OWNER’S MANUAL XREEDR HONDA XR250R OWNER’S MANUAL © Honda Motor Co., Ltd. 1999 MPOKI‘ANT NOTICE 0 OPERATOR ONLY. NO PASSENGER This motorcycle is designed and constructed as an operatomnly model The seating configuration does not safely permit the carrying of a passenger. Do not exceed the maximum weight capacity O 0N/0FF~ROAD USE This motorcycle is designed for “dual purpose" user ' READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: AWARNiNG Indicates a strong possibility of severe personal iniury or death if instructions are not followed. CAUTION: Indicates a possibility of personal iniury or equipment damage if 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 XR250R 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 notice and without incurring any obligation. No part of this publication may be reproduced withoutwritten permission. WELCOME The motorcycle presents on a challenge to master the machine a challenge to adventure. You ride through the win , linked to the road by a vehicle that responds to our commands as no other does. Unlike an automobile, there IS no metal around your e an airplane, a reeeaide inspection and regular maintenance are essent' to your safety. Your reward is 1' om. To meet the challen salely. and to ‘2"ng the adventure fuj¥, on should become thoroughly familiarwi this owners manual FORE YOU RUDE E OTORCYCLE When service is required, remember that your Honda dealer knows your motorcycle best If you have the required mechanical “know-how" 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 ! ' Following codes in this manual indicate each countryl [ U Australia 0 The specifications may vary with each locale. OPERATION Page 1 MOTORCYCLE SAFETY akwwu Sale Riding Rules Protective Apparel Modifications Loading and Accessories Off road Salety 7 PARTS LOCATION 10 Instruments and [Indicators 12 MAIOR COMPONENTS 12 24 27 29 31 35 (Information you need to operate this motorcycle) Suspension Brakes Clutch Engine Oil Fuel Tyres Page 37 ESSENTIAL INDIVIDUAL COMPONENTS 37 Right Handlebar Controls 38 Left Handlebar Controls 39 FEATURES (Not required for operation) 39 Steering Lock 40 Seat 41 Toolbag storage 42 OPERATION 42 Preride Inspection 43 Starting the Engine 4-6 Manual Staner Decompressor 47 Running—in 48 Riding so Braking 51 Parking 51 Antitheft Tips MMWHEMNCE Page 52 MAINTENANCE 8§3§$§83§§3gflfigg$$333 Competition Inspection Maintenance Schedule Tool kit Serial Numbers Colour Label Maintenance Precautions Air Cleaner Engine Oil Spark Plug Idle Speed Throttle Opemfion Spark Arrester Drive Chain Brake Pad Wear Wheel Removal Front Suspension Rear Suspension Wheel Spokes Side Stand Stoplight Switch Adjustment Bulb Replacement RR 94 CLEANING 95 STORAGE GUIDE 98 SPECIFICATIONS 101 NOISE CONTROL SYSTEM MOTORCYCLE SAFETY . Motorcycle riding requires special efforts on your part to ensure your safety Know these requirements beforeyou ride: SAFERIDING RULES 1. Always make a preride inspection (page 42) before you start the engine You may prevent an accident or equipment damage. 2 Many accidents involve inexperienced riders Most countries require a special motorcycle riding 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: 0 Wear bright or reflective clothing 0 Don‘t‘ ride in another motorist’s ”blind spot. 4. Obey all national and local laws and regulations. OExcessive speed is a factor in many accidents. Obey the speed limits. and NEVER have] faster than conditions warrant. - Signal before you make a turn or lane change. Your size and maneuverability 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. 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 2 The exhaust system becomes hot during opemtion. and it remains hot for a while after stopping the engine Be useful not to touch the exhaust system while it is Ile Wear clothing that fully covers your egs. 3. Do not wear loose clothing which could mtch on the control levers, kickstarten lootpegs, drive chain or wheels MODIFICATIONS AWARNIN OModiflcatizm of the motorcycle, or removal of original equipment. may render the vehicle unsafe or Obey all national and local equipment regulations LOADING AND ACCmmES *A motorcycle is sensitive to changes in weight distribution. Addition of accessories or cargo can impair the motorcycle’s stability and performance. To prevent an accident, use extreme are when adding and riding with cargo and accessories. These general guidelines may help you decide whether, or how to equip your motorcycle. Loading The combined weight 01 the rider, urge, and all accessories must not exceed the maximum weight capacity. 100 kg (220 lbs) 1. 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 of gravity, handling is proportionally affected. 2 All cargo and necessaries must be secure for stable handling. Recheck cargo and accessory mounts lrequently 3. Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebars, fork, or fender. Unstable handling or slow steering response may resu t. 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: ll Carefully inspect the accessory to make sure it does not reduce ground clearance. or limit suspension travel, steering travel or control operation. 2. Do not add electrical equipment that will exceed the motorcycles electrical system capacity, An electrical failure could cause a dangerous loss of lights or engine power at night, far from help, OFF-ROAD SAFETY Learn to ride in an uncongested off-road area free of obstacles before venturing onto unlamiliar terrain, 1. Always obey local off-road riding laws and regulations 2 Obtain pennission to ride on private property Avoid posted areas and obey “NOTrespassing” 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 oocur far from help, 5, Never ride beyond your ability and experience 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 off-road areas. Don’t modify your exhaust system. Remember that excessive noise bothers everyone and creates a bad image [or motorcycling. PAKl'S LOCATION Indicators Speedometer Headlight dimmer Brake fluid rewrvoir switch Clutch lever Front brake lever Thronle grip Smer decompremr lever Horn button Engine stop switch Fuel rm mp Oil filler cap/dipstick Toolhag flange Choke lever Genshifl pedal Foot peg Side stand Kickstarler Fuel an cap Foot peg Rear brake pedal INSTRUME‘JTSAND INDICATORS (l) The indicators are in the speedometer. above the headlight. Their functions are described in the table on the following page. (1) Speedometer (2) Odometer (3) Tripmeter (4) Turn signal indimmr (5) High beam indicator (6) Tnpmeter reset knob 10 (2) (3) (4) (5) ( Ref. No. ) Descriptian Function (1) Speedometer Shows riding speedi (2) Odometer Shows accumulated mileage (3) Tripmeter Shows mileage per trip or section of route. (4) Turn signal indicator Hashes when eiiher turn signal operates. (5) High beam indicator Lights when the headlight is on high beam. (6) Tripmeter reset knob Resets tripmeter :0 zero (0). Turn the knob in direction shown. 11 MAJOR COMPONENTS (Information you need to operate this motorcycle) ‘WARNING t It the Pre- ride Inspection (page42) is not performed, severe personal Iniury or vdlicle damage may result. SUSPENSION Front Suspension The front suspension may be adjusted for the rider’s weight and riding conditions by changing the oil volume and compression damping Use the chart to the right to determine the correct adjustment for you. 12 Condition 0m Dmvinl Oil volume Entire range 0; travel is mhard. Sotm Entire range or tnvel is mo son (humming). Stifler 1mm travel is good, but the final stages 01 navel an (onset! (bouoming). The W sages a! travel are good but the final sages are hard. Reduce The initial slates of navel are loo soft. but the final stages are good. stiffer Reduce The initinl sages ol knvel are me hard, but the final are good. Sofie! Oil Volume AdE' stment w o eve s prov: e a soft ride and are for light loads and smooth riding conditions High oil levels provide a firm ride and are for heavy loads and rough riding conditions, 1. Raise the trout wheel off the ground by placing a support block under the engine. 