HONDA. XL1 85$ OWN ER’S MANUAL MANUEL DU CONDUCTEUR MANUAL DEL PROPIETARIO © HONDA MOTOR C0,, LTD,1992 WWW IMPORTANT NOTICE ' OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. ° 0N/0FF»ROAD USE TI'IIS motorcycle is designed for “dual purpose" uses ’ READ THIS OWNER’S MANUAL CAREFULLY Pay speual attention to siaiements preceded by the following words: 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 pan of the motorcycle and should remain with the motorcyt‘le when resold, HONDA XL185S OWNER’S MANUAL All information in this publication is based on the latest production information available at. the time of approval for printing. HONDA MOTOR CO., LTD, reserves the right. to make changes at any time without noiice and without. incurring any obligation No part of this publication may be reproduced without written permission. WELCOME The motorcycle presents you a challenge to master the machme, a challenge to adventure You ride through the wind linked to the road by a vehlcle that responds to your commands as no other does llnlllre an autumobile, there is no metal cage around you. lee an alrplane, a pre-nde inspectlon and regular maintenance are essenllal to your safety. Your reward is freedom. To meet the challenges safely, and to enjoy the adventure fully, you should become thoroughly famillar with this owner's manual BEFORE YOU RIDE THE MOTORCYCLE. When serylee is required, remember that your Honda dealer knows your motorcycle best It you have the required mechanical “knowhow” and tools your dealer can supply you with an omelal Honda Sen vice Manual to help you perlon-n many maintenance and repatr tasks. Pleasant riding, and thank you for choosing a Honda, 0 Following codes in this manual lltdicate each country. U Auslmlia SI Singapole SA South Africa DK General expon (km/h) - The speelltcatlons may vary with each locale OPERATION Page 1 MOTORCYCLE SAFETY 1 Safe Riding Rules 2 Protective Apparel Modificziions Loading and Accessories Off-road Safety ms“ 7 PARTS LOCATION 10 Instruments and Indicators 12 MAJOR COMPONENTS (Information you need to operate this motorcycle) 12 Suspension 14 Brakes 18 CluLch ztl Fuel 24 Engine Oil 25 Tyres 27 ESSENTIAL INDIVIDUAL wMPONENTS Z7 Ignition Switch Page 23 Engine SLop Switch 29 Lelt Handlebar Controls 30 FEATURES (Not required Ior operation) 30 Steering Lock 31 Helmem Holder 32 Document Companment 33 OPERATION 33 Pre-ride Inspection 34 Starting the Engine 37 Running-in 33 Riding 40 Braking 41 Parking 41 Amirtheft Tips MAINTENANCE Page 42 MAINTENANCE 43 Maintenance Schedule 45 Tool Kit 46 Serial Numbers ~17 Colour Label 47 Maintenance Precautions 48 Air Cleaner 49 Engine Oil 51 Crankcase Breather 52 Spark Plug 54 Valve Clearance 56 Throttle Operalion 57 Starter Decompressor 58 Idle Speed 59 Cam Chain Adiuslmenl 50 Drive Chain 66 Front and Rear Suspension Inspection 67 Side Stand 68 Wheel Removal 71 Brake Shoe Wear Page 72 Battery 74 Fuse Replacement 76 Stoplight Switch Adjustment 77 CLEANING 7s STORAGE GUIDE 78 Storage 79 Removal from Storage 8|) SPECIFICATION S 83 NOISE CONTROL SYSTEM {AUSTRA- LIA ONLY) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED MOTORCYCLE SAFETY AWARM “ Motorcycle riding requires special 9(- Ions on your part to ensure your safe- ty, Know these requirements before you rid : SAFE RIDING RULES 1. Always make a pre~ride inspection (page 33 before you siart the engine You may prevent an accident or equipment damage 2. Many aCCldenls involve inexperienced riders. Most countries requ‘ a special motorcycle riding test or “fence. Make sure you are qualified betore you ride. NEVER lend your motorcycle to an inexperienced rider, 3, Many automohlle/motorcycle acndents hap» pen I: cause the automobile driver does not "see' the motorcyclist. Make yourseli CUnSplCuOUS to help avoid the accident that wasn't your fault. ‘ Wear bright or reflective clothing 0 Don't nde in another metonsl's "blind spot.“ 4 Obey all Ilatlonal and local laws and regulation; - Excesswe speed is a tactor in many ac- Cldents. Obey the speed limlts, and NEVER travel lastEI than Condilluns warrant, 0 Signal betore you make a turn or lane change Youl size and maneuverability tan surmise other motorists 5 Don't let other motorists surprise you Use extra caution at intersecnons, parklng lot enr Lrantes and exits, and drlveways, 6, Keep both hands on the handlebars and both feet on the (ootpegs whlle riding, A passenger should hold on [o the motorcycle or the operator wttll both hands and keep both feet on the passenger lootpegs PROTECTIVE APPAREL 1 Most motorcycle accldent fatalities are due to head lnjurles. ALWAYS wear a helmet. You should also wear a face shield or goggles as well as boots, gloves and protectlve Clolhlng A passenger needs the same protecuon. , The exhaust system becomes hot durlng operation, and it remains hot for a whlle after stopping the engine Be careful not to touch the exhaust system while it is hot. Wear clothlng that fully covers your legs. Do not wear loose clothing which tuuld catch on the control levers, kickslarter, lootpegs, drive chain or wheels. MODIFICATIONS A WAHNW ‘ Modification of the motorcycle, or removal oi original equipment. may render the Vehicle unsafe or illegal. Obey all national and local equipment regulations. LOADING AND ACCESSORIES WARN G A motorcycle is sensitive lo changes in weight distribution. Improper loading oi cargo can impair the motor— cycle‘s stability and performance. To prevent an accident, use extreme care when riding with cargo. These general guidelines may help you decide whether or how to equip your motor- cycleY and how to load ii safely. Loading 1, Keep cargo weighl low and close to the center of the motorcycle. Load weight equal- ly on both sides to minimize Imbalance. As Weight is located further from [he motorcy- cle's center of gravity‘ handllng is proper nonany affected. 2. All Cargo must be Secure {or stable handllng. Recheck cargo security frequently, V Do not attach large or heavy items [such as a sleeping bag or lent) to the handlebars, fork, or fender. Unstable handling or slow sieering response may result Accessories You are personally responsible {or proper selec- tion, installation, and use of nonrHonda ac- cessories. Always follow the guidelines under Loading, and these: 1, Carefully inspect the accessory to make sure it does not obscure lights, reduce ground clearance, or limit suspension travel, steering travel or comrol operation 2, Luggage racks are (or lightweight items. Bulky items may Snag on a tree or other near- by object Causing loss of control, 3. Do not add electrical equipment that will ex» ceed the molorcycle‘s electrical system capacity, An electrical failure could Cause 2 dangerous loss 01 lights or engine power at night, in traffic or iar lronr help. OFF-ROAD SAFETY Learn to ride in an uncongesied offload area free of obstacles before venturing into unfamiliar terrain. 1. Always obey local offrroad riding laws and regulations, 2. Obtain permission to ride on private proper» ly. Avoid posted areas and obey “No Trespassing" signs 3. Ride with a friend on another motorcycle so that you can assist each other in case of trouble 4‘ Familiarity with your motorcycle is critically important should a problem occur iar irom help 5, Never ride beyund your ability and ex penance or faster than conditions warrant. 