03/05/20 09:55:46 31KCY680_001 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. Honda Motor Co., Ltd. 2003 03/05/20 09:55:49 31KCY680_002 2004 Honda XR400R OWNER’S MANUAL 03/05/20 09:55:54 31KCY680_003 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good judgment. You will find important safety information in a variety of forms, including: Safety Labels –– on the motorcycle. Safety Messages –– preceded by a safety alert symbol DANGER, WARNING, or CAUTION. These signal words mean: Safety Messages and one of three signal words: 03/05/20 09:56:01 31KCY680_004 A Few Words About Safety You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings –– such as Important Safety Reminders or Important Safety Precautions. Safety Section –– such as Motorcycle Safety. Instructions –– how to use this motorcycle correctly and safely. This entire book is filled with important safety information –– please read it carefully. Safety Messages 03/05/20 09:56:14 31KCY680_005 Contents These pages give an overview of the contents of your owner’s manual. The first page of each section lists the topics covered in that section. Basic Operation & Riding ........................ 27 How to start and stop the engine, shift gears, and brake. Also, riding precautions. Introduction Motorcycle Safety ..................................... Important safety information, precautions about loading, accessories, and modifications, and the location of safety labels. 1 Operating Controls ................................... 11 The location, function, and operation of the throttle, brakes, clutch, and other basic controls. Before Riding ............................................ 21 The importance of wearing a helmet and other protective gear, plus how to make sure you and your motorcycle are ready to ride. Contents Servicing Your Honda .............................. 41 Why your motorcycle needs regular maintenance, what you need to know before servicing your Honda, a maintenance schedule, and instructions for specific maintenance items. 03/05/20 09:56:25 31KCY680_006 Contents Tips ............................................................. 137 How to transport and store your motorcycle, and how to be an environmentally-responsible rider. Table of Contents ...................................... 180 Sequential listing of topics in this owner’s manual. Index ........................................................... 184 Taking Care of the Unexpected ............... 147 What to do if you have a flat tire, your engine won’t start, etc. Quick Reference Handy facts about fuel, engine oil, tire sizes, and air pressures. Technical Information.............................. 155 ID numbers, technical specifications, and other technical facts. Consumer Information ............................ 171 Information on warranties and how to get Honda service manuals. Contents 03/05/20 09:56:33 31KCY680_007 Introduction Congratulations on choosing your Honda offroad motorcycle. When you own a Honda, you’re part of a worldwide family of satisfied customers− people who appreciate Honda’s reputation for building quality into every product. Your Honda was designed as a recreational motorcycle for off-road use by one rider only. Before riding, take time to get acquainted with your motorcycle and how it works. To protect your investment, we urge you to take responsibility for keeping your motorcycle well maintained. Scheduled service is a must, of course. But it’s just as important to observe the break-in guidelines, and perform all the preride and other periodic checks detailed in this manual. Introduction We also recommend that you read the owner’s manual before you ride. It’s full of facts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a table of contents, a detailed list of topics at the beginning of each section, and an index at the back of the book. As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your Honda, other property, or the environment. Read the Warranties Booklet (page 175 ) thoroughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities. 03/05/20 09:56:39 31KCY680_008 Introduction Whenever you ride, tread lightly. By staying on established trails and riding only in approved areas, you help protect the environment and keep off-road riding areas open for the future. If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction. Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information. You may also want to visit our website at www.honda.com. Happy riding! Introduction 03/05/20 09:56:41 31KCY680_009 03/05/20 09:56:46 31KCY680_010 Motorcycle Safety This section presents some of the most important information and recommendations to help you ride your motorcycle safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your motorcycle. Important Safety Information ...........................2 Loading, Accessories & Modifications ............5 Loading .........................................................5 Accessories & Modifications........................7 Safety Labels.....................................................9 Motorcycle Safety 1 03/05/20 09:56:53 31KCY680_011 Important Safety Information Your motorcycle can provide many years of service and pleasure−if you take responsibility for your own safety and understand the challenges you can meet while riding. There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations throughout this manual. The following are a few that we consider most important. Always Wear a Helmet It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear (page 22 ). 2 Motorcycle Safety Never Carry a Passenger Your motorcycle is designed for one person only. There are no handholds, footrests, or seat for a second person−so never carry a passenger. A passenger could interfere with your ability to move around to maintain your balance and control of the motorcycle. Ride Off-Road Only Your motorcycle is designed and manufactured for off-road use only. The tires are not made for pavement, and the motorcycle does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your motorcycle across. 