2. Remove the pressure release screws (1) to release any accumulated air pressure 3. Remove the fork caps (2) and springs from the fork tubes Inspect the O-rings on the [ork caps and replace them i! they are damaged AWARNING 'The fork caps are under extreme spring pressure. Use care when removing the caps and wear eye and face protection. (1) Pressure relase saews (2) Fork caps 13 4. Compress the fork all the way and measure the oil level (3) from the top of tu es. Standard oil level: 82 mm (32 in) T a lower the oil level (decrease volume), use a syringe Add oil with a graduated beaker for accurate measurements, The recommended oil level range is 77—108 mm (3.0—4.3 in) N OTE: e Increase or decrease oil in increments of 4 cm8 (0.1 US oz , 0‘1 Imp 02) ‘ To prevent fork damage, do not fill past the recommended maximum level To prevent poor performance. do not use a level lower than the recommended minimum 5. Be sure the oil level is the same in both fork tubes. 6. Clean and dry the fork spring with a lint lree cloth Install the fork springs Oil the fork cap Orings and install the fork caps, Torque the fork caps to: 29 N-m (3.0 kgf‘m , 22 |bf~ftl 1‘ (3) Oil level (3) Compression dm% 3: IS yustment ects how quickly the fork compresses. The Iork compression damping adjuster (1) has 19 positions (clicks) or more. Turning the adjuster screw one full turn changes the adjuster 4 positions. To adjust the acfiuster to the standard position. proceed as follows: 1. Remove the cap (2) and turn the damping adjuster clockwise until it will no longer turn (lightly seats). This is the full hard se ’ . 2‘ Turn the dumping adjuster counter— clockwise 7 clicks back from full hard. This is the standard position. 3‘ Make sure that both the right and left forks are adjusted in the same position. CAUTION: tAlways start with full hard when adjusting damping. (1) Damping adjuster (2) C81) 15 Rem-Suspension , The rear suspension can provide the desired ride under various rider weight and t'l‘he rear shock absorber assembly riding conditions through adjustments of includes a damper unit that mains the rebound damping, compression big: pressure nicmgm gas Do not damping and spring preload adjuster. attempt to disassemble, disconnect or Use the following chart to determine ihe service the damper unit; an mlosion correct adjustment for your causing serious injury may result. tPuncture or exposure to flame may also result in an explosion, musing serious mlury, ‘Service or disposal should only be done by your Honda dealer or a qualified mechanic, equipped with the proper tools, safety equipment and the official Honda Shop Manual. ‘6 Always begin with Step I , then test ride the motorcycle. I! the condition still exists. proceed to Step 11 and test ride the motorcycle again If necessary, proceed to Step 1114 Stew I I] 111 Condition Bottoming Shortenthe spriuglength Turn the compression (to increase the preload) damping to 2 sfifle’r posi- tion (to increase the dampingiorce) Soft Turn the compression Shorten the spring length Tum the rebound damp damping to n stiffer posi- (to increase preload) ingto a stiffer position (to tion ( to increase the increase the damping damninv force) force) Hard Increase the spring Turn the compression Turn the rebound damp length (ta decrease pm damping to a softer posi- ingtoasoner posifion (ta load) nonuo decrease damping decreasedamphgforce) force} Excessive Shorten the spring length sinking (to increase the pie-load) 17 mm: Preload should be adjusted when the engine is lc‘glld bemuse it is necessary to remove the m er. An opu'onal pin spanner is available for turning the lock nut and adjusting nut to adjust spring preload‘ 1‘ Remove the seat (page 40L 2‘ Remove the right side cover (1). ®Remove the two bolts (2) ®Pul| the right side cover. 3. Remove the muffler (3). ®Loosen the muffler clamp bolt (4) ®Remove the lower (5) and upper muffler bolts (6), ®Pull the muffler away from the exhaust pipe. 13 (1) Right side cover (2) Bolts (3) Muffler (4) Muffler clamp bolt (5) Mufllet boll (lower) (6) Muffler bolt (upper) 4‘ Remove the rear brake fluid reservoir stay mount bolt (7L Make sure you keep the reservoir in a level position throughout the procedure to prevent air entering the brake system. 5. Loosen the screw (8) on the air cleaner connecting tube clamp and remove the air cleaner connecting tube from the carburetor, <7) (8) (7) Bolt (8) Screw (13) Subfmne lower side bolt CAUTION: I Be careful not to allow dust into the mrhnretor, severe engine damage could result. 6‘ Disconnect the electrical connectors (9). 7. Loosen the band and clip (10) 8‘ Remove the chain cover (11) by removing the two screws (12). 9‘ Remove the three subframe mounting bolts (13) (14) (15) 10. Remove the subframe by pulling it straight back 9) (9) Electrical connectors (12) Screws (10) Band and Clip (14) Subtrame lower side bolt (11) Chain cover (15) Subtrame upper bolt 19 11 Raise the rear wheel off the ground by placing a support block under the engine 12 Measure the spring length (16) Standard spring length is: 1815 mm (7.15 in) 13 Adjust the spring length. 0 To increase spring preload: Loosen the lock nut (17) with the optional pin spanner and turn the adjusting nut 08) to shorten the spring length. Do not shorten tn less than: 1735 mm (6.83 in) 0 To decrease spring preload: Loosen the lock nut (17) and turn the adjusting nut (18) to increase the fhpnng length Do not increase to more 1855 mm (7.30 in) NOTE: ' Each mm of the adjuster changes spring length and spring preload. One turn equals 2 spring lenglh/ spring preload 1.5 mm (0.06 in) / 16.9 kg (37.3 lbs) 14. Tighten the lock nut. (17) (16) Spring length (17) Lock nut (13) Adjusting nut (18) (A) Increase Prelnad (B) Decrease Preload 15. Install the removed parts. “WARNING ' If a torque wrench was not used for installation, see your Honda dealer as soon as possihle to verify proper as- sembly. @Iustall the sublrarne. Tighten the three bolt to the specified torque: Subtrame upper bolt (15): ZGN- m(27kg(m, 20lbfft) Subtrame lower side bolts (13) (14): 42 N-m143kgf-m 31lbf-ft) @Connect the electrical connectors by matching the cable colours ®Reinstall the band and the clip @l‘ighten the air cleaner connecting tube clamp and the rear bmke fluid reser- voir stay mount bolt. ©lnstall the muffler and tighten the bolts. Be careful] not to damage the pa installed inside the muffler clamp. Tighten to the specified torque: Muffler clamp bolt (3): 20--Nm(20kgfm,14lbfftl Muffler bolt (lower) (4): 32 N-m (3.3 kgf-rn , 24 Ibf‘ft) Muffler bolt (upper) (5): 32 N-m (3.3 kgf-m , 24 [bf-f!) ©Reinstall the side cover. chain cover and seat. 21 Com ression Dam ‘ . ihe compression fiagx‘hping adjuster has at least 20 positions. Turning the adjuster one full turn advunoes the adjuster 4 positions. To adjust to the standard position: 1. Turn the damping adjuster (1) clockwise until it will no longer turn (lightly seats). This is the full hard setting. 2‘ Turn the adjuster counterclockwise 9-12 clicks until the punch mark (2) on the adjuster aligns with the relerence mark (3). This is the standard position (3) (Z) (1) u) Damving adjuster (2) Punch mark (3) Reference mark Rebound Daingg'gg; e re un amping adjuster is located at the lower end of the shock absorber It has at least Zowsitions Turning the adjuster one full turn advances the adjuster 4 positions To adjust to the standard position: 1‘ Remove the chain Coven (page 19) 2‘ Tum the damping adjuster (l) clockwise until it will no longer turn (lightly seats). This is the lull hard setting. 3rTurn the adjuster counterclockwise 7-10 clicks until the punch mark (2) on the adjuster aligns with the reference mark (3 )r This is the standard position (1) Damping adjuster (2) Punch mark (3) Reletenoe mark BRAKES Both the front and rear brakes are the hydraulic disc types. As the brake pads wear. the brake fluid level drops. There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks. if the control lever or pedal tree travel becomes excessive and the brake pads are not worn beyond the recommended limit (page 79 ), there is probably air in the brake system and it must be bled. See your Honda dealer for this service 2‘ Front Brake Fluid Level: “WARNING ‘ Brake fluid my cause irritation. Avoid Contact with skin or eyes. In case of contact. flush manually with water and call a doctor if your eyes were expand. 