6. If you are not familiar with the terrain, ride cautiously. Hidden rocks, holes, or ravines could spell disaster, 7. Spark arresters and mufflers are required in most areas. Don’t modiiy your exhaust system. Remember that excessive noise bothers everyone and creates a bad image for motorcycling PARTS LOCATION Clutch lever Speedometer Engine Stop switch Headlight switch Ignition switch Rear View mirrors From brake lever Headlight dimmer switch Throttle grip Horn button Fuel filler cap Document Steering lock Fuel cock compartment Helmet holder Tool box Gearshift Footpeg Side stand Passenger footpeg pedal Kick smner Battery Fuse pedal Rear brake pedal V / \\ / \ < 3 ) \_\/4/ Passenger lootpeg Footpeg Oil filler cap/dipstick INSTRUMENTS AND INDICATORS The indicators are In the speedometer and ilk ducavor pane] about the headlight. Their (um lmns are described in the table on the following page (1) Speedometer <2. Tachometer (3) Odometer (4) Tripmeler (5) Tachometer red zone l6! Turn srgnal indicator xigm m High beam indxcaior mm (8) Neutral indicator light 19» Tripmeler reset bnnb (Except up Rer. Nor Description Function 1 Speedometer Shows ridlng speed. 2 Tachometer Shows engine rpm. 3 Odometer Shows accumulated mileage, 4 Tripmeter Shows mileage per trip or section of route Never allow the tachmneter needle to enter the red zone, even aiter the engine has been broken in 5 Tachometer red zone CAUT'ON‘ - The red zone indicates the maximum li its of engine speed and running the engine in the red zone may adversely affect its service lite. Turn signal Y , . . s indicator umber] Flashes vll'len either turn signal operates 7 $5359“ ”“3“" Lights when the headlight is on high beam. 8 New“ '"d‘caw‘ Lights when the transmi on is in neutral, lgreenl g Tripmeier reset knob To reset the tnpmeter to zero (Dir tum the knob m "U direction shownv 11 MAJOR COMPO NTS (Information you need to operate this motorcycle) AWARNWG - n the Pre-ride Inspection image 33) is not periormed. severe personal injury or vehicle damage may result. SUSPENSION Rear Suspension Each shock absorber at has five adjustment positions ior different load or riding Condiuons, Use a Pin spanner (2) to adjust the rear shocks Pnsnm I .s (or light loadsand smooth road con- dltmns. Positionslllovincrease spring preload for 2 stiffer rear suspEnsion, and can be used when the motorcycle is heavily loaded Be cer~ (U Shock absorber (2) Pin spanner (am to adjust both shock absorbers lo the same position The standard position: I ' The rear shock absorber assembly n- cludes a damper unit that cont. ns high pressure nitrogen gasl The in- structions [ound in this owner's manual are limited to adjustmem of the shock assembly only. Do nol al.- tempt to disassemble, disconnect or service the damper unii; an explosion causing serious injury may result, Punciure 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 ols, safely equip- ment and the offi lal Honda Service Manual. BRAKES Front Brake Brakes are items of personal safety and should always be maintained in proper adjustment. The distance the brake lever moves before the brake sxarLs zo engage is called free play. Measured at the up of the from brake lever 11). free play should be maintained at. 10—20 mm 13/373/4 in). Minor adjustments can be made with the brake adjuster (4) at the lever (IL (ll Front brake lever 10—20 mm (3/8—3/4 in) 1. ‘Pull back the rubber dust cover (2L Loosen the lock nut (3) and turn the adjuster (4) Tighten the lock nut (3) and check the adjustment. 2. If [he adjustel is threaded out near its limit or it the correct free play cannot be obtained, loosen the lock nul (3) and turn in the cable adjuster (4) eomplete‘y. Tighten the \ock nut 13) and pull on the dust cover. (2) Dust Caver (A) Increase free play (3) Lock nut (B) Decrease free play (4) Brake cable adjuster (5) Adjustmg nut (6) Lock nu! V At the lower end of the cable. lowsen the lock nut (6). Turn the adjusllng nut (5) to ubtain the specified free play. Tighten the lock nut (6) and check the adjustment. (A) Increase tree play (B) Decrease free play 4, Apply Lhe brake several times and check [or free wheel rotation after the brake lever is releaxd, NOTE: . ll proper adjustment cannot be ohtalned by [his method. see your authonzed Honda dealer Other Check Check the brake cable for kmks or Slgns ol wear that could cause sucking or [allure Lubricate the brake cable wllh a commercially available cable Iubrlcant to prevent premature Wear and Corroslon, Make sure the brake sz spring and fasteners are in good condltlon, Rear Brake Pedal Height Adjustment: A stopper bolt m is provlded to allow adtust» ment of the pedal helght, Loosen the lock nut {21, and turn the stopper bolts Tighten the lock nut, Brake A ’ustment; 1. Place the motorcycle on its side stand. 2. Measure the distance the rear brake pedal moves belore the brake starts to take hold. Free play should be. 20—30 mm (3/4—1-1/4 int. 1! adjustment ls necessary, turn the rear brake adjusting nut 13) (ll Stopper bult (2) Lock nut 13) Adjusting nut 3. Apply the brake several times and check for free wheel rotation after the brake pedal is released. NOTE: ' Make sure the cut-out on the adjusting nut is seated on the brake arm pin ’ It proper adjustment cannot be obtained by this method, see your authorized Honda dealer. m Make sure the brake arm, spring and tasteners are in good condition CLUTCH Adjustment: Clutch adjuslmem may be requlred it the motor» cycle stalls when shifting imo gear, or tends to creep or u the clutch slips, causing acceleration to lag behind engine speed. Minor adjustments can be made wtth the clutch cable adjuster at the lever (1) Normal clutch lever tree play IS: 10720 mm 13/3—3/4 in). 1. Pull back the rubber dust cover 12;, Loosen (1? Clutch lever IS the lock nut (3) and turn the clutch cable ad» juster [4L Tighten the lock nut {3| and check the adjustment 2‘ If the cable adjuster is threaded out near its llnnt or the correct tree play cannot be on tamed using the cable adjuster m. a major adjustment must be made Loosen the lock nut (3) and turn In the Cable adjuster (4| com- pletely Tighten the lock nut (3) and install the rubber dust cover (2). tzt Dust cover (A) Decrease free play at Lock nut (B) Increase free play (4) Clutch cable adjuster 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 15) 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 doe: not creep. Gradually release the clutch lever and open the throttle. The motorcycle should begin to move smoothly and accelerate gradually. (5D Lock nu! (6) Adjusting nut (Al Increase free play 03) Decrease free play NOTE: ‘ If proper adjustment cannot be obtained or the Clutch does not operate Correctly‘ see your authorized Honda dealer, Other Checks: Check the clutch Cable [or kinks or signs 01 Wear that could cause sticking or failure. Lubncate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion FUEL Fuel Cock The three Way fuel cock (ll is under the left side of the fuel tank m With the fuel cock in the OFF posmon, fuel can- not flow from the tank to the carburetor Turn the cock off whenever the motorcycle is not in use 0N With the fuel cock m the ON posltion. fuel will flow from the main fuel supply [a the carburetor RES Wilh me fuel rock in the RES position, fuel WIlI flow from the reserve fuel supply to the cart burelor. Use the reserve fuel only when the main Supply is gone. Refill the tank as soon as possible after switching [0 RES. The reserve fuel supply is' 15 l (0.4 US gal, 03 Imp gal) 20 AWARNWK: - To av running out oHuel that may result in a sudden stop, learn how to operate the fuel cock when riding the motorcycle. - Be careful not to much any hot engine parts while operating the fuel cock. NOTE. ~ Remember to Check that the fuel cock is m the ON position each time you refuel, If the cock Is left In |he RES poslllon. you may run out of fuel wrth no reserve fll ll" :Q‘ (ll Fuel cock Fuel Tank The fuel tank capacity, including reserve, is: 7,0 [11.8 US gal, 15 Imp gall To open the fuel can (It, pull out the breather lube (2| from the steering stem nut 13L Then turn the tank Cap counterclockwise Alter refueling, insert the breather tube into the steering stem nut, Use unleaded or lowelead petrol with a research octane number or 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 FOR AUSTRALIA ONLY: Use unleaded petrol with a research octane number of 91 or higher, CAUTION: * Ii “spark knock" or “pinging" occurs ata steady engine speed under normal inad. change brands of petrolr Ii spark knock or pinging persiste. 