuBricate every 1,000 km (600 miles) or sooner if chain appears dry. The O-I‘ings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents. Clean the chain with high flashrpoint solvent, such as paraffin. Wipe dry and lubricate only with SAE 80 or 90 gear oil. Commercial chain lubricants may contain solvents which could damage the rubber Orings. 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 (0 improve its service life. However. special precautions must be taken when adjusting, lubricating, washing, and replacing the chain. SIDE STAND (Reler to the maintenance precautions on page 50). Check the side stand system for proper function. 0 Check the spring ( l) for damage or loss of tension and the side stand assembly for freedom of movementl oCheck the side stand ignition cut-off system 1. Sit astride the motorcycle; put the side stand up and the transmission in neutral. 2.5mm the engine and with the clutch lever pulled in, shift the transmission into gear, 3. Lower the side stand The engine should stop as you put the side stand down. If the side mud system does not operate as described. see your authorized Honda dealer for service. (1) Spring 67 BRAKE PAD WEAR (Refer to the maintenance precautions on page 50), Brake pad wear depends upon the severity of usage. the type of riding, and road conditions (Generally. the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval (page 46). < FRONT BRAKE > (1) (I) Wear indicator mark 68 Front Brake Chick the wear indicator mark (1) on each pa 4 If either pad is worn to the wear indicator mark, replace both pads as a set, See your authorized Honda dealer for this service. (1) BRAKE SHOE WEAR (Refer to the maintenance precautions on page 50L The rear brake is equipped with a brake wear indicator. When the brake is applied, an arrow (1) attached to the brake arm (2) moves toward a reference mark (3) on the brake panel (4). If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced See your authorizd Honda dealer for this service. NOTE: *When the brake service is necessary. see your authorized Honda dealerr Use only genuine Honda pans or its equivalent ( / //// (l) (4) w/\ (2)\ \\\ii \ (1) Arrow (2) Brake arm (3) Reference mark (4) Brake panel WHEEL REMOVAL Front Wheel Removal (Refer to the maintenance precautions on 1. Raise the front wheel of! the ground by page 50 ). placing a support block under the engine NOTE: 2. Disconnect the speedometer Cable (1) by ~This motorcycle is equipped with a side removing the speedometer cable set stand only. Therefore, if from or rear screw (2). wheel removal is required, it will be necessary to raise the Center of the motorcycle with a jack or other firm support. If none is available, see your authorized Honda dealer for this service. (1) Speedometer cable (2) Speedometer cable set screw 70 3. Loosen the axle pinch bolts (3) and remove the front axle (4). Pull out the front axle. Remove the front wheel. N 0T E: . Do not depress the brake lever when the wheel is off the motorcycle. The caliper pistons will be forced out o! the cylinders with subsequent loss of brake fluid. If this occurs. servicing of the brake system will be necessary. See your authorized Honda dealer for this service. (3) Axle pinch bolts 1 (4) Front mde 71 Installation Notes: 0To install the front wheel assembly, install the brake disc between the bmke pads taking care not to damage the brake pads and insert the axle through the left fork leg. U Make sure that the lug (5) on the fork leg is contacting the lug on the speedometer gear box. Tighten the front axle and axle pinch bolts to specified torques. Front axle torque: 75 N-m (7.5 kg-m , 54 Ib—fl) Axle pinch bolts torque: 22 Nm (2.2 kg-m .16 lb") I After installing the wheel, apply the brake seveml times and then check it the wheel rotates freely. Recheck me wheel if the brake drags or ii the wheel does not rotate freely. 72 AWARNING t If a torque wrench was not used for installation, see your authorized Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. (5) (5) Lugs Rear Wheel Removal 1. Raise the rear wheel off the ground by placing a support block under the engine. 