'KEEP OUT OF REACH OF CHIL DREN. CAUTION: ‘ Handle brake fluid with care because it can damage plastic and painted surfaces. a 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 water to enter the brake fluid reservoir. Brake fluid must be added to the reservoir 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 FLUH) from a sealed container up w the UPPER level mark (6). Reinstall the diaphragm, diaphragm plate, and cover. Tighten the screws securely. (2) (l) LOWER level mark (2) Screws (3) Reservoir cover (4) Diaphragm plate (5) Diaphragm (6) Upper level mark Other Checks: Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings. Rear Brake Fluid Level: AWARHING ' Brake fluid my cause irritation. Avoid Contact with skin or eyes, In use of contact, flush thoroughly with water and call a doctar if your eyes were exposed. 'KEEP OUT OF RFACH 0F CHILL DREN. CAUTION: - Handle brake fluid with care because it can damage plastic and painted surfaces. : When adding brake fluid, he sure the reservoir is lwrimntal before the cap is removed or brake fluid may spill out. tUseonlyDOl‘4brakefluidfroma sealed container. . Never allow oontaminants such as dirt or water to enter the brake fluid reservoir. 26 Check that the fluid level is above the LOWER level mark (1) with the motorcycle in an upright position. Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark (1). Remove the reservoir slay mount bolt (2). Make sure you keep the reservoir in a level position. Remove the reservoir cap (3). Fill the reservoir with DOT 4 BRAKE FLUID from a sealed container up to the UPPER level mark (4)‘ Tighten the reservoir cap securely (1) LOWER level mark (3) Reservoir cap (2) Reservoir stay (4) UPPER level mark Ilwunt bolt CLUTCH Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep; or if the clutch slips. causing acceleration to lag behind engine speed. Minor adjustments can be made with the clutch cable adiuster (4) at the lever (1). Normal clutch lever free play is: 10-20 mm {OJ—0‘8 in) (1) Clutch lever 1, Bill back the rubber dust cover (2). Loosen the lock nut (3) and turn the adjuster (4)4 Tighten the lock not (3) and check the adjustment. 2. It the adjuster is threaded out near its limit or it the correct free play cannot be obtained, loosen the lock nut (3) and turn in the cable adjuster (4) completely. Tighten the lock nut (3) and install the dust cover (2) Dust cover (A) Increase free play (3) back nut (B) Decrease free play (4) Adjuster 27 3r 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 adjusuneut. 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 graduallyr N OTE: ‘ If proper adjustment cannot be obtained or the clutch does not work correctly, the cable or clutch friction dist: may be worn. Refer to the official Honda shop manual or see your Honda dealer. 23 Other Chem: Check the clutch cable for kinks or signs of wear that could cause sticking or failure. Lubricate the clutch cable with a conunercially available cable lubricant to prevent premature wear and corrosion. (5) lock nut (e) Adjusting nut (A) Increase {nee play (B) Decrease [tee play ENGINE 0]]. Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The oil filler cap is in front of fuel tank and has a dipstick for measuring the oil level. Oil level must be maintained between the upper (1) and lower (2) level marks on the dipstick (3). NOTE: tThe oil level cannot be checked accurately immediately after the engine has been run at high speed. 'Make sure that motorcycle is standing upright on firm level ground while idlingi 1. Park the motorcycle on a firm. level surface. 2.Start the engine and let it idle {or 5 minutes If the air temperature is below 10°C (50°F), let the engine idle for an additional 5 minutes (a total of 10 minutes). An engine that is not warmed suificiently may give an inaccurate (low) oil level readingi During idling. support the motorcycle in an upright position to assure an accurate oil level reading. Stop the engine. illmnediately remove the oil filler cap/ dipstick (3) and wipe it clean 4. Hold the motorcycle upright, insert the dipstick until it seats. but don‘t screw it in. 5. Remove the dipstick. The oil level should be between the upper (1) and lower (2) level marks on the dipstick. If required, add the specified oil (see page 62) up to the upper level mark Do not overfill. (3) (1) (1) Upper level mark (2) Lower level mark (3) Oil filler cap/ dipstick D 6. Reinstall the oil filler cap/dipfiick Check for oil leaks, CAUTION: O Running the engine with insufficient oil can cause sedans engine damage. 30 NOTE: ‘ The engine contains a crankcase oil level check bolt (4). Remove the bolt and check that the level is flush with the lower edge of the hole, If it is. start the engine and check the engine oil level. If the cankcase oil level is low. add the recommended engine oil before seaming the engine to check the engine oil level. FUEL Fuel Cock The three way fuel cock (1) is on the left side near the carburetori OFF With the fuel cock in the OFF position. fuel cannot flow from the tank to the carburetor. Turn the cock OFF whenever the ragtowycle is not in user Wm the fuel cock in the ON position. fuel will flow from the main fuel supply to the carburetor, With the fuel cock in the RES position, fuel will flow from the reserve fuel supply to the carburetori Use the reserve fuel only when the main supply is gone. Refill the tank as soon as possible after switching to RES. The reserve fuel supply is: 2.0 B (0.53 US gal , 0.44 Imp gal) “WARNING ' To avoid running out of fuel that may result in a sudden stop, learn how to operate the fuel cock when riding the motorcycle. * Be careful not to touch any hot eny‘ne partswhile operating the fuel cock NOT E: ' Remember to check that the fuel cock is in the ON position each time you refuel, I! the cock is left in the RES position. you may mn out of fuel with no reserve OFF ON (1) Fuel cock 31 Fuel Tank The fuel tank capacity including the reserve supply 154 90 l (233 US gal , 1‘93 Imp gal) The reserve supply alone is: 2.0 a (0.53 us gal , 0,44 Imp gal) To open the fuel fill cap (1), pull out the breather tube (2) from the steering stem nut Then turn the fuel fill cap counterclock- wrse‘ After refueling, be sure to tighten the fuel fill cap fumly by tuming it clockwise Insert the breather tube into the steering stem nut. Use unleaded pen-cl with a research octane number of 98 or higher. 32 CAUTION: ' If “spark knock” or “pinking” occurs at a steady engine speed under normal load, change blinds of petroL If spark knock or pinking persists, consult your Honda dealer. Failure to dosoisconsideredmisuse,anddam- age caused by misuse is not covered by Honda’s limited Warranty. (l) (3) Filler neck (1) Fuel nu cap (2) Breather mbe AWARNING ‘ Petrol is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine snapped. Do not smoke or allow flames 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 ignite. if any fuel is spilled, make sure the area is dry before starting the engine. 1*Avoid repeated or prolonged Contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN. 33 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 10 ‘36 ethanol Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosoivents and corrosion inhibitors for methanol Never use petrol containing more than 5 '36 methanol. even it it has cosolvents and corrosion inhibitors. 34 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 of fuels containing methanol since evidence of their suitability is as yet incomplete ~Betore buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol If it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a petrol that contains alcohol, or one that you think contains alcohol, switch to a petrol that you know does not contain alcohol. TYRES Proper air pressure will provide maximum stability, riding comfort and tyre life. Check tyre pressure frequently and adjust if neccessary. NOT E: 0 Tyre pressure should be checked before you ride while the tyres are “cold", Off road tyres are standard on this model Select the right replacement tyres in accordance with the following specifica- IOI'ISZ Cold tyre Ffont 150 (1.5 , 22) pressureskPa Rear: 125(1.25,18l W/dpsi) Maximum weight 100 kg (220 lbs} apathy Tyresize Front: 3.00v 21 51? Rear. 4.00718 GAP Check the tyres for cuts, embedded nails, or other sharp objects. See your Honda dealer for replacement of damaged tyres or punctured inner tubes AWARNIHC t Do not attempt to patch a damaged tyre or inner tube. Wheel balance and tyre reliability may be impaired. ‘ Improper tyre inflation will cause abnormal tread wear and create a safety hazard. Underinflation 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. * Operation with excessively worn tyres is hanrdous and will adversely affect traction and handling. 