03/05/20 09:56:59 31KCY680_012 Important Safety Information Take Time to Learn and Practice Developing off-road riding skills is a gradual, step-by-step process. Start by practicing at low speeds in a safe area and slowly build your skills. Personal instruction from an experienced rider can also be valuable. If you need assistance, ask your dealer about riding groups in your area. Also be sure to read the Tips & Practice Guide f or the Of f -Highway Motorcyclist booklet that came with your motorcycle (USA only). Be Alert for Off-Road Hazards The terrain can present a variety of challenges when you ride off-road. Continually ‘‘read’’ the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards. Ride within Your Limits Pushing limits is another major cause of motorcycle accidents. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and ride safely. Motorcycle Safety 3 03/05/20 09:57:03 31KCY680_013 Important Safety Information Don’t Drink and Ride Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your motorcycle properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base. To help avoid problems, inspect your motorcycle before every ride and perform all recommended maintenance. 4 Motorcycle Safety 03/05/20 09:57:11 31KCY680_014 Loading, Accessories & Modifications Your Honda was designed as a rider-only motorcycle. It was not designed to carry a passenger or cargo. A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the motorcycle. In addition, exceeding the weight limits or carrying an unbalanced load can seriously affect your motorcycle’s handling, braking, and stability. Adding accessories or making modifications that change this motorcycle’s design and performance can also make it unsafe. Also, the weight of any accessories will reduce the maximum load the motorcycle can carry. More specific information on load limits, accessories, and modifications follows. Loading How much weight you put on your motorcycle, and how you load it, are important to your safety. If you decide to carry cargo, you should be aware of the following information. Overloading or carrying a passenger can cause a crash and you can be seriously hurt or killed. Follow all load limits and other loading guidelines in this manual. (cont’d) Motorcycle Safety 5 03/05/20 09:57:23 31KCY680_015 Loading, Accessories & Modifications Load Limits Following are the load limits for your motorcycle: Maximum weight capacity = 220 lbs (100 kg) Includes the weight of the rider and any accessories. Loading Guidelines As discussed on page 5 , we recommend that you do not carry any cargo on this motorcycle. However, if you decide to carry cargo, ride at reduced speeds and follow these commonsense guidelines: Keep cargo small and light. Make sure it cannot easily be caught on brush or other objects, and that it does not interfere with your ability to shift position to maintain balance and stability. 6 Motorcycle Safety Place weight as close to the center of the motorcycle as possible. Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebar, fork, or front fender. Make sure that all cargo is tied down securely. Never exceed the maximum weight limit. Check that both tires are inflated properly. 03/05/20 09:57:31 31KCY680_016 Loading, Accessories & Modifications Before you consider making any modifications or adding an accessory, be sure to read the following information. Accessories We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-Honda accessories. Check with your dealer for assistance and always follow this guideline: Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Make sure the accessory does not reduce ground clearance and lean angle, limit suspension travel or steering travel, alter your riding position, or interfere with operating any controls. Accessories & Modifications Modifying your motorcycle or using nonHonda accessories can make your motorcycle unsafe. Follow all instructions in this owner’s manual regarding modifications and accessories. (cont’d) Motorcycle Safety 7 03/05/20 09:57:36 31KCY680_017 Loading, Accessories & Modifications Modifications We strongly advise you not to remove any original equipment or modify your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycle’s handling, stability, and braking, making it unsafe to ride. We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark arrester or emission control system components) that would make the motorcycle illegal in your area. 8 Motorcycle Safety 03/05/20 09:57:46 31KCY680_018 Safety Labels This page shows the locations of safety labels on your motorcycle. Some labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your Honda dealer for a replacement. Motorcycle Safety 9 03/05/20 09:57:49 31KCY680_019 10 Motorcycle Safety 03/05/20 09:57:54 31KCY680_020 Operating Controls When you ride off-road, you need to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Read this section carefully before you ride. It describes the location, function, and operation of all the basic controls on your motorcycle. Component Locations .....................................12 Fuel Valve .......................................................15 Choke Lever ....................................................16 Engine Stop Button .........................................17 Front Brake Lever ...........................................17 Throttle ............................................................17 Clutch Lever....................................................17 Shift Lever ......................................................18 Rear Brake Pedal .............................................18 Kickstarter .......................................................18 Starter Decompressor Lever ...........................18 Side Stand .......................................................19 Tripmeter .........................................................19 Operating Controls 11 03/05/20 