2. Remove the rear brake adjusting nut (1), disconnect the brake rod (2) from the brake arm (3) by pushing down on the rear brake pedal. (I) Adjusting nut (5) Cotter pin (2) Brake rod (6) Stopper arm nut (3) Brake arm (7) Axle nut (4) Stopper arm 3. Disconnect the brake stopper arm (4) from the brake panel by removing the cotter pin (5), stopper arm nut (6), washer and rubber grommet. 4. Remove the axle nut (7) while holding the axle at the other end with a wrench. 5. Pull out the axle (8), 6. Remove the drive chain from the drive sprocket by pushing the rear Wheel forward. 7. Remove the rear wheel. (8) Rear axle Installation Notes: 0 Reverse the removal procedure. OTighten and torque the following nuts and bolts : Axle nut mrque: 90 N‘m19.0 kg-m , 65 lb»ft) Brake stopper arm nut torque: 27 N-m (2.7 kg-m , 20 lb»fll - Adjust the brake (page 16) and drive chain (page 63). I Apply the brake several times and check for tree wheel rotation after the brake pedal is released. 7‘ AWARNING ‘ If a torque Wrench was not used for installation, see your authorized Honda dealer u soon as possible to verity proper assembly. Improper assembly may lead to loss of braking capacity. CAUTION: ¢ Always replace used cotter pins with new ones. BATTERY (Refer to the maintenance precautions on rage 50). t is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance-free (sealed) type. If your battery seems weak and/or is leaking elemolyte (causin hard starting or other electrical troubles , Contact your authorized Honda dealerr CAUTION: 1IRemovin the battery cap strip can damage t e cap strip and result in leaks and eventual battery damage. tWhen the meta cle is to be stored for an extende period of time, remove the battery from the motorcycle and chage it fully. Then store it in a cool, ry place. If the battery is to be left in the meta cle. disconnect the ne tive cable mm the battery terminal . AWARNING tThe batte gives off explosive gases: keep 5 at s, flames, and cigarettes away. rowde adequate ventilation when cha ing or using the battery in an encl space. t'l‘he batte contains sulfuric acid (electrolyte . Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. —If electrolyte gets on your skin, flush with water. —If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. tElectrolyte is oisonous. —lf swallowe , drink large uanu'ties of water or milk and fo low with milk of magtesm or vegetable oil and calan'lph sician. 'KEEP 0 F REACH OF CH1], DREN. 75 Bane Removal: 5. Remove the battery cover ( 3) by 14 Remove the eft side cover (page 34), removing the bolts. 2. Remove the coupler holder ( 1). 6. Disconnect the positive (+) terminal lead 3, Disconnect the negative (—) terminal ( 4 ). lead ( 2) from the battery first. 7‘ Pull out the battery from the battery box, 4. Remove the right side cover (page 34). (l) Coupler holder (3) Battery cover (2) Negative (7) terminal lead (4) Positive H') terminal lead 78 ST OPLIGHT SWITCH ADJUSTMENT (Refer to the maintenance precautions on page 50). Check the operation of the stoplight switch ( 1) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut (2). Turn the nut in the dir on (A) if the switch operates too late and in direction (B) if the switch operates too soon. \_/ (B) r / (A) m (2) (l) Stoplight switch (2) Adjusting nut 77 FUSE REPLACEMENT (Refer to the maintenance precautions on page 50). When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system See your authorized Honda dealer for repair. CAUTION: IITurn the ignition switch OFF before checking or replacing fuses to prevent accidental short—circuiting. 78 AWAHNJNG 'Never use a {use with a different rating from that specified. Sedans damage to the electrical system or a file may result, causing a dangerous loss of lights or engine power. Blown fuse WHLl‘l H'H HllHll l l E VI Fuse box: The f se box (1) is located behind the right side cover. The specified (use are: 10A,1 5A 1‘ Remove the right side cover (page 34). 2‘ Remove the fuse box cover (2) by removing the screw (3). l (1) Fuse box (4) Fuse remover <2) Fuse box cover (5) Spare [uses (3) Screw 3. Pull out the {use with the fuse remover (4). II the fuse is blown. install a new fuse. The spare fuses (5) are located in the fuse box. 4.1nstall the fuse box cover and right side cover. 79 3. Pull out the fuse. If the fuse is blown The main fuse (1) is located behind the install a new fuse. right3 soidAe cover. The specified fuseis The spare main [use (4) is located near the fuse box (5). 