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- tanty. (1) Fuel cap 12) Breather tube (3t Steering stem nut 21 AWARNWG 22 Petrol is extremely flammable and is explosive under certain conditions. Reine] in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where petrol is stored or where the fuel tank is refueled. Do not overiill the tank [there should be no fuel in the filler neck). After refue- ling, mnke sure the fuel can is closed securely. Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite i! 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 CHILDREN. Petrol Containing Alcohol It you decide to use a petrol containing alcohol lgasoholl, he sure it's octane rating is at least as hlgh as that recommended by Honda. There are two types of “gasohol”; one containing ethanol, and the other contalnlng methanol. Do not use petrol that conlalns more than 10% ethanol. Do not use petrol contalning 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. NOYE: ' Fuel system damage or engine performance problem resulting lmm the use of fuels that contain alcohol is not covered under the war- ramy. Honda Cannot endorse the use of luels containing methanol since evidence of thelr suitability is as yet incomplete. ‘ Beiore buying fuel from an unfamiliar m lion, try to find out the fuel contains alcohol, ii i: does, confirm the type and percentage oi alcohol used. If you notice any undesirable opeming symptoms while using a petrol that contains alcohol, or one that you think cunr [zins alcohol, switch lo a petrol that you know does not ccnlain alcohol, 23 ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be mainlalned between the upper (2) and lower (3) level marks on the dipstick up. 1. With the motorcycle held upright on firm, level ground, start the engine and let it idle (or a few minutes. 2. Stop the engine and remove the oil filler Cap/dipsllck, wipe ll Clean, and reinserl (he dipstick, wllhoul screwing it in. The oil level should be between the upper and lower marks on the dipstick 3. If required, add the specified oil up to the up per level mark (See page 49L Do not overlin, 4. Reinstall the Oll filler cap/dipstlck. Check [or oil leaks. 24 CAUTION: ' Running the engine with insufficient oil can cause serious engine damage. ll? Oll filler Cap/dipstick 12] Upper level mark 43! Lower level mark TYRES Propm air plessure w.“ pl‘oVIde maximum slabxhly, I‘ldmg Comfort and tyre life, Chuck |yre pressure frequently and adrusr If necessary, NOT E: Check the wre {or Cuts, mlhedded nails or other 5mm objeds See youraurhnnzed Honda Dealer inner [ubes ‘ Tyle pressure Should be Checked bdore you ride while the tyres are “Cold", Un/ofi-road tyres are sumdard on this model Select the right replacement Iyresin accordance wuh the followmg specificauons. Front Rt- , , 2757 4107 [”9 5‘” 2145p 1359i) , 15“ 150 5"“ tyre ‘ R‘de’ ““15 «15‘ 22) us, 2:) pressure . kPa (1:13" am 151) 175 k ,‘c ' < a» 1 g h‘pawnger 11mm 4171 m) Tyre brand BRIDGESTONE 'rwsa wa YOKOHAMA Y962 Y96‘1 (or replacement or damaged tyre or punctured 25 AWARNING 25 Do not attempt to patch a damaged tyre or inner tube. Wheel balance and tyre reliability may b paired. Improper tyre inflallon will cause ab- normal tread wear and create a satiny hazardr Underinilation may result in the tyre slipping on, or coming off of the rim causing lyre defla n if in may result in a loss of vehicle .ontrol. Operation with excessively worn tyre is hazardous and will adversely allect traction and handling. The use of tyres other than those listed on the tyre information label may adversely aflect handling. Maintenance of spoke tension and wheel trueness are critical to safe motorcycle operation. During the tirsi 1000 km 1600 miles! spokes will loosen more rapidly due to initial seating or partsr Excessively loose spokes may result in high speed in- stability and pass le loss of control. Replace tyre before tread depth at the center of the tyre reaches the following limiiv Mlnimum (read depth mm (1/8 lnl ESSENTIAL INDIVIDUAL COMPON ENTS IGNITION SWITCH The Ignition switch 11) is located near the indxcz- tor panel 11) Ignition switch | Key Pnsition human Key Removal y, . . Key can be OFF E051“? and hghu cannot be opermed. removed . Engine and lights can be apelated Key cannot be For u Type, the engine must be an m opemte the “fins removed 27 ENGINE STOP SWITCH The three posiuon engine slop swnch (1) is next to the ihroule gm). When [he swnch |S “1 the RUN position, the englne will operate. When the switch is in enner OFF posilmn, the engine will not operate. This switch XS intended primarily as a safety or emergency switch and should norma1~ ly remain in the RUN position, (1) Engine slop switch 28 LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch (I) Select Hi (or high beam, L0 (or law beam. Turn Signal Switch up Move to L to signal a left turn, R to signal a right turn PI‘EE to turn signal off MOVE: to the middle position t0 him Slg‘nal oir (U Only) Horn Button (3) Press the button to sound the horn. Headlight Switch (4) The headlight switch has three positions, H “P" and "OFF" marked by a red dot to the left at "P" H: Headlight, taillight, position light and meter lights on, P: Position light, taillight and meter lights on OFF (dot), Headllght, taillight, pusitlon light and meter llgth 0“, 1!! Only) The headlight, taillight, position light and meter lights come on when the engine is turned on. (Except up (U onlyt (l) Headlight dimmer switch (2) Turn slgnal sztch (3) Horn button (4) Headlight switch 29 FEATURES (Not required for operation) STEERING LOCK The Steering lock 11) is on the steering column under the headllghl case Tum (he handlebar all the way to the right, insert the steering key in the lock, turn the key 60' to the left, and press the lock all the way in, Turn the key back to the original position and removev To unlock the sleenng, perform the locking sequence in the reverse order, 30 (1) Sleer‘ing lock HELMET HOLDER The helmet hulder (1) is on the lelt side below the seat. Insert the lgnition key (2) and turn it to unlock. Hang your helmet on the holder pin <3) and push it in to lock Remove the key, AWARNWG ' The helmet holder is designed for helmet security while parked. Do not ride with a helmet attached to the holder; the helmet may interlere with sale operation and result in loss at control. m Helmet holder (2) Ignition key (3) Holder pm 31 DOCUMENT COM PARTMENT Your motorcycle is equipped with a document Compartment 11) behind the seat, This owner's manual and other documents should be stored in [his bag When Washing your motor cycle, be careful not w flood this area wnh Water /’,‘/ol% 4 \ Ill Document compartmem 32 OPERATION PRE-RIDE INSPECTION MARNWG v If the Pre-ride inspection is not per iorrned, serious damage or an acci- dent may result. Inspect yeur motorcycle every day oeiore you ride it, The items listed here will only take a law minutes to check, and in the long run they can save time, expense and possibly your liie. l. Engine oil Ievel»add engine oil it required (page 24!. Check for leaks. 2. Fuel ley till the iuel tank when necessary (pages 21- 2|. Check lor leaks. 3. Brakesecheck operation. Adjust iree play it necessary (pages 14717) 4. Tyresicheck condition and pressure (pages 2546]. 5. Drive chain—check condition and slack (pages 60765’. Adjust and lubricate if necessary. a. Throttle—check (or smooth opening and full closing in all steering positions 7. Lights and homicheck that the headlight tall/brake light. turn signals, indicators and horn (mlction properly. 