09:57:58 31KCY680_021 Component Locations engine stop button clutch lever starter decompressor lever 12 Operating Controls tripmeter front brake lever throttle 03/05/20 09:58:03 31KCY680_022 Component Locations fuel valve choke lever shift lever side stand Operating Controls 13 03/05/20 09:58:08 31KCY680_023 Component Locations kickstarter rear brake pedal 14 Operating Controls 03/05/20 09:58:17 31KCY680_024 Operating Controls ON Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. Fuel Valve ON OFF RES OFF Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor. The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor. RES Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor. (cont’d) Operating Controls 15 03/05/20 09:58:27 31KCY680_025 Operating Controls The reserve fuel supply is: 0.40 US gal (1.5 ) The tank should be refilled as soon as possible after switching to reserve, and the fuel valve should be returned to the ON position after refueling to avoid running out of fuel with no reserve. Choke Lever (1) Ｃ 16 Operating Controls ON Used to start a cold engine with air temperature below 35°C (95°F). DETENT Used to warm a cold engine immediately after starting with air temperature below 35°C (95°F). OFF Used for normal operation, for restarting a warm engine, or starting a cold engine with air temperature above 35°C (95°F). Ａ Ｂ (1) choke lever The choke lever is used for starting the engine (page 29 ). The choke increases the percentage of fuel in the fuel/air mixture delivered to the engine. (A) fully ON (B) detent position (C) fully OFF 03/05/20 09:58:36 31KCY680_026 Operating Controls Engine Stop Button Throttle The engine stop button is used to turn the engine off during normal riding situations. To operate, push the button in and hold it in until the engine stops completely. The throttle controls engine rpm (speed). To increase engine rpm, rotate the grip toward you. To reduce engine rpm, rotate the grip away from you. The throttle will automatically return to the closed position (engine idle) when you remove your hand. Front Brake Lever The front brake lever is used to slow or stop your motorcycle. To operate, pull the lever. For information on braking techniques, see page 37 . Clutch Lever The clutch lever is used to disengage the clutch whenever you shift gears. To operate, pull the clutch lever in all the way before shifting, then slowly release it after shifting. Operating Controls 17 03/05/20 09:58:46 31KCY680_027 Operating Controls Shift Lever Kickstarter The shift lever is used to select the next higher or lower gear in the transmission. To operate, raise the shift lever (after pulling in the clutch lever) to engage the next higher gear or depress the shift lever to engage the next lower gear. See Shif ting Gears, page 35 . The kickstarter is used to start the engine. To operate, swing the kickstarter out from its stored position and depress it through its entire stroke. See Starting Procedure, page 29 . Starter Decompressor Lever Rear Brake Pedal The rear brake pedal is used to slow or stop your motorcycle. To operate, depress the pedal. For information on braking techniques, see page 37 . 18 Operating Controls The starter decompressor lever may be used if you experience starting difficulties or to help restart the engine while your motorcycle is rolling downhill. To operate, pull the lever in. See Starter Decompressor Lever, page 32 . 03/05/20 09:58:56 31KCY680_028 Operating Controls FRONT Side Stand The side stand is used to support your motorcycle while parked (page 39 ). To operate, use your foot to lower the stand. Before riding, raise the stand. (2) Tripmeter FRONT (2) (2) tripmeter reset knob (1) The tripmeter ( 1 ) is used to record the distance traveled (USA: miles, Canada: kilometers) per trip or section of route. To operate, pull the tripmeter reset knob ( 2 ) out (OFF) and turn it until the meter shows all zeros ( 0 ), then push the knob in (ON). (1) tripmeter (2) tripmeter reset knob Operating Controls 19 03/05/20 09:58:58 31KCY680_029 20 Operating Controls 03/05/20 09:59:03 31KCY680_030 Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and how to perform the recommended pre-ride inspection of your Honda. Are You Ready to Ride？...............................22 Protective Apparel ......................................22 Is Your Motorcycle Ready to Ride？ .............24 Pre-ride Inspection ......................................24 Before Riding 21 03/05/20 09:59:13 31KCY680_031 Are You Ready to Ride? Before you ride your motorcycle for the first time, we strongly recommend that you: read this owner’s manual make sure you understand all the safety messages know how to operate all the controls Before each ride, we also suggest that you make sure you: are in good physical and mental condition are free of alcohol and drugs are wearing an approved motorcycle helmet (with chin strap tightened securely), eye protection, and other protective clothing 22 Before Riding Protective Apparel For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved jersey, shirt, or jacket whenever you ride. Although complete protection is not possible, wearing the proper gear can reduce the chance of injury when you ride. Following are suggestions to help you choose the proper gear. 03/05/20 09:59:23 31KCY680_032 Are You Ready to Ride? Not wearing a helmet increases the chance of serious injury or death in a crash. Be sure you always wear a helmet, eye protection and other protective apparel when you ride. Helmets and Eye Protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and have a chin strap that can be tightened securely. (USA only). Always wear a face shield or goggles to protect your eyes and help your vision. Additional Riding Gear In addition to a helmet and eye protection, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. Off-road motorcycle gloves to help protect your hands. Riding pants with knee and hip pads, a riding jersey with padded elbows, and a chest/ shoulder protector. An open-face helmet offers some protection, but a full-face helmet offers more. Regardless of the style, look for a DOT (Department of Transportation) sticker in any helmet you buy Before Riding 23 03/05/20 09:59:34 31KCY680_033 Is Your Motorcycle Ready to Ride? Before each ride, it’s important to inspect your motorcycle and make sure any problem you find is corrected. A pre-ride inspection is a must because off-road riding can be tough on a motorcycle and you don’t want to have a breakdown far from help. Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed. Always perform a pre-ride inspection before every ride and correct any problems. 24 Before Riding Pre-ride Inspection Check the following items before you get on the motorcycle: Tires Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damage or excessive wear (page 118 ). Spokes & Rims Make sure the spokes and rim locks are tight. Also check the rims for damage (page 112 ). Leaks Look under the motorcycle for signs of leaking fluids (fuel, engine oil, brake fluid). 03/05/20 09:59:52 31KCY680_034 Is Your Motorcycle Ready to Ride? Engine Oil Check the level and add oil if needed (page 67 ). Spark Plug & Cap Fuel Check the level and add fuel (page 61 ) if needed. Also make sure the fuel fill cap is securely fastened. Check these items after you get on the motorcycle: Drive Chain Check the condition and slack. Adjust and lubricate if needed. Also check the chain guide slider and slipper for wear and replace if needed (page 123 ). Cables Check the cable housings for wear. Check the fittings for looseness. Replace or tighten as needed. Nuts & Bolts Use a wrench to make sure all accessible nuts, bolts, and fasteners are tight. Check for looseness (page 84 ). Throttle Check the freeplay and adjust if needed. Rotate the throttle to make sure it moves smoothly without sticking, and snaps shut automatically when it is released, in all steering positions (page 77 ). Brakes Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally. Check for proper freeplay (page 107 ). (cont’d) Before Riding 25 03/05/20 09:59:59 31KCY680_035 Is Your Motorcycle Ready to Ride? Clutch Lever Check for smooth operation and adjust if needed (page 80 ). Headlight Check for proper operation. Remember, be sure to take care of any problem you find or have your Honda dealer correct it before you ride. 26 Before Riding 03/05/20 10:00:08 31KCY680_036 Basic Operation & Riding This section gives basic information on how to begin riding your motorcycle. It includes how to start and stop your engine, how to use the throttle, clutch, and brakes, and what to do when you’re through riding. For more advanced information−how to make turns, ride on hills, etc., see the Tips & Practice Guide f or the Of f -Highway Motorcyclist booklet that came with your Honda (USA only). Safe Riding Precautions..................................28 Starting & Stopping the Engine ......................29 Preparation ..................................................29 Starting Procedure.......................................29 Starter Decompressor Lever .......................32 Flooded Engine ...........................................33 How to Stop the Engine ..............................34 Shifting Gears .................................................35 Braking ............................................................37 Parking ............................................................39 Post-ride Inspection ........................................40 To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page 163 ). For information about carburetor adjustment for riding at high altitude, see page 164 . Basic Operation & Riding 27 03/05/20 10:00:15 31KCY680_037 Basic Operation & Riding Safe Riding Precautions Before riding your motorcycle for the first time, please review the Important Saf ety Inf ormation beginning on page 2 and the previous section, titled Bef ore Riding. Even if you have ridden other motorcycles, take time to become familiar with how this motorcycle works and handles. Practice in a safe area until you build up your skills and get accustomed to your motorcycle’s size and weight. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your motorcycle’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death. 28 Basic Operation & Riding 03/05/20 10:00:26 31KCY680_038 Starting & Stopping the Engine Always follow the proper starting procedure described below. Your motorcycle can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter. Starting Procedure To restart a warm engine, follow the procedure for High Air Temperature. Normal Air Temperature 10°−35°C (50°−95°F) Preparation (1) Make sure that the transmission is in neutral. Turn the fuel valve ON. Ａ Ｂ Ｃ (1) choke lever (A) fully ON (B) detent position (C) fully OFF 1. Pull the choke lever ( 1 ) up all the way to fully ON (A ). (cont’d) Basic Operation & Riding 29 03/05/20 10:00:35 31KCY680_039 Starting & Stopping the Engine 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. Allowing the kickstarter to snap back f reely against the pedal stop can damage the engine case. 4. Immediately after the engine starts, push the choke lever down to the detent position (B ). 30 Basic Operation & Riding 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 down all the way to fully OFF (C ). If idling is unstable, open the throttle slightly. 03/05/20 10:00:49 31KCY680_040 Starting & Stopping the Engine High Air Temperature 35°C (95°F) or above 1. 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 f ails to restart: 1. Pull the starter decompressor lever (page 32 ) in, open the throttle fully, and operate the kickstarter several times while pressing the engine stop button to clear the engine. Release the starter decompressor lever. 2. Start the engine (see step 3 under Normal Air Temperature). Low Air Temperature 10°C (50°F) or below 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 ) is pushed down all the way to fully OFF (C ). Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. Basic Operation & Riding 31 03/05/20 10:00:59 31KCY680_041 Starting & Stopping the Engine Starter Decompressor Lever An automatic engine decompression system is interlocked with the kickstarter to make starting easier, but if you have difficulty starting the engine, you may use the manually-operated starter decompressor lever. 1. With the throttle fully closed, push down lightly on the kickstarter until you feel some resistance. 2. Pull the starter decompressor lever ( 1 ) in and push the kickstarter down again slowly about 1/4 to 1/2 of a full stroke. 3. Release the starter decompressor lever and kickstart your motorcycle in the usual manner. The starter decompressor lever may also be used to help restart the engine while your motorcycle is rolling downhill. (1) (1) starter decompressor lever 32 Basic Operation & Riding 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. One of two things should happen. The engine will start−or the engine will not start and the rear tire will skid. 03/05/20 10:01:11 31KCY680_042 Starting & Stopping the Engine If the rear tire skids: Flooded Engine 3. Pull the starter decompressor lever in. This will release engine compression and allow the rear wheel to roll while turning the engine over. 4. Release the starter decompressor lever. 5. If the engine does not start, pull the starter decompressor lever in again. Wait until the motorcycle gains speed and release the lever. If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine: 1. Push the choke lever down all the way to OFF. 2. Pull and hold the starter decompressor lever. 3. Open the throttle fully. 4. While pushing the engine stop button, crank the engine several times with the kickstarter. 5. Release the starter decompressor lever and engine stop button. 6. Follow the High Air Temperature starting procedure (page 31 ). Basic Operation & Riding 33 03/05/20 10:01:16 31KCY680_043 Starting & Stopping the Engine How to Stop the Engine To stop the engine, shift into neutral, push the engine stop button in, and hold it in until the engine stops. 34 Basic Operation & Riding 03/05/20 10:01:26 31KCY680_044 Shifting Gears 2 3 4 5 1 Your motorcycle has five forward gears. 3. Depress the shift lever from neutral down to first gear. 4. Release the front brake. Gradually open the throttle while you slowly release the clutch lever. If engine rpm (speed) is too low when you release the clutch lever, the engine will stall. If engine rpm is too high or you release the clutch lever too quickly, your motorcycle may lurch forward. 5. When you attain a moderate speed, close the throttle, pull the clutch lever in, and raise the shift lever. After shifting, release the clutch lever and apply the throttle. To start riding, after the engine has been warmed and the side stand raised: 1. Close the throttle and pull the front brake lever in. 2. Pull the clutch lever all the way in. (cont’d) Basic Operation & Riding 35 03/05/20 10:01:35 31KCY680_045 Shifting Gears 6. To continue shifting up to each higher gear, repeat step 5 . 7. To shift down to a lower gear, close the throttle, pull the clutch lever in, and depress the shift lever. After shifting, release the clutch lever and apply the throttle. Remember to close the throttle and pull the clutch lever in completely before shifting. Improper shif ting may damage the engine, transmission, and drive train. Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high. Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm. 36 Basic Operation & Riding Downshifting can help slow your motorcycle, especially on downhills. However, downshifting when engine rpm is too high can cause engine damage. To prevent transmission damage, do not coast or tow the motorcycle for long distances with the engine off. 03/05/20 10:01:43 31KCY680_046 Braking To slow or stop, apply the front brake and rear brake smoothly, while downshifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. To prevent stalling the engine, pull the clutch lever in before coming to a complete stop. For support, put your left foot down first, then your right foot when you are through using the rear brake. For maximum braking, close the throttle and firmly apply the brake lever and pedal controls. Applying the brakes too hard may cause the wheels to lock and slide, reducing control of your motorcycle. If this happens, release the brake controls, steer straight ahead until you regain control, then reapply the brakes more gently. Generally, reduce your speed or complete braking before beginning a turn. Avoid braking or closing the throttle quickly while turning. Either action may cause one or both wheels to slip. Any wheel slip will reduce your control of your motorcycle. When riding in wet or raining conditions, or on loose surfaces, the ability to maneuver and stop will be reduced. All of your actions should be smooth under these conditions. Rapid acceleration, braking, or turning may cause loss of control. For your safety, exercise extreme caution when braking, accelerating, or turning. (cont’d) Basic Operation & Riding 37 03/05/20 10:01:47 31KCY680_047 Braking When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. When you brake to a stop, pull the clutch lever in before stopping completely to prevent stalling the engine. For support, put your left foot on the ground first, then your right foot when you’re through braking. 38 Basic Operation & Riding 03/05/20 10:01:51 31KCY680_048 Parking Lower the side stand to support your motorcycle. If you’re through riding for the day, also turn the fuel valve OFF. Always choose a level place to park. Basic Operation & Riding 39 03/05/20 10:01:56 31KCY680_049 Post-ride Inspection When you return home after riding, thoroughly clean your motorcycle and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way. After cleaning, carefully inspect your motorcycle for leaks or damage. Be sure to lubricate the drive chain (page 127 ) to prevent rusting. 