1 Remove the right side cover (page 34) 4. Reconnect the wire connector and install 2. Disconnect the wire connector (2) of the the right side cover. stater magnetic switch (3). \V “E (4) Spare main [use (5) Fuse box (1) Main fuse (3) Starter magnetic switch (2) Wire connector so BULB REPLACEMENT (Refer to the maintenance precautions on page 50) t The light bulb becomes very hot while the light is ON, and remain hot {or a while after it is turned OFF. Be sure to let it cool down before servicing. CAUTION: 4 Do not put finger prints on the headlight bulb, as they may create hot apots' on the bulb and cause it to reak Wear clean gloves while replacing the bulb. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. NOTE: ' Be sure to turn the ignition switch OFF when replacing the bulb. . Do not use bulbs other than that specified. ¢ Alter installing a new bulb, check that the light operates properly. 81 Headlight/Position Light Bulb 1. Remove the two screws (1) from the headlight case. 2. Gently pull the lower end of the headlight (2) [orward and remove the headlight. 3, Disconnect the connectors (3). 4. *Headlight bulb. 0 Remove the seat rubber (4). 0 Remove the headlight bulb (5) while pressing doun on the pin (6). (3) Connectors (1) Screws (2) Headlight 82 - Position light bulb: 0 Pull out the socket (7). 0 Slightly press the position light bulb (8) and turn it counter— clockwise. 5. Install a new bulb in the reverse order of removal. (7) (8) (4) Seat rubber (7) Socket (5) Headlight bulb (3) Position light bulb (6) Pin Stop/Taillight Bulb 2. Slightly press'the bulb (3) and turn it 1, Remove the taillight lens (1) by removing counterclockwnse. the two screws (2), 3. Install a new bulb in the reverse order of remowl. (l) Taillight lens (3) Bulbs (2) Screws Front/ Rear Turn Signal Bulb 1. Remove the turn signal lens (1) by removing the two screws (2). (l) (I) Turn signal lens (2) Screws 34 2. Slightly press the bulb (3) and turn it coumerclockwisev 3‘ Install a new bulb in the reverse order of removal. (3) Bulb Lisence Light Bulb 1. Remove the rear fender (1) by removing the two bolts (2). 2. Remove the license light cover (3) and license ligh‘ lens (4) by removing lhe two nuts (5). (1) Rear fender <2) balls (3) License light cover (4) License light lens (5) Nuts 3. Slightly press the bulb (6) and turn it counterclockwise 4. Install a new bulb in the reverse order of removal, (6) (6) Bulb 85 CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect for damage, wear, and oil, coolant or brake fluid leakage. CAUTION: ‘ High pressure water (or air) can damage certain parts of the motorcycle. Avoid spraying high pressure water (typical in coin-operated car washes) at the following areas: Ignition Switch Instmments Carburetors Wheel Hubs Drive Chain Muffler Outlets Under Seat Under Fuel Tank Handlebar Switches Brake Master Cylinder LAlter cleaning. rinse the motorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. NOTE: . Clean the plastic pans using a cloth or sponge dampened with a solution oi mild detergent and water. Rub the soiled area gently rinsing it frequently with fresh water. 2. Dry the motorcycle, start the engine. and let it run for several minutes. 3. Test the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking performance, AWAHNlNG *Braking efficiency may be tempora- rily impaired immediately after washing the motorcycle. Anticipate longer stopping distance to avoid a possible accident. 4. Lubricate the drive chain immediately after washing and drying the motorcycle. CAUTION: ~Do not use steel wool or a cleaner containing abrasives or compounds to clean the wheels, as they can cause damage. STORAGE GUIDE Extended storage, such as for winter. requires that you take certain steps to reduce the efiects of deterioration from non-use of the motorcycle. In addition, necessary repairs should be made BEFORE storing the motorcycle; otherwise, these repairs may be iorgotten by the time the motorcycle is removed from storage STORAGE 1, Change the engine oil and filterl 2. Lubricate the drive chain (page 66). 3. Make sure the cooling system is filled with a 50/5056 antifreeze solution. 4. Empty the fuel tank into an approved petrol container using a commercially available hand siphon or an equivalent method. Spray th ‘ side 01' the tank with an aerosol rust-in ting oili Reinstall the fuel fill cap on the tank, NOTE: ' If storage will last more than one month, carburetor draining is very important. to assure proper performance after storage. 