35 Replace tyres before trend depth at the center of the tyre reaches the following limit: Minimum tread depth 3 mm (1/8 in ) 36 ESSENTIAL INDIVIDUAL CONfl’ONENTS RIGHT HANDLEBAR CONTROLS Engine Stop Switch The engine stop switch (1) is nan to the thruttle grip, When the switch is in the O (RUN) position, the engine will operate. When the switch is in the R (OFF) posiiion, the engine will not operate. This switch is intended primarily as a safety or & mergency switch and should normally re mainin the O (RUN) position (1) Engine stop switch LEI-T HANDLEBAR CONTROLS HeadlidItDimmerSwitch (1) Push the dimmer switch to SD (HD to select high beam or to §D (L0) to select law beam. Turn Siyml Switch (2) Move to ¢ (L) to signal a left turn, ¢ (R) tosignalarightturn.Presstomm signal off, Huh: Button (3) Press the button to sound the horn‘ (l) Headlight dimmer swild: (2) Tum Signal swiwh (3) Horn button 38 FEATURES (Not required for operation) STEERING LOCK The steering lock (1) is on the steering stern. To Lock: Turn the handlebar all the way to the left and insert the key into the lock, turn the key 180" clockwise and remove it. (1) Steering lock SEAT Removal: llR'ernove the two bolts (1) securing the seat (2). 2. Slide the seat back. Installation: 1% locating slot (3) under the front of the seat with the pin (4) on the rear of the fuel tank. 2. Align the locating prongs (5) an the bottom of the seat with the hooks (6) on the frame. 3. Slide the seat into position. 4 Install the bolls and fighten them. (1) Bolts (2) Seal (3) Slot (4) Pin (5) Prong: (6) Hooks TOOL BAG STORAGE The tool bag (1) and owners manual (2) is in the tool bag storage (3) at the rear 01 the seat Some repairs adjustments and parts replacement can be performed with this tool. This owners manual and other documents should be stored in the tool bag storage. When washing your matorcycle, be careful not to flood this area with water‘ (1) Tool bag (2) Owners manual (3) Tool bag storage 41 OPERATION FEE-RIDE INSPECTION AWARNJNG 0]! the Prefide Inspection is not performed severe pe iniury or vehicle dninage 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 lile. 1. Engine oil level—add engine oil if required (page 29 ), Check for leaks. 2. Fuel level-fill fuel tank when necessary (page 32 ), Check for leaks. 3. Front and rear brakes—check operation; make sure there is no brake fluid leakage. 4. Tyres— check condition and pressure ge 35 ). 5. Spokes and rim locks—check and tighten if necessary (page 86 ). 42 6. Drive chain>check condition and slack (page 73 ). Adjust and lubricate if necessary, 7. Chain guide slider and slipper-check slider wear (page 74 i it Throttle—check for smooth opening and lull closing in all steering positions (pages 70— 71) 9.Clutch-check operation, and adjust it necessary (pages 27‘28). 10. Lights and hum—check that headlight, tail/brake light. turn signals. indicators and horn function properly ll. Spark plug and high tension terminal— check for looseness. 12. Engine stop switch—check for proper function (page 37). 13.Nuts. bolts, fastenersrcheck the front wheel to see that the axle nut and axle holder nuts are tightened securely. Check security of all other nuts, bolts, and fasteners. Correct any discrepancy before you ride. Contact your Honda dealer {or assistance if you cannot correct the problem. Sl‘ARl‘ING THE ENGINE Always follow the proper starting procedure described below. AWARNING 0 Never run the eng‘ne in an enclosed area. The exhaust wntains poisonous carbon monoxide gas that can cause loss of consciousness and lead to death. *Attempting to start the engine with the transmission in gear and the clutch engaged may result in injury or damage. NOTE: I This motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarrer. Preparation Make sure that the transmission is in neutral. Turn the engine stop switch to O (RUN) and the fuel cock ON. StartingProcedure To restart a warm engine, follow the procedure for “High Air’l‘emperature." Normal Air Tmrature 10° —35° (50° —95°lj L Pull the choke lever (1) up all the way to Fully ON (A) (1) Choke lever (A) Fully 0N (E) Detent Position (C) Fully OFF 43 2. Keep the throttle fully closed 3. Operate the kickstarter to start the engine. Starting from the top of the stroke. kick through to the bottom with a rapid, continuous motion, Do not operate the throttle CAUTION: ' Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case. 4. Immediately after the engine starts, push the choke lever (1) down to the Detent Position (B). CAUTION: * Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. 5.Warm up the engine by opening and closing the throttle slightly. 6. About a half minute after the engine starts, push the choke lever (1) down all the way to Fully OFF (CL If idling is unstable open the throttle slightly. High Air Temperature 35 °C 195 r’F or above L Do not use the choke 2. Keep the throttle fully closed 3. Start the engine following step 3 under “Normal Air Temperature". If the engine fails to restart: 1. Pull the decompression lever (page 46) in, open the throttle fully, turn the engine stop switch to E (OFF) and operate the kickstarter pedal several times to clear the engine. Release the decompression 1%”, Burn the engine stop switch to 2. Start the engine following step 2 under “Normal Air Temperature'i 1 1‘ Follow steps 1 — 3 under “Normal Air Temperature" 2, Warm up the engine by opening and closing the throttle slightly. 3. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke lever (1) down all the way to fully OFF (C). MANUAL STARTER DECOMPRESSOR Although an engine decompression system is interlocked with the ldcllstaner. the manual starter decompressor can also be used if you experience starting difficulties To 01mm: 1. With the throttle fully closed, push down lightly on the kickstarter until you feel some resistance. 2‘ Pull the dccompressor lever (I) and push the kickstarter down again slowly about 1/4 to 1/2 of afull stroke 3‘ Release the decompressor lever and kickstmt the motorcycle in the usual manner‘ The manual starter decompresor can also help restart the engine in an off-road situation where the motorcycle is rolling clown a hill 1. Close the throttle, Pull the clutch lever in and shift into 2nd or 3rd gear. 2. With the motorcycle rolling, release the clutch lever. 46 3. If the rear tyre skids instead of turning over the engine. pull the decompressor lever. Releasing compression allows the rear wheel to roll while turning the e ‘ eover. 4. Re ease the decampressor lever. If the engine does not start, pull the deoompressor lever again. Wait until the motorcycle gains speed and release the decompressor leverl (l) Decompressor lever Flooded Eng'ne It the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine. push the choke lever down to Fully OFF (0‘ Turn the engine stop switch to R (OFF). Pull and hold the manual decompressor lever. Open the throttle fully and crank the engine seven] times with the kickstarter. Release the decompressor lever. turn the engne stop switch ta 0 (RUN) and follow the “High Air Temperature” Starting Procedure (page 43 ). RUNNING-IN Help assure your motorcycle's future reliability and performanoe by paying extra attention to how you ride during the first opemting day or 25 km (15 miles). During this period, avoid futhrotfle starts and mpid acceleration. 47 RIDING AWARNING - Review Motorcycle Safety (Pages 1 — 5 ) before you ride. ‘ Make sure the side stand is fully retracted before riding the motorcycle. It the stand is extended, it may interfere with control during a left film. NOTE: * Make sure you understand the function of the side stand mechanism (See MAIN- TENANCE SCHEDULE on page 56 and egylsanation for SIDE STAND on page 1. After the engine has been warmed up, the motorcycle is ready for riding, 2. While the engine is idling, pull in the clutch lever and depress the 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 48 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 5. This sequence is repeated to progres— sively shift to 3rd. 4th, 5th and 6m(mp) geari 6. Raise the pedal to shift to a higher gear and depress the pedal to shift to a lower gearl Each stroke of the pedal engages the next gear in sequence. The pedal automatically returns to the horizontal position when released. 