40 Basic Operation & Riding 03/05/20 10:02:02 31KCY680_050 Servicing Your Honda Keeping your motorcycle well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your motorcycle in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good. Bef ore You Service Your Honda The Importance of Maintenance .....................43 Maintenance Safety.........................................45 Important Safety Precautions......................45 Maintenance Schedule ....................................47 Maintenance Record .......................................51 Competition Inspection ...................................52 For information about the exhaust emission and noise emission requirements of the U.S. Environmental Protection Agency (EPA) and the California Air Resources Board (CARB), see page 165 . Servicing Your Honda 41 03/05/20 10:02:07 31KCY680_051 Servicing Your Honda Service Preparations Component Locations .....................................55 Tools................................................................57 Side Cover Removal .......................................58 Air Cleaner Housing Cover Removal .............59 Seat Removal ..................................................60 Engine Throttle ............................................................77 Clutch System .................................................80 Engine Idle Speed ...........................................83 Spark Plug .......................................................84 Spark Arrester .................................................86 Service Procedures Chassis Suspension ......................................................88 Brakes............................................................107 Wheels ...........................................................112 Tires & Tubes................................................118 Side Stand .....................................................122 Drive Chain ...................................................123 Headlight & Taillight ....................................130 Fluids & Filters Fuel ..................................................................61 Engine Oil .......................................................64 Air Cleaner ......................................................73 Crankcase Breather (California only) .............76 Appearance Care ...........................................133 42 Servicing Your Honda 03/05/20 10:02:15 31KCY680_052 The Importance of Maintenance A well-maintained motorcycle is essential for safe, economical, and trouble-free riding. It will also help reduce air pollution. Careful preride inspections and good maintenance are especially important because your motorcycle is designed to be ridden over rough off-road terrain. To help you properly care for your motorcycle, this section of the manual provides a Maintenance Schedule. The service intervals in this schedule are based on average riding conditions. More frequent service is needed if you subject your motorcycle to severe use (see the Competition Inspection checklist, page 52 ) or ride in unusually wet or dusty areas. Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair. If your motorcycle overturns or is involved in a crash, be sure your Honda dealer inspects all major parts, even if you are able to make some repairs. Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. (cont’d) Servicing Your Honda 43 03/05/20 10:02:19 31KCY680_053 The Importance of Maintenance Remember, proper maintenance is the owner’s responsibility. Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section. 44 Servicing Your Honda 03/05/20 10:02:26 31KCY680_054 Maintenance Safety The maintenance section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Important Safety Precautions Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. (cont’d) Servicing Your Honda 45 03/05/20 10:02:31 31KCY680_055 Maintenance Safety Read the instructions before you begin, and make sure you have the tools and skills required. To help prevent the motorcycle from falling over, park it on a firm, level surface, using the side stand or a maintenance stand to provide support. To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a non-flammable (high flash point) solvent such as kerosene−not gasoline−to clean parts. Keep cigarettes, sparks, and flames away from all fuelrelated parts. 46 Servicing Your Honda 03/05/20 10:02:39 31KCY680_056 Maintenance Schedule To maintain the safety and reliability of your motorcycle, regular inspection and service is required as shown in the Maintenance Schedule that follows. The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment. Therefore, we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools. Procedures for items in this schedule are provided in a service manual available for purchase from your dealer (page 172 ). Because your motorcycle does not have an odometer, service intervals in the maintenance schedules are expressed in terms of riding days as well as miles. To avoid overlooking required service, we urge you to develop a convenient way to record the number of days and/or miles you ride. If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability. (cont’d) Servicing Your Honda 47 03/05/20 10:02:51 31KCY680_057 Maintenance Schedule Perform the pre-ride inspection (page 24 ) at each scheduled maintenance period. Summary of Maintenance Schedule Notes and Procedures: Each item on the maintenance schedule requires some mechanical knowledge. Certain items (particularly those marked ＊ and ＊＊) may require more technical information and tools. Consult your Honda dealer. NOTES: 1. Service more frequently when ridden in wet or dusty conditions. 2. California type only. 3. Replace every 2 years. Replacement requires mechanical skill. ＊ Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 172 ). ＊＊ In the interest of safety, we recommend these items be serviced only by your Honda dealer. 