8. Engine slop switch—check for proper func- tion (page 28!. 9. Battery electrolyteicheck the level and add il necessary (pages 72—73). Correct any discrepancy beiore you ride. Cone tact your authorized Honda dealer for assistance ii you cannot correct the problem. 33 STARTING THE ENGINE WARNWG ‘ 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 ‘ Attempting to start the engine with the trnnsmission in gear and the clutch engaged may result in injury or damage NOTE: ‘ This motorcycle can be kickstaried with the transmission in gear by disengaging the clutch before operating the kicksiarier. Since the engine decompression system is in- terlocked with the kickstzrter, a quick, Vigorous kick from the top of the stroke is most effective. 34 Preparation 1, Make sure the transmission is in neutral and the fuel cock is ON, 2, lnsert the key in the ignition switch and mm to ON The neutral indicator (green) should go out 3, Make sure the engine stop switch is in RUN. Starting Procednre 3 lmmedlaxely after the engine suns, push the {Except SI type) choke knob down to the Delem Position (B). 4 About a half minute after the engine starts, Cold ehgme push the choke knob down all the way to Fulr 1. Ralse the choke knob (1) [0 Fully ON (AL .y OFF ‘0 2. Open the Lhrome slightly and oveyate the 5 1r Idling is unslable‘ open the mantle kickslarler With the right foot, stamng from slightly. the top 0! the stroke and following (hrough w the bottom wnh a mold and continuous kickv CAUTION: - Do not allow lhe kickstarter to snap back freely against the peda! s‘op as engine case damage cauld resull‘ (1) Choke knob 1B) DelenL posillon 35 l (A) Fully ON (C) Fully OFF Starting in Extremely Cold Weather Prime the engine belore starting by cranking the engine several times with the kickstzrter, The ignition switch should be OFF. the choke Fully ON (A) and the throttle opened slightly, F01- low the “Cold Engine" Startmg Procedure, Starting procedure (SI type) To restart a warm engine‘ follow the proce dure for High air Temperalule Normal Alr Temgelature 10 35 C150 ) , Pull lhe choke knob (1| up all the way to fully ON (A) 2. With the throttle :lightly opent operate the kickstarter. Kick from the top of the stroke through to the bottom with a rapid, collllnlt' ous motion. 3. Warm up the engine by opening and closing the throttle slightly. 4. About a half minute after the engine starts, push the choke knob down all the way to fully OFF (Cl. 5, If Idling is unstable, open the throttle Sllght- ly. 36 Iligh Amratum 35C I95'Fl or above I Do not use the choke 2. Start the engine following step 2 under "Normal Air Temperature", Low Air Temgeratute 10C 150?) or below 1 Follow Steve I 7 ‘2 under “Normal Air Temperature 2 Warm up the engine by opening and closing the ihmttle slightly 3 Continue warming up the engine until it runs smoothly and responds to the throttle when the Choke knob is at fully OFF (Cl Flooded Engine ii the engine fails to start after several repeated attempts, it may have become flooded with ex- cess iuel To clear the engine. him nit the ignition switch and push the choke knob down [0 Fully OFF 1:). Open the throttle tully and crank the engine several time- with the kick starter. Turn the Ignition switch to ON and open the throttle slightly, start the engine u n; the kickstarter, RUNNING-IN During the first 1,000 km (600 miles), avoid full throttle use and never labour the engine Do not operate at any one speed [or prolonged periods During initial runningdn, newly machined sur faces will be in Contact with each other and these suriaces will wear in quickly, Running-in maintenance “1,000 km (600 miles) is designed to compensate for this initial minor wea Timely pertotmance at the rullningrlll maintenance will ensure optimum service liie and performance irom the engine CAUTION: ‘ The red zone indicates the maximum limits at engine speed and running the engine in the red zone will adversely affect its service life. 37 RIDING WARNWG Review Motorcycle Salely {pages 1*6) before you ride * Make sure the side stnnd is fully retracted before riding the motor- cycle. 38 . Warm up the engine. 2, With the engine idling, squeeze the clutch lever and shit: into low (150 by depressing the gearshm pedal. . Slowly release the clutch lever While gradual ly increasing speed, Coordmanon of these two operations Wlll assure a smooth start When the motorcycle attains smooth forward motion, slow down the engine, squeeze the clurch lever again and Shift into 2nd by rais~ mg the shift pedal, Do the same for the other gears. 5. 6. Coordmale the throttle and brakes for smooth deceleration. Both from and rear brakes should be used at the same time and should not be applied strongly enough m luck the wheel, or braking effectiveness will be reduced and comm] of the motorcycle he diificull. Shift Points (81 type) Proper shlmng will provide better luel econ- only. When changing gears under normal con anions, use these recommended shill points: Shifting U2: From lsl to led' 20mm From 2nd to 3rd: 30km/h From 3rd to 4th: 40km/h From 4th to 5th: 50km/h Shifting Down. From 5th to 4th: 30km/h From uh to 3rd: ZOkm/h Disengage the clutch when speed drops below loknl/h, when engine roughness is evident, or when engine stalling is imminem, shift down to ISL gear for acceleration, 39 BRAKING 1. For nominl braking, gradually apply both the trout and rear brakes while downshiftirlg to suit your road Speed 2. For maximum deceleration, close the throttle and apply the front and rear brakes firmly. Pull in the clutch lever before coming to a complete stop to prevent stalling the engine. A WARNWG * independent use of only the iront or rear brake reduces stopping pertur- mance. Extreme braking may cause either wheel to lockY reducing control of the motorcycle. ’ When possible, reduce speed or brake before entering a turn; closing the throttle or braking in mid-turn may cause wheel slip. Wheel slip will reduce control at the motorcycle. When riding in wet or rainy condi- tions, or on loose surfaces, the ability to maneuver and stop will be reduced. All oi your actions should be smooth under these conditions. Sudden uc- celeratiun, braking or turning may cause loss or control. For your safety. exercise extreme caution when brak- ing, accelerating or turning. when descending a long, steep grade, use engine compression braking by downshilting, with intermittent use of both brakes. Continuous brake ap< plication can overheat the brakes and reduce their effectiveness. Do not ride the brakes. In other words, don‘t operate the brake pedal unless you intend to brake. This causes excessive brake wear and can damage. or lead to loss of the brakes through overheating. Your brake light may also coniuse other drivers. PARKING 1. After stopping the motorcycle, shiit the transmission into neutral, turn the fuel cock OFF, tum the ignition switch OFF and remove the key. 2. Use the side stand to support the motorcycle while parkedr CAUTION: ‘ Park the motorcycle on firm, level ground to prevent overturning. 3. Lock the steering to help prevent theft (page 30). ANTI-THEFT TlPS 1. Always lock the steering and never leave the key in the steering look This sounds simple but people do forget 2. Be sure the registration information (or your motorcycle is accurate and current. 3. Park your motorcycle in a locked garage whenever possible. At Use an additional antitheit device of good quality, 5. Put your name, address, and phone 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: PHONE N0: _ — __— 41 MAINTENANCE 42 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 this 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. 