23‘56 AWAHIHNG * Do not dawnshift when traveling at a speed that would force the engine to over-rev in the next lower gear, the rear wheel may lose traction, resulting III a possible loss of vehicle control. CAUTION: ' Do not shift gears with-mt disengag- ing the clutch and closing the throttle The engine and drive train could be damaged by overspeed and shock a Do not tow the motorcycle or coast for long distances while the engine is off. The transmission will not be pmpe“l rly lubricated and damage may '00 not run the engine at high rpm with the transmission in neutral or the clutch lever pulled in. Serious engine damage may result. BRAKING 1. For normal braking, gradually apply both the front and rear brakes while downshifting to suit your road speed. 2. For maximum deceleration, close the throttle and apply the front and rear brakes fu'mly. Pull in the clutch lever before coming to a complete stop to prevent stalling the engine. AWARNING ' Independent use of only the front or rear brake reduces stopping performance. Fxtreme ‘ may cause either wheel to lock, reducing control of the motorcycle. * When possible, reduce speed or brake before entering a turn; closing the throttle or brakin in mid-turn my cause wheel slip. eel slip will reduce control of the motorcycle. AWARNWG tWhen riding in wet or rainy condi- tions, or on loose surfaces, the ability to maneuver and stop will be reduced. All of your actions should be smooth under these conditions. Rapid accel- eration, braking or turning may cause loss of control. For your safety, exer- cise extreme caution when braking, accelerating or turning. t When descending a long, steep grade, use engine compression braking by dovvnshiftii-igY with intermittent use of both brakes. Continuous brake applican‘tm can overheat the brakes and reduce their effectiveness. PARKING 1. After stopping the motorcycle. shin the transmission into neutral and turn the fuel cock OFF and turn the handlebar fully to the left. Turn the engine stop switch to W (OFF), 2. Use the side stand to support the motorcycle while parked, CAUTION: *Park the motorcycle on firm. level ground to prevent it from falling over. . If you must park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility of rolling off the side stand or overturning. ANT I-THEFI‘ TIPS 1. Always lock the steerinf and never leave the key in the steering ock. This sounds simple but people do Iorget. 2. Be sure the registration information for your motorcycle is accurate and current. 3, Park your motorcycle in a locked garage whenever possible. 4. Use an additional antitheft 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: ADDRE$t PHONE N0; 51 MAINTENANCE 0 When service is required, remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it. The scheduled maintenance may be performed by a qualified service facility that normally does this kind of work; or you may perform most of the work yourself if you are mechanically qualified. 0 The maintenance intervals shown in the following schedule are based upon average riding conditions Machines subjected to severe use (oompetition). or ridden in unusua]ly wet or dusty areas. require more frequent servicing. 0 Consult your Honda dealer for recommendations applicable to your individual needs and user I If your motorcycle is involved in a collision, have your Honda dealer inspect the major components including frame, suspension and steering parts. for misalignment or damage. COMPETITION lNSPECl'ION—Check all items before each race. ITEMS INSPECT FOR: ACTION uminmion or was 1’18th. proper heat range, and high- umim tenninal secumy ree of sleenllg sl onlsuspensiml Duration, an oil lulu good bom condition. air pressure and oil opaation. no 53 WSPECI'FOR: ACTION REFER TO I I1mm Ain 776 ear secure '1’ 22 Canmlubles 5mm openfiun, and correct Lubrimem' N0”) 1: Compeciljnn uselnalycmlse more rapid clutch disc war. Refer to me offidnl Honda Shop Manual, a: see ymar Honda dealer [or cluxch disassemhly and wear inspecLian. Reler lo Maintenance Schedulb (pages 55 - 56 ) for reguhrservice intervals. 54 MAINTENANCE SCHEDULE Perform the Prefide Illspeclian W942 ) at em scheduled mam-um period I: INSPECT AND CLEAN Anjusr LUBRICATE OR REPLACE 1F NECESSARY c: CLEAN R REPLACE A ADJUsr L LUBRICATE " FUEL AIR - VAL E 01L FREQUENCY ' ENG OIL SrRAIINER DOWN .. EN DRIVE CHAIN SLIDER WHICHEV'ER - INITIAL MAI'NT. COMES Fms'r xmokm I I Buy WMGDOIIIO or every 3 I I I Refer w d$ FREQUENCY WHICHEV'ER mrrw, COMES Fm 1.5 i 1 I Cze'vefy l.600|un(1,000mi)m I I . SHOULD BE SERV'ICED BY YOUR HONDA DEALER. UNLBS THE OWNER HAS THE PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALn-‘AED REFER TO THE OFFlclAL HONDA SHOP MANUAL .. IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLV BY YOUR HONDA DEALER NOTE: 1. Service more frequently when ridden in wetm' dusty conditions. 2. Replace every 2 yeals. Replmmem requires mechnnical skill. 56 TOOL KIT The spark plug wrench (1), mulflpurpose wrench (2) and 5 mm he: wrench (3) are stored in the tool bag (4), (4) (1) Spark plug wrench (3) 5 mm hex wrench (2) Mullivpurpose wrench (4) Tool bag 57 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. FRAME NO. 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 ENGINE N0, (1) FMS number 58 (2) Engine number COIDUR LABEL MAINTENANCE PRECAUTIONS The colour label (1) is attached to the flame behind the left side cover (See page 40), It is helpful when ordering replacement ‘If your motorcycle is overturned or parts. Record the colour and code here for involved In a collision, inspect control your reference. levers, cables, brake hoses, calipers accessories, and other vital parts for COLOUR damage. Do not ride the motorcycle if damage impairs safe operation. Have CODE your Honda dealer inspect the major components, including frame, suspension and steering parts, for misalignment and damage that you may not be able to detect. *Use new, genuine Honda parts or their equivalent for maintenance and repair Parts which are not of equivalent quality may impair the safety of your motorcycle OStop the engine and support the motorcycle securely on a firm, level surface before performing any maintenance. (1) Colour label AIR CLEANER 2. Unhook the set spring (3). (Refer to the maintenance precautions on 3. Remove the air cleaner (4), page 59), 4.Wash the air cleaner in clean. nonflam The air cleaner should be serviced at mnble or high flash point solvent and let it regular intervals (pageSS). Service more drythomugblyr frequently When "dmg 1“ “““Wafly wet 0’ “WARNIH G dusty areas‘ 1.Lift the Dring on each quick-release ~Never use petrol or low flash point lastener (l) and turn it counterclockwise solvents for cleaning the air cleaner. until it releases. Open the air cleaner Afire or ucplosion could result housing cover (2). (2) (1) Quidwelease fastener (2) Air cleaner housing cover (a) Set spring (4) Air cleaner so 5. Soak the air cleaner in gear oil (SAE 80- 90) until saturated, then squeeze out the excess oil‘ 6‘ Install the air cleaner with the lug on the holder aligned with the hole in the air cleaner, then hook the set spring and install the left side cover, ENGINE OIL (Refer to the maintenance precautions on page 59). Engine Oil 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 of the proper grade or viscosity of oil to be used at various atmospheric temperatures. l—l—l—h—l It 44 El n mlK (1) SINGLE GRADE (2) MULTI GRADE Engine Oil Engine oil quality is the chief factor affecting engine service life Change the engine oil as specified In the maintenance schedule (page 55 )r NOTE: ‘ Change the engine oil with the engine at normal operating temperature and the motorcycle on its side stand to assure complete and rapid draining 1. Start the engine and let it idle for a lew minutes 2.5101) the engine, place an oil drain pan under the case Remove the oil filler cap/dipstick, the drain bolt (1) on the down tube and drain bolt (2) on the left crankcase, 3. After the oil has drained. make sure the sealing washers an the drain plugs are in good condition: 4‘ Install the drain bolts to the specified torqued Crankcase drain bolt torque: 25 N-rn (2‘5 kgf~m , 18 Ibf‘ft) Frame drain bolt torque: 39 N-m 14.0 kgf-m , 29 |bf~ftl (2) (1) Drain bolt (down tube) (2) Drain bolt (left crankcase) CAUTION: ‘To fill the vi] tank up to the upper level. oil should he added in two steps. 