48 Servicing Your Honda Maintenance Procedures: I: inspect and clean, adjust, lubricate, or replace, if necessary C: clean A: adjust L: lubricate R: replace 03/05/20 10:03:12 31KCY680_058 Maintenance Schedule Frequency Items EMISSION RELATED ITEMS Fuel Line Fuel Strainer Screen Throttle Operation Air Cleaner Crankcase Breather Spark Plug Valve Clearance Engine Oil Engine Oil Filter Engine Oil Strainer Screen in Down Tube Decompressor System Engine Idle Speed Whichever Comes First mi km Month Note Initial Maint. 100 150 1 Note 1 Note 2 Regular Maint. Interval 600 1,000 6 I R R C I I I R R I I I I 1,200 2,000 12 I C I C I I I R R C 1,800 3,000 18 I I I I C I I I R R 2,400 4,000 24 I C I C I I I R R C Refer to page: I I − − 77 73 76 84 − 64 68 − − 83 ＊ Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 172 ). ＊＊ In the interest of safety, we recommend these items be serviced only by your Honda dealer. (cont’d) Servicing Your Honda 49 03/05/20 10:03:32 31KCY680_059 Maintenance Schedule Frequency Items NON−EMISSION RELATED ITEMS ＊ Drive Chain Drive Chain Slider Brake Fluid Brake Pad Wear Brake System Headlight Aim Clutch System Side Stand Suspension Spark Arrester Nuts, Bolts, Fasteners Wheels/Tires Steering Head Bearings Whichever Comes First mi km Month Note Note 1 Initial Maint. 100 150 1 I, L Note 3 I I I I I Regular Maint. Interval 600 1,000 6 1,200 2,000 12 1,800 3,000 18 2,400 4,000 24 I, L: every 300 mi (500 km) or 3 months I I I I I I I I I I I I I I I I I I I I I I I I I I C: every 1,000 mi (1,600 km) or every 100 operating hours I I I I I I I I Refer to page: 123 124 108 110 107 131 80 122 88 86 − 112, 118 − Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 172 ). In the interest of safety, we recommend these items be serviced only by your Honda dealer. ＊＊ 50 Servicing Your Honda 03/05/20 10:03:38 31KCY680_060 Maintenance Record Keeping an accurate maintenance record will help ensure that your motorcycle is properly maintained. Use the space under Notes to record anything you want to remind yourself about or mention to your dealer. Of course, if you find any problem while servicing your motorcycle, be sure it is corrected as soon as possible. Miles (km) or Months 600 (1,000) or 6 1,200 (2,000) or 12 1,800 (3,000) or 18 2,400 (4,000) or 24 3,000 (5,000) or 30 3,600 (6,000) or 36 4,200 (7,000) or 42 4,800 (8,000) or 48 5,400 (9,000) or 54 Date Performed By: Notes Servicing Your Honda 51 03/05/20 10:03:51 31KCY680_061 Competition Inspection All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools. Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda. NOTE: No Refer to the Maintenance Schedule (page 48 ) for regular service intervals. Item Inspect For: Action 2 3 4 5 6 all pre-ride inspection items engine oil fuel line valve clearance engine idle speed carburetor choke Refer to Page: 24 contaminants deterioration, damage, or leakage correct clearance correct idle speed proper operation change replace adjust adjust − 64 − − 83 − 52 Servicing Your Honda 1 03/05/20 10:04:03 31KCY680_062 Competition Inspection No Item Inspect For: Action 7 8 9 decompression mechanism clutch discs air cleaner proper freeplay proper operation, see NOTE 1 contamination or tears 10 spark plug gap, tightness, proper heat range, hightension terminal security 11 steering head bearings 12 front suspension 13 rear suspension free rotation of handlebar and steering stem nut tightness smooth operation, air pressure, oil capacity, no oil leaks, good boot condition smooth operation, no oil leaks, proper spring height adjust replace clean or replace tighten, replace or secure adjust or retighten replace or adjust replace or adjust Refer to Page: − − 73 85 − 88, 91 89, 98 NOTE 1: Competition use may cause more rapid clutch disc wear. Refer to the official Honda Service Manual, or see your Honda dealer for clutch disassembly and wear inspection. (cont’d) Servicing Your Honda 53 03/05/20 10:04:15 31KCY680_063 Competition Inspection No Item Inspect For: Action 14 15 smooth operation wear replace replace wear beyond service limit 67.2 in (1,707 mm) / 108 pins replace replace 110 125 18 swingarm bearings rear suspension linkage bushings brake pads drive chain: max. length/pin sprockets Refer to Page: 89 89 wear and secure installation 126 19 20 21 22 seat headlight tripmeter control cables 23 engine mounting bolts security proper beam aim proper operation smooth operation, kinks and correct routing tightness replace or tighten tighten adjust replace lubricate or replace tighten 16 17 54 Servicing Your Honda 60 130 19 − − 03/05/20 10:04:22 31KCY680_064 Component Locations clutch lever steering head oil filler cap/ dipstick rear suspension fuel tank air cleaner front brake hose left side cover front suspension chain slipper drive chain crankcase oil drain bolt frame oil drain bolt side stand crankcase breather tube plug (California only) rear wheel axle chain slider Servicing Your Honda 55 03/05/20 10:04:27 31KCY680_065 Component Locations kickstarter fuel fill cap throttle front brake lever spark plug lower clutch adjusting nut spark arrester front wheel axle chain adjuster rim lock 56 Servicing Your Honda carburetor rear brake pedal rim lock 03/05/20 10:04:33 31KCY680_066 Tools Refer to Saf ety Precautions on page 45 . (3) The multi-purpose wrench ( 1 ) in the tool bag (3 ) delivered with your motorcycle can be used to remove the spark plug. Some repairs, adjustments, and part replacements may be performed with this tool. You will need to provide your own tools to perform other owner maintenance. (2) (1) (1) multi-purpose wrench (2) plug wrench (3) tool bag Servicing Your Honda 57 03/05/20 10:04:44 31KCY680_067 Side Cover Removal Refer to Saf ety Precautions on page 45 . Removal 1. Remove the right seat bolt (page 60 ). 2. Use a hex wrench to remove the two bolts ( 1 ). 3. Pull the side cover out. RIGHT SIDE Installation 1. Slide the top of the side cover under the bottom edge of the seat. 2. Align the tabs to the cutout of the rear fender. 3. Install the securing bolts and tighten them. 4. Tighten the seat bolt. (1) (1) bolts 58 Servicing Your Honda Use the same procedure to remove and install the left side cover. 