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 condi» tions, will require more frequent service than spemfied in the MAINTENANCE SCHEDULE. Con~ sult your authorized Honda dealer {or recommendations applicable to your individual needs and use, 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 Prende lnSDeCtion at each Scheduled maintenance period. I INSPECT AND CLEAN. ADJUSTV LUBRICATE OR REPLACE IF NECESSARY C : CLEAN R' REPLACE A : ADJUST L : LUBRICATE WHICHEVER - ODOMETER READING FREQUENCY COMES [NOTE 11)] FIRST 51000an I 4 8 12 REFER TO ITEM ‘ x 100mm 0'6 25 5 75 PAGE NOTE ONTI—IS 5 12 IR - IFUEL LINE I I I 7 ~ FUEL STRAINER SCREEN c c C ~ THROTTLE OPERATION I I I 5b ‘ CARBURETOR-CHOKE I I I ’ AIR CLEANER NOTE (2) C c c Is CRANKCASE BREATHER NOTE (3) C C c 51 SPARK PLUG I R I 52 ’53 ‘ VALVE CLEARANCE I I I l I 54 ’55 EVERY ENGINE 01L R 2,000km 24, 49—51 ( Z50 mil R ENGINE OIL STRAINER SCREEN I c 50751 a. ENGINE OIL CENTRIFUGAL c FILTER ' DECOMPRESEDR SysTEM I I I I 57 - CAM CHAIN TENSION A A A A 59 ‘ CARBURETOR'IDLE SPEED I I I I 53 43 WHICHEVER ODOMETER READING FREQUENCY COMES " [NOTE (111 WEST x1000km 1 4 s 12 REFER To ITEM x lOOOmi 0.6 25 5 7.5 PAGE NOTE ONTH s 12 18 DRIVE CHAIN NOTE (4) EVERY 11100ka6001111 I. L 60765 DRIVE CHAIN SLIDER I I I I 60 7 BATTERY I I 1 72—73 BRAKE SHOE WEAR I I 1 71 BRAKE SYSTEM I I I 1 14711 ' BRAKE LIGHT SWITCH 1 I I 76 - HEADLIGHT AIM I I 1 7 CLUTCH SYSTEM I I I I 18719 SIDE STAND I I I 67 ' SUSPENSION l I I 66 - NUTS. BOLTS. FASTNERS NOTEm I 1 7 -- WHEELS/TIRES NOTEm I 1 I I 7 -- STEERING HEAD BEARINGS I I 7 - Should be armed try an aulhomzd HONDA deakr, unlgss m: mull! hzs pmver Imls and sen/Ice flat: and .5 mechamcally mum Rel" n) me mum: HONDA sen/Ice manual -~ I" m “unreal of may, we recommend 1w ”ems he Senvced ONLY by an auumnm HONDA mug NOTES 1 A1 n-gm 04mm rudmg rental :1 4h: hequeMy "mm zsIabhshed 1m 2 SW. move Imquuu‘) when ndmg lmusua‘ly w or m, Mus 3 Sense mam humanly “he" ndmz m ram or 3| mu Ihmu‘e 4 Sevnce more {mummy when “an"; OFF ROAD 44 TOOL KIT The tool kit in is in the loo) compartment (2) on the left side. below the seat, Some roadside repairs, minor adjustments and pans replace- nrent can be perionned with the tools contained in the kit. a Pin spanner 0 Spark plug wrench 24 mm box end wrench 10x 12 mm open end wrench 14 x17 mm open end wrench Pliers No, 2 screwdriver No. 2 Phillips screwdriver No. 3 Phillips screwdriver Screwdriver handle Tool bag Handlebar (1| Tool kit 9 '9% (£3 fi (2) Tool compartment 45 SERIAL NUMBERS The frame and engine serial numbers are re quired when registering your motorcycle. They may also be required by your dealer when order- ing replacement parts. Record [he 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 left side of the crankcase, FRAME NO. ENGINE N0. 46 (1) Frame number (2» Engine number COLOUR LABEL The colour label (1) is attached to the left side 0‘ the sublube, It is helpful when ordering replacement parts, Record the colour and Code here {or your reference. COLOUR CODE (1} Colour label MAINTENANCE PRECAUTIONS AWARNWl If your motorcycle is overturned or in- volverl in a collision‘ inspect control levers‘ clble. brake cables, caliper‘ ac- cessories, and other vital parts lor damage. Do not ride the motorcycle it damage impairs safe operation. Have your authorized Honda dealer inspect the major components, including frame, suspension and steering parts, ior misalignment and damage that you may not be able to detect. Before performing any maintenance, stop the engine and support tlre motorcycle on a firm, level surface. Use new, genuine Honda parts or their equivalent for maintenance and repair. Parts which are not of equiv- alent quality may impair the safety of your motorcycle 47 AIR CLEANER 4‘ Wash the element in non-flammable or high {Refer to the maintenance precautions on page “as“ 00"“ 50W“ M let " dry ‘hmughlys 47} AWARNING Never use petrol or low flash point solvean for elenning the agr cleaner element. A fire or exploslon could The air cleaner should be serviced at regular in- tervals (page 43), When riding in dusty areas, more frequent service may be necessary, 1. Remove the left side cover 11) by loosening result‘ the screw 5, Soak the element in gear oil (SAE 80—90) 2. Remove the air cleaner cover screws (2| and and squeeze cm the excess the cover (3L 6. Install the removed parts in the reverse order 3' Loosen the wing nut (4) and remove the of drummbly‘ element (5). {Zl Screws (4| Wing nut in Left side Cover (31 Cover (5. Element 43 ENGINE 01L (Refer to the maintenance precautions on page 47) Engine Oil Good engine oil has many desirable qualitiesv Use only high detergem, quality motor oil Cerr [filed on the container to meet or exceed rer quiremenls for service 515‘ SF or 56. Viscosity: Viscosity gmde of engine oil should be based on average atmospheric fiemperalure in your riding area. The following provides a guide to the seler: non of the proper grade or viscosity of oil to be used at various atmospheric temperaLures. we a u) u um (2) Mulligrade (1) Single grade 49 Engine Oil Change Engine oil quallty is the chief lactnr allectlng engine service lllev Change the engine Oil as specified in the maintenance schedule “3326 43L NOTE: ‘ Change engine oil with the engine at normal operating temperature and the motorcycle on lts side stand to assure complete and rapid drainlngv 1. Remove the oil filler cap/dipstick and Oll filter screen cap (ll to drain the oil. 11) Oil filter screen cap [2! Spring 13) Screen 50 [AWARNING - A warmed-up engine and the oil in it are hot: be carelul not to burn yourselfa 2 Operate the kickstaner several times to drain any oil which may he left In the engine, 3. Remove the spring (2) and filter Screen m 4. Wash (he screen in Clean solvent Make sure the sealing rubber and 01mg are m good condition, Install the screen, spring and Cap Oil filler screen cap torque 23 N-m as kg—m, l7 ftrlb) 5 Fill U16 crankcase wiLh me recommended grade oil; approxnnately: (191’ 11.0 US qt, 17.8 Imp ql) Install the oil filler cap/dipsnck, V 5:: the engine and let it idle {or 273 min u \1m 8 Stop the engine and check that the oil level is at the upper level mark on the dipstick with the motorcycle uprlgm on firm, level ground. Make sure there are no oil leaks. NOTE: ‘ 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 lotal service station tor reclamation. Do not throw it in the rubbish or pour it on the ground, CAUTION: ~ Used engine oil may cause skin cancer if repeatedly left in Contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it. is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. CRANKCASE BREATHER (SI type! (Refer to the maintenace precaution on page 47). 1, Remove the drain plug 11) (mm the tube and drain deposits 2. Reinstall the drain plug, NOTE: ‘ Service more frequently when ridden In rain, at full throttle, or alter the motorcvcle is washed or uvertumed Servtce if the deposit level can be seen in the transparent section of the drain tube, (1) Dmin plug 51 SPARK PLUG [Refer to maintenance precautions on page 47). Recommended plug 15A. U) Standard: DREESVL (NGK) or X24ESRVU(NIPP0NDENSOl For cold climate (Below s'c, 41'F): DR7ES (NGKi or XZZESR-U (NIPPONDENSO) For extended high speed riding: DRsES (NGK) or X27ESR U (NIPPONDENSOl Recommended plug (Except SA, U) Standard: DsEA (NGK) or X24ES-U (NIPPONDENSOI For cold climate (Below SC, 41?; D7EA (NGK) or XZZES-U (NIPPONDENSOI For extended high speed riding» D9EA lNGK) or X27ES-U (NIPPONDENSO) 52 . Disconnect the spark plug cap from the spark plug. 2. Clean any (lirl irom around the spark plug base. Remove the spark plug using the plug wrench Iumished in the tool kit, 3' Inspect the electrode and Center porcelain tor deposits erosion or cabon iouling. ll the erosion or deposit is heavy, replace the plug. Clean a carbon or wet-fouled plug with a plug cleaner, otherwise use a Wire brush. 