5. With the motorcycle upright on firm level groun 6 Fill the oil tank with the spectf ed oil (See page 62 ) up to the upper level mark and install the oil filler cap/ dipstick. 7. Start the engine and let it idle for 5 minutes. During idling, support the motorcycle in an upright position on a firm, level surface to assure an accurate oil level reading, Stop the engine. 8,1mmidiately remove the oil filler cap/ dipstick and add the specified oil up to the upper level mark. 9. Reinsiall the oil filler cap/dipstick. Check for oil leaks. CAUTION: ' Running the engine with insufficient oil can cause serious engine 'Used eng'ne oil maycause skin mn- 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 gun as possible after handling used NOTE: *Please disvose 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 Engine Oil Filter 3. .Check that the oil filter cuver Ofing (4) NOTE; IS in good condition and then install the ‘ Change the filter after draining the new oil filter. Use the Honda oil filter or engine oil an equivalent filter specified for yaur model. Other filters not specified for your 1. Remove the oil filter bolts (1) and oil model may not filter impurities properlyl filter cover (2). 2. Remove the oil filter (3) (mm the cover. (2) (1) Oil filter bolts (2) Oil filter cover (3) Oil filter element (4) O-ring 4. Install the filter with the rubber seal (5) facing out, away from the engine. You will see “OUT-SIDE" mark (6) on the filter body, near the seal CAUTION: ' Improper installation of the oil filter can cause serious engine damage. (5) Rubber seal (6) OUTSJDE mark 5, Reinstall the oil filter cover. making sure the bolts are lightened securely. Oil Filter Bolt Torque: 12 N‘rn (1,2 kglAm , 9 lbf‘fl) 6‘ Perform steps 5 — 9 of Engine Oil Change. Engine oil after draining and oil filter change: 14 a (15 US qr, 1.2lmpq1) SPARK PLUG (Reler to the maintenance precautions on page 59). Recommended plugs: Standard: CR9EHi9 (NGK) or U27FER9 (DENSO) For coid climate: (Below 5 °C, 4! °F) CR8EH—9 (NGK) or U24FER9 (DENSO) (1) Spark plug can For most riding conditions this spark plug heat range number is satisfactory However, it the motorcycle is going to be operated (or extended periods at high speeds or near maximum power in hot climates, the spark plug should be changed to a colder heat range (a higher number) 1. 5‘2“ any dirt from around the spark plug we 2. Disconnect the spark plug cap (1) and remove the spark plug with the multi- purpose wrench provided in the tool bag. (2) Spark plug gap (3) Side electrode 61 3. Visually inspect the spark plug electrodes (or wean The center electrode should have square edges and the side electrode should not be eroded. Discard the spark plug it there is apparent wear or if the insulator is cracked or chipped. .Check the spark plug gap ( 2) using a wiretype feeler gauge, If adjustment is necessary. bend the side electrode ( 3) carefully The gap should be: 0.8—0.9 mm (0.03—004 in) Make sure the plug washer is in good condition, ,With the plug washer attached, thread the spark plug in by hand to prevent crossthreadjngl 6. Tighten 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 turn after the plug seats. is on CAUYION: ‘The spark plug must be securely tightened. An Improperly tightened plug can become very hot and possibly damagethe engine. 'Neveruse asparkplugwithan im- proper heat range. Severe engine dmagewuld result. IDLE SPEED (Refer9 to the maintenance precautions on P3895 Idle S9 The engine must be at normal opemting temperature for accurate idle speed adjustment Ten minutes of stopandgo riding is sufficient. NOTE: ‘ Do not attempt to compensate for faults in other systems by adjusting idle speed. See your Honda dealer for regularly scheduled carburetor adjustments (1) Throttle stop screw (2) Pilot screw (A) Increase rpm (B) Decrease rpm 1. Warm up the engine and hold the motorcycle upright Shift to neutral 2. Connect a tachometer to the engine. 3. Adjust idle speed with the throttle stop screw (1), IDLE SPEED: 1,300 i 100 min" trpm)(ln neutral) Idle Mm: 1 Adjust the fuel mixture by turning the pilot screw (2) clockwise until you hear the engine miss or decrease in speed then counterclockwise until the engine again misses or decreases In speed Set the pilot screw exactly between these two extreme positions, From a fully closed position, the correct setting (between extremes of rich and lean) will be approximately: 1 3/4 tu ms 2. if the idle speed changes after adiusting fuel mixture. readjust the idle speed by turning the throttle stop screw, THRO'ITLE OPERATION (Refer to the maintenance precautions on page 59). Cable Ins Lion: CHER for smooth rotation of the throttle grip from the fully open to the fully closed in all steering positions. Inspect the condition of the throttle cables from the throttle grip down to the carburetor. If the cables are kinked. chated or improperly routed. they should be replaced or rerouted, Check the cables for tension or stress at all steering position Lubricate the throttle cables with a commercially available cable lubrimnt to prevent premature wear and corrosion AVIARHING ‘Far safe operation and positive engine response, the throttle cable must be properly adjusted. 70 Free Play Ad‘ustrnent Measure e grip free play at the throtflegnp The standard efree play should be approximately- — 6 mm (0.03—0.24 in) (2) (1) (1) [mar lock nut (2) Lower adjuster Maior free play adjustments, such as after replacing the throttle cables or removing the carburetor, are made with the lower adjuster (2), Minor free play adjustments are made with the upper adiuster (4) To adjust free play. loosen the lock nut (1) or (3), and mm the adjuster (2) or (4). Tighten the lock nut after adjustment (4) (3) (3) Upper lock nut (4) Upper adjuster 71 SPARKARRESI‘ER 1. Remove the three bolts (2), the spark (Refer to the maintenance precautions on an‘ester (1), and the gasket (3) from the page 59). muffler (4). The exhaust system spark arrester must be 2. Use a brush to remove carbon deposits purged of accumulated carbon periodically from the spark arrester screen Be (see Maintenance Schedule for servicing careful to avoid damaging the spark period. Page 56). arrester screen. The spark arrester must , s be free 01 breaks and holes. Replace if necessary. Check the gasket Replace, if t The exhaum symm becomes very hot necessary. during operation and remains hot far 3. Install the spark arrester and the gasket a period of time after stopping the in the muffler and tighten the three bolts engine. Allow the adumst system to securely. coal beta-e performing this operation. (1) Spark master (3) Gasket (2) Balls (4) Muffler 72 DRIVE CHAIN (Refer to the maintenance precautions on page 59). 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 The drive chain should be checked and lubricated as part of the Pre—ride Inspection (page 42) Under severe usage or when the motorcycle is ridden in unusuany dusty or muddy areas, more frequent maintenance will be necessary. Ins ecti : 1 lum the engine oft raise the rear wheel off the ground by placing a support under the engine and shift the transmission into neutral 2. Check slack in the lower drive chain run midway between the sprockets Drive chain slack should be adinsted to allow the following vertical movement by hand: 30—40 mm (1441.3 in) 3. Roll the motorcycle forward Stop Check drive chain slack Repeat this procedure several times Drive chain slack should remain constant It the chain is slack only in certain sections, some links are kinked and binding Binding and kinking can frequently be eliminated by lubrication N 0T E. ' Excessive chain slack may allow the drive chain to come off and damage the engine cases. (1) Drive chain 73 4‘ Check the chain slipper (2) and chain guide slider (3) for wear. When the depth (5) of the chain slipper reaches the limit, the chain slipper must be replaced Chain slipper depth limit: 8 mm (0.3 in) Replace the chain guide slider if the chain is visible through the wear inspection window (4 ). (2) (3) (4) (2) Chain slipper (3) Chain guide slider 74 (4) Inspeaion window (5) Depth 5, Measure a section of the drive chain to determine whether the chain is worn beyond its sewice limit. Remove the drive chain and measure the distance between a span 0! pins from pin center to pin center. If the dismee exceeds the service limit, the chain is worn out and should be replaced. New chain 1,603 mm (63.1 in) Service limlt: 1,611 mm (53.4 in) Span of pins measured: 102 6. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Damaged Sprocket Wom Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth GOOD dard Sprocket ’ 5: Drive sprocket Driven sprocket (engine) (rear wheeD 13 teeth 39 teeth NOTE: OK the drive chain or sprockets are excessively worn or damaged, they should be replaced. Never use a new chain with worn sprockets; rapid chain wear will result. Ad'ustment: l t‘fie drive chain requires adjustment, the procedure is as follows: 1. Loosen the rear axle nut (1) while holding the axle 2 Turn both the right and left adjusters(2) :gually to increase or decrease chain 3 After adiusting. be sure the same adyuster index marks (3) align with the stopper pins (4) on both sides of the swingan'n (1) Axle nut (2) Chain adjuster (3) Index mark (4) Stopper pin 75 NOTE: ' If the drive chain slack is excessive when the rear axle is moved to the furthest limit of adjustment, the drive chain is worn and must be replaced, 4. Turn the axle end bar to the lower edge of swing arm. Tighten the rear axle nut to: 93 N~m (9.5 kgf-rn . 69 Ibf~f0 [AW/\RNING t Its torque wrench is not used for this installation, see your Honda dealer as soon m possible to verify proper assembly. 5. Recheck chain slack 76 Lubricafion and cle u ncaltfedfvery 500 (300 miles) or sooner am appears TheO-iingsinthischaidiiycanbedamaged by steam clesuing, high pressure wshers, and certain solvents. Clean the side surfaces 01 the chain with a dry cloth. Do not brush the rubber O-riugs Bnishiug will damage them, Wipe dry and lubricate only with SAE or 90 gear oil Commercial chain lubri- cants may contain solvents which could damage the rubber!)- D. I. D 520VC5 or RK 520M029 Removal and Cleanin : When me We chain becomes dirty, it should be removed and cleaned prior to lubrication. 1. With the engine oil, carefully remove the master link retaining clip (1) with a pair of pliers, Do not bend or twist the clip, Remove the master link Remove the drive chain from the motorcycle 2. Clean the side surlaoes of the chain with a dry cloth Do not brush the rubber 0 rings. Brushing will damage them Use of a solvent may also damage the O-rings. Inspect the drive chain and clip for possible wear or damage. Replace any chain that has damaged rollers, loose fitting links. or otherwise appears unservioeable. AWARNWG t Never use petrol or law flash point solvents for cleaning the drive chain. A fire or explosion could result. 34 inspect the sprocket teeth for possible wear or damage. Replace it necessary, 4. Lubricate the drive chain (page 76). (1) Retaining clip 77 5‘ Pass the chain over the sprockets and join the ends oi the chain with the master link, For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link, The master link is the most critical part affecting the security of the drive chain, Master links are reusable, if they remain in excellent condition, but it is recommended that a new master link retaining clip be installed whenever the drive chain is reassembled. Install the master link retaining clip so that the closed end of the clip will face the direction of forward Wheel rotation. 6iAdjust the drive chain and rear brake pedal free play 78 BRAKE PAD WEAR (Refer to the maintenance premutions on page 59% Brake pad wear depends upon the severity of usage, the type of riding, and riding area conditions. (Generally, the pads will wear taster on wet and dirty riding terrain) Inspect the pads at each regular maintenance interim] (page 56). Front/Rear Brake Check the cutout ( l) in each pad‘ 11 either pad is worn to the cutout. replace both pads as a set See your Honda dealer for this service, (FRONT BRAKE> (1) (I) Cutout 79 WHEEL REMOVAL (Refer to the maintenance precautions on page 59). Front Wheel Removal 1. Raise the front wheel off the ground by placing a support block under the engine. 2‘ Remove the speedometer cable set screw (1) and disconnect the speedometer cable (2 )l 3. Loosen the axle holder nuts (3) 4, Unscrew the axle (4). Remove the wheel. N OT E: - Do not depress the brake lever when the wheel is off the motorcycle The mliper piston will be forced out of the cylinder with subsequent loss of brake fluid. If this occurs, servicing of the brake system will be necessary. See your Honda dealer for this service. (1) Screw (2) Speedometer cable (3) Axle holder nuts (4) Front axle ln§t_a gtion notes: C Reverse the removal procedure. 0 Insert the axle through the wheel hub and left fork leg, Make sure that the tang (5) on the speedometer gearbox is located behind the tang (6) on the right fork leg. 0 Tidlten the axle Axle torque: 74 Nm (7.5 kgf-m , 54 lbf-ft) (6) (5) (5) Tang (Speedometer gearbox) (6) Tang (right fork leg) 0 Tighten the upper axle holder nuts to the specified torque first, then tighten the lower axle holder nuts to same torque. Axle holder nut torque: 12 N-m (1,2 kgf-m ,9 Ibf-ft) 0 After installing the wheel‘ apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely. it If a torque wrench was not used {or installation, see your Honda dealer as soon as possible to verify proper as- sembly. Improper assembly may lead to loss of braking capacity. 81 Rear Wheel Removal 3. T urn both afiusters (2) so the rear wheel 1. Raise the rear wheel off the ground by an be moved all the way forward for placing a support block under the engine maximum drive chain slack 2. Loosen the rear axle nut (1) while 4 Move the rear wheel forward. Derail the holding the axle dnve chain from the driven sprocket 5. Mme the rear axle (3) back all the way to Elfiswingarmend. Pulldowntherear e. 6, Remove the rear wheel with the rear axle. (1) Rear axle nut (2) Adjusters (3) Rear axle NOTE: * Do not depress the brake pedal While the wheel is off the motorcycle. The caliper pistons will be forced out of the cylinders with subsequent loss of brake fluid. If this occurs. servicing of the brake system will be necessary. See your Honda dealer for this service Installation notes: 0To install the rear wheel, reverse the remowl procedure. 0 Make sure that the lug (4) on the brake caliper is located in the slot (5) in the swingarm (6). 0 Axle nut torque: 93 Nam (9.5 kgf-m , 69 lbf-fl) 0 Adjust the drive chain (page 73 ). 0 Apply the brake several times and check for free wheel rotation after the brake pedal is released. AWARNING tlfatorquewrenchwasnot used for installation, see your Honda dealer as soon as possible to verify proper as sembly. Impmper assembly my lead to loss of braking capacity. (5) (4) (4) Lug (5) Slot (6) Swi llgarm FRONT SUSPENSION (Refer to the maintenance precautions on page 59). ' Operating the motorcycle with loose, Check the [ark operation by locking the worn, or damaged steering or front front brake and pumping the forks up and suspension components may down several times The suspension should adversely affect vehicle handling and function smoothly. with no oil leakage from stability. the fork legs. Damaged, binding. or leaking * If any suspension components appear fork should be repaired before the worn or damaged, consult your motorcycle is operated. Check security of Honda dealer {or further inspection. allfork and handlebar mounting bolts (1). The suspension components are di- rectly related to safety and your Honda dealer is qualified to deter- mine whether or not replacement partsorrepairsareneeded. (1) Mounting bolts 84 REAR SUSPENSION (Refer to the maintenance precautions on page 59 )l Check the rear suspension periodically by careful visual examination Note the following items: 1. Swingarm bearings should be checked by pushing hard against the side of Ihe rear wheel. Free play indicates worn bearings. 