88 AWARNING ' Petrol is extremely flammable and is explosive under certain conditions. Perform this operation in a well- ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where petrol is drained or stored and where the fuel tank is refueled. 5. To prevent rusting in the cylinders. perform the following: 0 Remove the spark plug caps from the spark plugs. Using tape or string, secure the caps to any convenient plastic body part so that they are positioned away from the spark plugs. 0 Remove the spark plugs from the engine and store them in a safe place. Do not connect the spark plugs to the spark plug caps. 0 Pour a tablespoon (15720 cc) of clean engine oil into each cylinder and cover the spark plug holes with a piece oi cloth. 0 Crank the engine several times to distribute the oil. 0Reinstall the spark plugs and spark plug Caps 6. Remove the battery. Store in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month. 7. Wash and dry the motorcycle, Wax all painted surfaces. Coat chrome with rustinhibiting oil. 8.1nflate the tyres to their recommended pressures. Place the motorcycle on blocks to raise both tyres off the ground. 9. Cover the motorcycle (don't use plastic or other coated materials) and store in an unheated area. free of dampness with a minimum of daily temperature variation. Do not store the motorcycle in direct sunlighL REMOVAL FROM STORAGE 1. Uncover and clean the motorcycle. Change the engine oil i! more than 4 months have passed since the start of storag 2. Charge the battery as required. Install the battery. 3. Drain any excess aerosol rust—inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol. 4. Perform all Pre-ride Inspection checks (page 35 ). Test ride the motorcycle at low speeds in a safe riding area away from traffic. 90 SPECIFICATIONS DIMENSIONS Overall length Overall widlh Overall height Wheelbase Ground clearance WEIGHT Dry Weight CAPACITIES Engine oil (After draining) (After dmining and oil filter change) (After disassembly) Fuel tank Fuel reserve Cooling system capacity Passenger capacity Maximum weight capaCIty 2,355 mm192.7 in) 760 mm (299 in) 1,125 mm(44,3 in) 1,600 mm163.0 in) 140 mm (55 in) 200 kg (441 lbs) 2.1 012.2 US ql,1i8 Imp (II) 225 B (2.38 USqt,1,98 Imp qt) 2‘8 0 (30 US qt , 2.5 Imp qt) 11.0 M291 US gal,2.42 Imp gal) 34 B (0.90 US gal, 0‘75 Imp gal) 16 M1] USqt, 1.4 Imp qt) Operator and one passenger 184 kg (405 Ibs)(G,lIG,SP) 174 kg (384 lbs) IE,F,ED,U,$W,AR,FI,l1lT,]IPOI 91 ENGINE Bore and stroke Compression mtio Displacement Spark plug Standard For cold climate (Below 5 12,41 aF) For extended high speed riding Spark plug gap Idle speed CHASSIS AND SUSPENSION Caster Trail Tire size, from Tire size, rear 92 75.0 X 660mm(295 >< 2.60m) 5823 cm3l356 cu in) DPRSEAi9 (NGK) or X24EPR7 U9 (NIPPONDENSO) DPR7EAi9 (NGK) or X22EPR7 U9 (NIPPONDENSO) DPR9EAi9 (NGKlor X27EPR7U9 (NIPPONDENSO) 0.80—0.90 mm (0.031 *D,035 in) 1,100 i 100 min" (rpm) (E,G,F,ED,U,SP,AR,FI,HG,HIT,HPO) 1,200 i 50 mim" (rpm) (SW) 35° 164 mm (6.5 in) 100/90719 57S 170/80‘15M/C 77S POWER TRANSMISSION Primary reduction Gear ratio (Except SW type) Isl 2nd 3rd 4th 5th Gear ratio (SW type) lst 2nd 3rd 4th Final reduction ELECTRICAL Battery Generator 1.888 2571 1‘777 1.380 L125 0.961 2571 1.700 L227 0331 1750 12V‘ SAh 264 W/5,000 min" (rpm) 93 LIGHTS Headlight Tail/bmke light Turn Signal light Front Rear Position light Instrument light Neutral indicator light Turn signal indicator light High beam indicator light Lisence light FUSE Main fuse Other [uses 94 12V—60/55W 12V—5/21W X 2 12v721w 12Vi21W 12V—4W (Except U) 12V—3.4W 12V-1l7W 12V—1‘7W 12Vi1l7W 12V-5W 30A 1 0A, 1 5A NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH THE NOISE CONTROL SYSTEM 15 PROHIBITED: Owners are warned that the law may prohibit : (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, oi any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the Vehicle after such device or element of design has been removed or rendered inoperative by any person. 95 e§.-NI-Nane__ II a; Him Him 33".: ham Es Oo8h> 5250 .m‘ 0‘ 3 mp «<5 mm 1.. ED. :1... =19 asueNulNauass eeg.n~I.Nen= 0.0 s. 00.2 .. E 2. . 5.. I Hun ”Elli 5. Doom;