4. Check the spark plug gap at using a vine- type teeler gauge. ll adjustment is neeessary. bend the slde electrode 42) carelully. The gap should he; 06*07 mm (0024701128 in) Make sure the plug washer ls m good condition (1) Spark plug gap at Side electrode 5, With the plug washer attached, thread the spark plug in by hand to prevent Cross- threadmgt 6. Tighten a new spark plug 1/2 turn with a spark plug wrench tacompress the washer. It you are reusing a plug, lt should only take 1/8—1/4 turn alter the plug seats. 7. Reinstall the spark plug cap, CAUTION: ~ The spark plug must be securely lightened. An improperly tightened plug can become very hot and possibly damage the engine. * Never use a spark plug with an im- proper heat range, Severe engine damage could result. 53 VALVE CLEARANCE (Effer to the maintenance precautions on page Excessive valve Clearance will cause noise and eventual engine damage. Little or no clearance will prevent the valve (rorn Closing and cause valve damage and power loss, Check valve Clearance when the engine is Cold, at the specified Intervals. NOTE: ‘ Checking or adjusting Valve clearance should he performed while the engine is cold The clearance may increase as the engine temperature rises. 1, Tum the fuel cock OFF and remove the seat and fuel tank. ARNIN ' Petrol IS extremely flammable and is explosive under certain conditions. Perform this operation in a well- ventilated area with the engine stop- ed. Do not smoke or allow open Flames or sparks in the area or where petrol is stored. 54 2, Remove the crankcase hole cap and timing mark hole cap. 3. Remove the valve adjuster covers. (l) “T" mark (2) Index mark 4. Rotate the crankshaft counterclockwise and align the T mark Ill with the index mark (2|. Make sure the piston is at the top of the C0m~ pression stroke by jiggling the rocker arms with your fingers. lt they are tree, the piston is at the top of the compression stroke. If they are tight, rotate the crankshatt 380° counterclockwise and realign the marks. CAUTION: ‘ Do not rotate the crankshaft clock- wise, or valve clearance checking/ad- justing will be inaccurate. 5, Check the clearance by inserting the leeler gauge (In between the adjusting screw (4) and valve stem. Standard clearance: Intake 0.05 mm [ODOZ in) Exhaust 0.05 mm {0.002 in) l3) Peeler gauge (4) Adjusting screw Adjust the Valves by loosening the lock nut is) and turning the adjusting screw {4) until there is a Slight drag on the feeler gauge. After tightening the lock nut, recheck the Clearance. . Install all parts in the reverse order of disassembly. {5) Lock nut 55 THROTTLE OPERATION (Refer to the maintenance precautions on page 47). Check for smooth rorarion oi the thmttle grip irom the lully closed to the {ully open position. Check at full lett and lull right steering positions Inspect the condition of the throttle cable from the throttle grip down to the carburetor. It the cable is kinked. chaled or improperly routed, it should be replaced and/or rerouted Lubricale (he cable wrth a commercially available cable lubricant to prevent premarure wear and corrosion. [AWAN w ‘ For sate operation and positive engine response. the throttle cable must be properly adjusted. 56 Adjust free play with the throttle cable adjuster (2). Measured in grip rotation, the standard throttle grip free play is: zws mm [1/8—1/4 my (1) Lock nut (2| Throttle cable adjuster STARTER DECOMPRESSOR (Refer to Lhe maintenance precautions on page 47). Excessive decompressor free play will cause hard starting, and insuriicient free play my cause erratic idling and burnt valves. (1. Upper lever (2i Lock nut 13) Adjuster NO TE: Adjust the decompressnr linkage atler ad~ iusting the valve clearance . Be sure the piston is at the top of the com- pression stroke and the “T" mark is aligned with Khe index mark 2. Measure the tree play at the tip of the decom- pression upper lever (1) To adjust. loosen the lock nut in and turn the adjuster (3!. Free play: 172 mm 41/32—1/15 in) 3 Install all parts in the reverse order of disassembly. Other Checks Check the deceinpression cable {or kinks or signs of wear that Could Cause sticking or failure. Lubncate the decompression cable with a com- mercially available cable lubricant to prevent pre mature wear and corrosion. 57 IDLE SPEED (Refer to the maintenance precautions on page 47). Idle Speed The engine must be at normal operating temperature for accurate idle speed adjustmentv Ten minutes or stop~and-go riding is sufficient NOTE: ‘ Do not attempt to compensate for faults in other systems by adjusting idle speed, See your authorized Honda dealer for regular- ly scheduled carburetor adjustments. (l) Throttle stop screw 58 (2) Pilot screw 1 Warm up the engine and hold the motorcycle upnghtl 2, Ad Just idle speed wilh the throttle stop screw (ll IDLE SPEED: 1,300 3 100 min" (rpm) {In neutral) Fuel Mixture 1 Adjust the fuel mixture by tumlng the pilot screw (2) clockwise until you hear the engine miss or decrease in speed, then counterclock- wise until the engine again misses or decreases in speed. Set the pilot screw exactly between these two extreme positions From a lully closed position. the correct set» ting (between extremes of rich and lean) will be approximately. 2-1/2 Turns open. (U) 2 Turns open. (51) 26/8 Turns open, (Except Us SI) 2. It idle speed changes alter adjusting luel mixture, readjust the idle speed by luming the throttle stop screw. CAM CHAIN ADJUSTMENT (Refer to the maintenance precautions on page When the cam chain is noisy. adjust the tension in the follawing manner: 1. Start the engine and set the idle speed. 2. Remove the rubber cap and loosen the cam chain adjuster (1) [not the 6 mm sealing bolt 12)]. This will automatically apply the proper tension to the cam chain. 3. After completing the adjustment, tighten the adjuster securely, up Cam chain adjuster (2| 6 mm sealing bolt 59 DRIVE CHAIN (Refer to the maintenance precaution on page The service life of the drive Chain is dependent upon proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain and sprockets. Under severe usage. or when the motorcycle is ridden in dusty areas, more frequent maintenance will be necessary. Drive chain inspection: 1. Turn the engine ofi, place the motorcycle on the side stand and shift the transmission lnto neutral 2. Push the chain tensioner ill downward Check slack in the lower drive Chain run midway between the sprockets. Drive chain slack should be adjusted to allow the (017 lowing vertical movement by hand' 30*40 mm (lrl/4‘lv5/E in). 50 3. Roll the motorcycle forward, Stop. Check 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 lubri- cation. (ll Chain tensioner (2) Chain guide slider , Check the chain slipper l3) and Chain guide slider (2) for wear, When the thickness in of the chain slipper in the slipper reaches lhe limit, lhe chain slipper must be replaced. Chain slipper thickness service limit: 1|) mm (04 in) (3) Chain slipper (4) Chain slipper thickness Sprocket insEctiont 1 Inspect lhe sprocket teeth for wear or damage Damaged SWDCke/‘1‘ Worn Splockel Teeth Yeah REPLACE “ REPLACE Normal smoker ruih GOOD 2. 1i ihe drive chain or sprocheis are excessive» 1y worn or damaged, they should be replaced. Never use a new chain with worn sprockets, rapid chain wear will result. 6‘ Adjustment Drive chain slack should be checked and ad lusted, rl necessary. every 1.000 km [600 miles). when operated at sustained high speeds or under Conditlons of trequent rapid acceleration, the chain may require more frequent adrusr. ment. (1) Cotter pin (2) Axle nut (3) Lock nut (4) Drive chain adjusting bolt 52 (5) Corresponding scale graduation: ll the drive Chain requires adjustment, the pn} Cedure is as foliows: 1, Raise the wheel a“ the ground by placing a block under the engine with the transmis» sion in neutral and the ignition switch oft 2, Remove the cotter pin 11) and loosen the axle nut (2|. 