2. Check all suspension component anachment points for security of their respective fasteners. 3. Check for oil leaks in the shock absorber units. ' If any suspension components appear worn or damaged, consult your Honda dealer for further inspecfion. The suspension components are di- rectly related to safety and your Honda dealer is qualified to deter- mine whether or not replacement parts orrepairsareneeded. WHEEL SPOKES (Refer to the maintenance precautions on page 59)‘ 1, Inspect the wheel rims (1) and spokes (2) for damage 2‘ T3ighten any loose spokes and rirn locks 3. Check wheel rim runout. If runout is noticeable, see your Honda dealer for inspection. (1) Wheel rim (2) Spoke 86 [AWARNWG ‘Maintemmce 0! spoke tension and wheel trilleness are may fslfe motorcyceoperatian. ' e inst 100 miles (150 Ian), spokes will loosen more rapidly due to initial seating of pans. mussiyely loose Sm]; STAND (Refer to the maintenance precautions on page 59). Check the rubber pad for deterioration and wear. Replace if wear extends to the wear line (See (1 ) in the picture), Check the side stand assembly for freedom of movement. If parts must be replaced, please contact your HONDA dealer. Replace if wear extends to any point of the wear line. (I) Wear line SIOPLIGHT SWITCH ADJUSTMENT (Refer to the maintenance precautions on page . 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 (Z ). (l) Stoplight switch (2) (2) Adjusting nut BULB REPLACEMENT (Refer to the maintenance premutions on page 59) IAWARMNG * The ligat hull) becomes very but while the light is ON, and remain hot for a While after it Is turned OFF. Be sure to let it cool down before servicing ' The hghting equipment 15 not legal for highway use. Do not operate this motorcycle on public streets, roads or highanS- N OTE: t Do not use bulbs other than that specified ' After installing a new bulb check that the light operates properly, Headlight Bulb 1 Remove the mounting bolts (1) and remove the headlight case (2 ) 2 Remove the two bolts (3) and remove the headlight (4% (1) Mounting bolts (2) Headlight use (3) 301: (4) Headlight 3, Pull back the rubber cover (5). 4‘ Install a new bulb in the reverse order of Remove the set spring (6) and disengage removal. the socket (7) from the headlight (8), NOTE: Slightly press the headlight bulb (9) and I When installing the bulb. align the tab on turn it counterclockwise, gledhsgfiket with the groove in the ea ' t. T? m (9) Headlight bulb (5) Rubber raver (7) Socket (6) Set Spring (8) Headlight 90 Stop/faillight Bulb L Remove the two screws (1). 2. Pull off the lens (2) and replace the bulb (3) with a new one (1) Screws (2) Lens (3) Bulb 91 Front/Rear Turn Signal Bulb 1 Remove the screw (1) and remove khe turn signal lens (2) 2.Sl.lgh tly press the bulb (3) and turn it counterclockwise. 3 Install a new bulb m the reverse order a! removal (2) (l) (1) Saw (3) Bulb (2) Turn signal lens 92 Lisenne Light Bbul 1 Remove the lisence light by removing the two mm (1) 2‘ Remove the lisence light cover (2) and lisence light socket (3) by removing the two nuts (4 ‘ 3. Pull out the bulbs (5), 4‘ Install a new bulb in the reverse order of removel‘ (1) Nuts (4) Nuts (2) Lisence light cover (5) Bulbs (3) Lisence light socket CLmNING Clean your motorcycle regularly to protect the surface finishes and inspect {or damage. wear, and oil 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: instruments Carburetor Muffler Outlet Wheel Hubs Under Fuel Tank Under Seat Brake Master Cylinders Drive Chain ,_i .After cleaning, rinse the motorcycle thoroughly with plenty 0! clean water. Strong detergent residue can corrode alloy parts. NOTE: 1| Clean the plastic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing it lrequently with lresh water. 94 2. Dry the motorcycle, start the engine, and let it mn for several minutes. ’Braking efficiency may be tempm rily impaired immediately after ‘ g the motorcycle. Anticipate longer stopping distance to avoid a possibleaccident. 3.‘l‘est the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking perfomlanoe. 4.Lubricate the drive chain immediately after washing and drying the motorcycle Exhaust Pipe Maintenance The exhaust pipe is stainless steel but may become stained by oil or mud If necessary, remove heat stains with a liquid kitchen abrasive. STORAGE GUIDE Extended storage. such as [or winter, requires that you take certain steps to reduce the effects of detefiorafion from non-use of the motorcycle. In addition, necessary repairs should be made BEFORE storing the motorcycle; otherwise, these repairs may be forgotten by the time the motorcycle is removed from stomge. STORAGE 1. Change the engine oil and clean the filter screen. 2. Drain the fuel tank and carburetor into an approved petrol container. Reinstall the fuel fill cap on the tank. NOTE: ' 1f storage will last more than one month. carburetor draining is very important, to assure proper performance after storage. 0 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 in the area where petrol is drained or stored and where the fuel tank is refueled. 3. To prevent rusting in the cylinder, perform the following: ' Remove the spark plug cap from the spark plug. Using tape or string. secure the cap to any convenient plastic body part so it is are positioned away from the spark plug. 0 Remove the spark plug from the engine and store it in a safe place. Do not connect the spark plug to the spark plug cap. ' Pour a tablespoon (15—20 cm“) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth. ' Crank the engine several times to distribute the oil. . Reinstall the spark plug and spark plug cap. 4. Wash and dry the motorcycle. Wax all painted surfaces Coat chrome with mstinhibiting oil, 5‘ Lubricate the drive chain (page 76). 6‘ Inflate the tyres to their recommended pressures, Place the motorcycle on blocks to raise both tyres ofl the ground. 7. 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 sunlight. REMOVAL FROM STORAGE 1. Uncover and clean the motorcycle. 2. Change the engine oil if more than 4 months have passed since the start 01 smrag e 3. Fill the fuel tank with fresh petrol 4 Perform all Preride Inspection checks (page 42). Test ride the motorcycle at low speeds in a sale riding area away from traffic. 97 SPECIFICATIONS DMENSIONS Overall length Overall width Overall height Wheelbase WEIGHT Dry weight CAPACITIES Engine oil Alter draining: Alter d 'ning l3}? oil filter change: After disassem Fuel tank Fuel reserve tank Passenger capacity Maximum weight capacity Front lurk oil capacity 2,155 mm (Stain) 820 mm (32.3 in) 1,245 mm (49.0 in) 1,410 mm (55.5 in) 112 kg (247 lbs) 1311 (1A US ql,1. 1Impq1) 1.4 011.5 US qt, 121mpqt) 1.7fl(1.8U5qt,1.rn5I pqt) 9‘0 ll (2. 38 US gal, 158p Imp gal) 2.0 ll (0.53 US gal, 0 44 Imp gal) Operator Only 100 kg (220 lbs) 477 cm3 (16,1 US oz, 16.8 Imp oz) ENGHVE Bore and stroke Compression ratio Displacement Spark plug Standard For cold climate (BelowS’C, 41°F) Spark plug 221) Valve clearance Intake: Exhaust: Idle speed CHASSIS AND SUSPENSION Caster Trail Tyre size. from Tyre size, rear Tyre pressure, front Tyre pressure, rear 73 X 59.5 mm (2.9 X 2.3 in) 10.2 : 1 249 cm“ (15.2 cu-in) CR9EH—9 (NGK) or U27FER9 (DENSO) CH8EHi9 (NGK? or U24FER9 (DENSO) 0.8—03 mm (0.03—004 in) 0.10 mm (0‘004 in) 0.12 mm (0.005 in) 1,300 i 100 min" (rpm) 24%5’ 92 mm (35 in) 3.00 - 21 51P “JD— 18 64P 150 kPa (1,5 kgf/cm’ , 22 psi) 125 kPa (1,25 kgf/cm‘, 18 psi) POWm TRANSMISSION Primary reducfion Final reduction Gear ratio. 151 2nd 3rd 4th 5th 6th ELECTRICAL Alternator LIGHTS Headlight Stop/Taillight Speedometer light High beam indicator Turn signal indicator Tum signal light Lisence light 100 3.100 3.000 2,769 1.941 10450 1 173 0 960 0 814 0.1“) kW/5,000 min" (rpm) 12V—35/35W 12V—21/5W 12V 3.4W 12V 1‘7W 12V 34W 12V 21W 12V 5Wx2 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH THE NOISE CONTROL SYSTEM IS 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, of any device or element of design incorpomted 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 oi design has been removed or rendered inoperative by any person. 101 oosmoxfiogo a; Kauai nv I)SOIS ‘0‘: fi 1:; / B a..3:....x§. 3...: is 5.3.3 ‘ 3...; 5.3.3 ...§.E.:§§ 5.x. 5.3.3.5; .13; m 5 x. 5.3%...” 3.15:3... 3:. 35.32.: S. momumx