3 Loosen the luck nuts 13) on both achusting bolts H). 4, Tum both adjusting bolts an equal number of turns until the correct drive chain slack is ob tained. Turn the adjusting bolls clockwise to tighten the ('13an or countercloclese to pro« vrde 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 at the chain, Chain slack should be 30*40 mm (1-1/4—1-5/8 in) 5, Check rear axle alignment by making sure the index marks align with Lhe Corr? spending scale (5) graduations on both sides of the swingarm, NOTE: ‘ Ii the drive chain slack is excessive when the rear axle is moved to the furthest limii of ad» juslrnent, me drive chain IS Worn and musL be replaced. 6' Torque the rear axle nut to: 7D N'm (7.0 kg»m, 51 be) 7 V Tighten the lock nuts. 8. Install a new comer pin CAUTION: ‘ Always replace the used cotter pin with a new onei s, Recheck drive mm slack‘ 9. Rear brake pedal free play is affected when repositioning me rear wheel to adjust drive chain slack, Check rear brake pedal free play and adjust as necessary (pages 16*”) Lubrication: Use SAE 80 or 90 gear all or a commercially pre- pared drive chain lubricants in preference to mo~ (or oil or olhcr lubricants Saturaw each chain link joint so that me lubricant peneuzbes between the link plates, pins, bushings, and rollers. 53 Removal and Cleaning: When the drlve chain becomes extremely dirty. it should be removed and cleaned prior to lubrication. 1. With the engine off, carelully remove the master link retaining clip 11] with a pair of pliers. Do not bend or twist the clip. Remove the master link. Renmve the drive chain from the motorcycle. 2. Clean the drive chain in solvent and allow it to dry, Inspect the drive Chain (or possible wear or damage. Replace any chain Lhal has damaged rollers, loose fitting links, or other- wise appears unserviceable 3. Inspect the sprockel teeth [or possible wear or damage. Replace if necessary. Never use a new drive Chain on badly worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain or sprocket will wear rapidly, 4. Lubricale the drive chain, 64 (1) Retaining clip 5. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link The master link 15 the most critical part at- fecting the security of the drive chain, Master links are reusable, if they remain in excellent condition, but it is recomended that a new master link retaining clip be installed whenever the drlve Chain is reassembled. install the master link retaining clip (D so that the closed end of the cup wm (ace the direction of forward wheel rotation, 6' Adjust the drive chain and rear brake pedal free play‘ 65 FRONT AND REAR SUSPENSION INSPECTION (Refer to the marmanance precautions on page 47!, 1. Check the from fork assembly by locking the from brake and pumping the fork up and down vigorously. Suspensinn actlon should be smooth and there must be no nil leakage 2. Rear fork bushing~lhis can be checked by pushing hard against the side of the rear wheel while the motorcycle is on a support block and feellng for looseness of the fork bushings. 3V Careluuy mspecL all (rom and rear suspen- sion fasteners for txghtness, 66 51m: STAND 4Reter to the maintenance precamions on page 47), Check the rubber pad [or dewrioration and Wear, Replace if wear extends to the wear line (See (1) in the picture). Check me srde stand assembly {or freedom 0( movementr If pans must be replaced. please Contact an authorized HONDA dealer. @GOOD @REPLACE QR / _ ® WEAR LINE ® Replace if wear exteods beyond me wear line. 67 WHEEL REMOVAL Front Wheel Removal (Reter to the maintenance precautions on page 47), l Ralse the tram wheel on the ground by plac~ ing a supporr block under the engine. 2, Remove the speedometer cable [1) from the front wheel hub assembly, 3, Loosen the from. brake adjusting nut (2) and remove the from. brake cable (3| from the brake arm. 4. Remove the cotter pin 14) and axle nut 15). 5. Remove the axle and the wheel Installation Note- ' Reverse the removal procedure. - Tlghten the axle nut to speclhed torque Axle nut torque: 43 N4m 14 x kg-m, 31 (Mb) 0 Adjust the brake (page 14), . Alter installing the wheel, apply the brakes several times, and Check for free wheel mla- tion when released, 68 WARNlA ' It a torque wrench was not used tor in- stallation, see your authorized Honda dealer as soon as possible In verity proper assembly. Improper assembly may lead to loss at braking capacl y. CAUTION: *Alwnys replace the need cotter pills with new ones. (1) Speedometer cable (2? Brake adjusting nut (3) ant brake cable (4) Cotter pin (5) Front axle nut Rear Wheel Removal (Refer to ma mamtenznce precautions on page 47), \. Raise the rear wheel ufi the ground by placing a Support under the engine. 2. Remove lhe rear brake adjusting nut {I}, disconnect the brake rod IZD from the brake arm (3) by pushing down on zhe rear brake pedal, (1) Adjusting nut (2) Brake rod |3l Brake arm (All Stopper arm (5) Caller pin (6| Axle nut axons . Disconnect the brake stopper arm [4) from (he brake panel by removing the cotter pin, stopper arm nut, washer and rubber gram met. V Remove the Cotter pin (5) and axle nu! (6h . Pull out the axle (7). . Remove the rear wheel. (7] Axle 69 Installation Note: ' Reverse the removal procedure. ' Tighten the axle nut to specified torque. Axle nut torque: 45 N«m 1A5 kgm, 33 ft-lbl 0 Adjust the brake (pages 16, 17\ and drive chain (Pages 62, 63). After installing the wheel, apply the brakes several times, and check for {lee wheel roll» lion when released. ARNW ‘ If a torque wrench was not used [or in- stallalioll, see your authorized Honda dealer as soon as possible to verily proper assembly. Improper assembly may lead to loss of braking capacity. cau‘nou: . Always replace used cotter pins with new ones 70 BRAKE SHOE WEAR none; ‘ When the brake service is necessary, see 47). min authorized Honda dealer. Use only ge~ The from and rear brakesare equipped with Hume Honda Paris or "5 equ'va'em brake Wear indicators. When me brake is applled‘ an arrow (1) attathed to the brake arm moves \oward a reference mark [2) on the brake panel If the arrow aligns with me reference mark on full application of the brake, the brake shoes mus| be replaced, < FRONT BRAKE > (Refer to the maintenance precautions on page / in Arrow (2) Reierence mark ‘ \ 4 x \r ‘ 1/\\\\i?_ ‘ m Arrow (2] Reierence mark ‘ 7 1 BATTERY (Reter Lo the maintenance precautions on page 47) ll the motorcycle is operated with insumcient battery electrolyte, sultation and battery plate damage will occur. If rapid loss 01 electrolyte is experienced, or if your battery seems to be weak. causing elec- trical problems, see your authorized Honda dealer. 72 Battery electrolyte: The electrolyte level must be maintained between the UPPER [1) and LOWER (2) LEVEL marks on the side of the battery. It the electrolyte level is low, remove the battery fills! Caps un top of the battery Carelully add distilled water to the UPPER LEVEL mark using a small plastic tunnel. (1) UPPER LEVEL mark (2) LOWER LEVEL mark 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 of the battery. - Filling the battery above the UPPER LEVEL line may cause the electrolyte to overflow. resulting in corrosion to engine or trame parts Immediately wash oit 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 kihked breather tube may pressurize the battery and damage its case. - The battery gives oii explosive gases; keen s arks. names, and cigarettes away. rovide 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. — 1i 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 im- mediatel . Electrolyte is poisonous. — it swallowed, drink large quan- tities of water or milk and follow with milk at magnesia or vegetable oil and call a physician. ‘ KEEP OUT OF REACH OF CHIL- DREN. 73 FUSE REPLACEMENT (Refer to the maintenance precautions on page The fuse holder (1| is on the right side of the battery case. The specified (use is 10A, The spare fuse (2) is on the inside of the battery cover. When frequent [use failure occurs, it. usually in dicales a short circuit or an overload in the elec- trical system. See your authorlzed Honda dealer {or repair. CAUTION: ’ Turn the ignition switch OFF before checking or replacing the (use: to pre- vent accidental short-circuiting. ' Never use a {use with a diflerem rating from that specified. Serious damage to the electrical system or a fire may result, causing a dangerous loss of lights or engine power. 74 CAUTION: ‘ Do not pry the clips open to get a fuse out; you could bend them and cause poor contact with the new (use. A loose tuse could cause damage to the electrical system and even start a fire. m Fuse holder (2) Spare inse To repiace the fuse, turn the fuse holder cap (3) oounberclbck wise. Pull out the old fuse. New fuse in“) the fuse holder, and close the fuse holder up {3) Fuse holder cap 75 STOPLIGHT SWITCH ADJUSTMENT (Refer to the maintenance precauLiox-s on page 47). Check the operation of me stoplight swuch m at the right side behind the engine from time to time. Adjustment Is done by turning the adjusting nut (2) Turn the nut in the direction IA} if the switch operates [00 late and in direction (B) K the swuch operates (00 soon. 76 (1) Stoplight switch (2) Adjusting nut CLEANING Clean your motorcycle regularly to protect the surlace hnishes and Inspect for damage, wear, and oil seepage, CAUTION: ~ Avoid spraying high pressure water {typical in coil-operated car washes) at the following areas: Wheel Hubs Ignition Switch Muffler Outlet Steering Lock Under Fuel Tank Drive Chain Carburetor Instruments Under Sent 1. After cleaning, rinse the motorcycle thoroughly with plenty of clean water. Strong detergent residue can corrode alloy parts. NOTE: ' Clean the plaslic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing ll ireqnently with trash water, 2. Dry the motorcycle, Start the engine, and let it run [or Several minutes, 3. Lubricate the drive chain immediately after washing and drying the motorcycle, 4‘ Test the brakes before riding the motorcycle in traffic, Several applications may be necessary to restore normal braking per- lormance. Brak ng performance may he im- paired immediately after washing the motorcycle. 77 STORAGE GUIDE STORAGE Extended storage, such as tor winter, requires that you take certain Steps to reduce the effects of deterioration lrom non-use of the motorcycle, In addition, necessary repairs should be made BEFORE storing the motorycle: otherwise, these repairs may be forgotten by the time the motorcycle is removed trom storage. 1, Change the engine Oil. 2. Lubricate the drive chain. 3, Drain the fuel tank and carburetor into an ap- proved gasoline conminer. Spray the inside of the fuel tank with an aerosol rust-inhibiting Dill Reinstall the fuel cap on the tank. NOTE: * Ii storage will last more than one month, car- bureLor draining is very important, to assure proper performance after storage. 78 At ARNWG " Petrol Is extremely flammable Ind 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 lefueled. 4' Remove the spark plug and pour a table- spoon (15—20 cmal of clean engine oil into the cyllnder. Operate the kickstarter several times to distribute the oil. then reinstall the spark plug. NOTE: ‘ When turning the engine over, the Engine Stop Switch should be OFF and the spark plug placed in its cable can and grounded to prevent damage to the Ignition system , Remove the battery. Store in an area pror tected from treezrng temperatures and direct Sunlight. Check the electrolyte level and slow charge the battery once a month. . Wash and dly the motorcycle, Wax all painted surfaces, inflate the tyres to their recommended pressures. Place the motorcycle an blocks to false both tyres off the ground. . Cover the motorcycle (donr't use plastic or other coated materials} and store in an unheated area, (tee of dampness with a minimum of daily temperature variation. Do not store the motorcycle in direct sunlight, REMOVAL FROM STORAGE l. Uncover and clean the motorcycle. Change the engine oil if more than 4 months have passed since the start or storage, . Check the battery electrolyte level and charge the battery as required. install the battery. . Dram any excess aerosol rustrinhibiting oil from the fuel tank. Fill the fuel tank wlth fresh petrol. . Perform all Pre-ride Inspection checks (page 33). Test ride the motorcycle at low speeds in a safe riding area away from traffic. 79 SPECIFICATIONS DIMENSIONS Except U U Only Overall length 2,080 mm (81 9 in) 2,065 mm (813 in! Overall width 850 mm (335 in! 855 mm (337 in) Overall height 1,110 mm (437 in) 1,130 mm (445 in) Wheelbase 1,3l0 mm [51.6 in) 1,315 mm [518 In) WEIGHT Dry weight 105 5 kg 4232 1 lbs! 1036 kg 1239] lb) CAPACITIES Engine oil 0 91(10 US qt, 0 8 Imp at) Afler drzlnmg 112112 US qt, ID Imp qt) Afier disassembly Fuel tank 7.0 [(1.3 US gal, 1.5 Imp gal) Fuel reserve tank LSUOA US gal, 0.3 Imp gal) Passenger Capatily Operator and one passenger 80 ENGINE Bore and stroke Compression ratio Displacement Spark plug (SA, U) Standard: For cold climate (Below 5'C, 41‘F): For extended high speed riding: Spark plug (Except SA, U) Standard: For cold climate (Below 5‘Cl 41F). For extended high speed riding' Spark plug gap Valve clearance: Intake Exhaust Idle speed CHASSIS AND SUSPENSION Caster Trail Tyre size, from Tm size, rear 63 x 57.8 mm (2.430 x 2.275 in) 9.2: 1 180.1 Cm3 (11,0 min) DRBESL (NGK) or X24ESRVU (NlPPONDENSOl DR7ES (NGK) or XZZESR-U (NIPPONDENSO) DRBES (NGKl or XZVESR-U (NIPPONDENSO) DBEA (NGK) or X24ES-U (NIPPONDENSO! D7EA (NGKI or XZZESVU (NIPPONDENSO! D9EA (NGK) or X27ESVU (Nll’PONDENSO) 06*0] mm [0024*0 028 inl 0.05 mm (0.002 ml 0.05 mm (0 002 in) 1,300 2 100 min“1 (rpm) 27'50' (Except U) 2710' (U only] 122 mm (4.8 in) (Except U) 120 m (4,7 in] (U anly) 235-2145? 4.10-18-59P 81 POWER TRANSMISSION Primary reduction Final reduction Gear rauo. 15L 2nd 3rd 4211 5th ELECTRICAL Battery Alternator LIGHTS Headlight (High/Low} Taxi/Brake light Turn signal light Position ligm Instrument Ilght Tachometer light Neutral indicator Tum 5|gnal indicator High beam inmcamr FUSE 82 3.3333 : 3.5000 : 2.7692 : 1.7222 ' 1.2727 : 1.0000 : 0.7777 : 6V AA H A.C. Generator Except U wise/35w 6V 5 3/17VV 6V 10W x 4 avisw 6V73W 6V—3W 6V73W sviuw 6V—1,7W 10A U Only wigs/35w 6V75/21W svaow x 4 eviaw svisw 6V7! 7W svisw 6V71.7W ev717w NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit, (a) The removal or rendering inoperative by any person other than (or purposes (II maintenance, repair or replacement, oi any device or elemem oi design lncorvorated into any new Vehlcle (or the purpose oi noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and 1b) The use oi the vehicle aiter such device or element of design has been removed or rendered inoperative by any person 83 SEIEINSOO ‘ / var—mum Am? mu. 0—3 a; 2% :9: £3: :53 may :9: £39 ., was 2.2 29:; :9: 2:; £5: :32 max: :9: 2% 33$. as: 22%;? a; £5; a? #5:: iii win? 2.: x51 .5; 2923» :9: m :nxicmn :9; 2; a»: 92:; .3523 :9: J. s 5;: 22:2 :2 23, Saga; :2 2i :5 in 2% :9: .5 y :2 55 :9: 2.5.; £33m 2:2: 8255552; 555; S; w . n .2533 r :9: a; we? :9: .5? . am; an; 23: :9: 2;: ,_ 23;: £2? 3:2: vex % ”$2; “is . \ ‘ .1233, \ 22x: 5: 59.5 22$ 2343;: 1213:? 2.5. 32:25: 22 3.: 95.? x22 $.31 coxinmsznx 9153?? $923335; 52:55:31 w 2.: w z‘vza/za: i», am,..: is” ( :5 a o x 3 E r E. c i 3 a. y; o 9.9 r. w , i V a s 2;; 9 oomaNiflaéaS 9—8. an s -Nenea 5V mam—1:»