03/05/20 10:04:52 31KCY680_068 Air Cleaner Housing Cover Removal Refer to Saf ety Precautions on page 45 . The air cleaner housing cover must be removed to service the air cleaner. LEFT SIDE (1) Removal 1. Lift the D-ring on each quick-release fastener ( 1 ) and turn it counterclockwise until it releases. Installation 1. Align the air cleaner housing cover with the air cleaner housing. 2. Push each quick-release fastener into its slot, lift its D-ring, and turn it clockwise until it is secure. (1) quick release fastener Servicing Your Honda 59 03/05/20 10:05:04 31KCY680_069 Seat Removal Refer to Saf ety Precautions on page 45 . The seat must be removed to adjust rear suspension pre-load. (1) Removal 1. Remove the two bolts ( 1 ) securing the seat. 2. Slide the seat back. (2) (4) Installation 1. Align the locating slot (2 ) under the front of the seat with the pin ( 3 ) on the rear of the fuel tank. 2. Align the locating prongs ( 4 ) on the bottom of the seat with the hooks (5 ) on the frame. 3. Slide the seat into position. 4. Install the bolts and tighten them. (3) (5) (1) bolts (2) slot (3) pin (4) prongs (5) hooks 60 Servicing Your Honda 03/05/20 10:05:14 31KCY680_070 Fuel Refer to Saf ety Precautions on page 45 . Fuel Recommendation Type Pump Octane Number unleaded 91 (or higher) Your engine is designed to use any gasoline that has a pump octane number of 91 or higher. Gasoline pumps at service stations normally display the pump octane number. For information on the use of oxygenated fuels, see page 169 . If pinging or spark knock occurs at a steady engine speed under normal load, change brands of gasoline. If pinging or spark knock persists, consult your Honda dealer. We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt, dust, or water in the fuel tank. Use of lower octane gasoline can cause persistent ‘‘pinging’’ or ‘‘spark knock’’ (a louder rapping noise) which, if severe, can lead to engine damage. (Light pinging experienced while operating under a heavy load, such as climbing a hill, is no cause for concern.) Servicing Your Honda 61 03/05/20 10:05:26 31KCY680_071 Fuel 1. To open the fuel fill cap ( 1 ), pull the breather tube ( 2 ) out of the steering stem nut ( 3 ). Turn the fuel fill cap counterclockwise and remove it. 2. Add fuel until the level reaches the bottom of the filler neck ( 4 ). Avoid overfilling the tank. There should be no fuel in the filler neck. Refueling Procedure Fuel Tank Capacity, including reserve: 2.51 US gal (9.5 ) Reserve Capacity: 0.40 US gal (1.5 ) (2) (4) Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. (1) (3) (1) fuel fill cap (2) breather tube 62 (3) steering stem nut (4) filler neck Servicing Your Honda Stop the engine and keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately. 03/05/20 10:05:31 31KCY680_072 Fuel 3. After refueling, turn the fuel fill cap clockwise until it is secure. 4. Insert the breather tube in the steering stem nut. If you replace the fuel fill cap, use only a genuine Honda replacement part. Servicing Your Honda 63 03/05/20 10:05:40 31KCY680_073 Engine Oil Refer to Saf ety Precautions on page 45 . Oil Recommendation Using the proper oil, and regularly checking, adding, and changing oil will help extend your engine’s life. Even the best oil wears out. Changing oil helps get rid of dirt and deposits held in the engine. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine and transmission. API classification viscosity (weight) JASO T 903 standard suggested oil＊＊ 64 Servicing Your Honda SG or higher except oils labeled as energy conserving on the circular API service label SAE 20W-50＊/10W-40 MA Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil 03/05/20 10:05:52 31KCY680_074 Engine Oil ＊ For normal air temperatures. Use SAE 10W-40 when the outside temperature is below 0°C (32°F). See next page for additional temperature/viscosity information. ＊＊ Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label. Your motorcycle does not need oil additives. Use the recommended oil. Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation. Do not use API SH or higher oils displaying a circular API ‘‘energy conserving’’ service label on the container. They may affect lubrication and clutch performance. NOT RECOMMENDED OK Do not use non-detergent, vegetable, or castor based racing oils. Servicing Your Honda 65 03/05/20 10:06:00 31KCY680_075 Engine Oil Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard has the following classification on the oil container. (1) (2) (1) code number of the sales company of the oil (2) oil classification 66 Servicing Your Honda 03/05/20 10:06:12 31KCY680_076 Engine Oil Checking & Adding Oil FRONT (1) (2) (3) (1) oil filler cap/dipstick (2) UPPER level mark (3) LOWER level mark 1. Park your motorcycle on a firm, level surface. 2. Clean around the oil filler cap/dipstick ( 1 ) and nearby surfaces. 3. Start the engine and let it idle for 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 sufficiently may give an inaccurate (low) oil level reading. During idling, make sure your motorcycle is supported in an upright position to assure an accurate oil level reading. Stop the engine. 4. Immediately unscrew and remove the oil filler cap/dipstick. Wipe it clean. 5. Hold the motorcycle upright. 6. Insert the dipstick until it seats, but do not screw it in. 7. Remove the dipstick and check the oil level. If the oil is at or near the UPPER level mark ( 2 ), you do not have to add oil. If the oil is below or near the LOWER level mark ( 3 ), add the recommended oil until it reaches the UPPER level mark. (cont’d) (Do not overfill.) Servicing Your Honda 67 03/05/20 10:06:21 31KCY680_077 Engine Oil 8. Insert the dipstick and screw it in tightly. 9. Check for oil leaks. 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, install and tighten the bolt, start the engine and check the engine oil level. If the crankcase oil level is low, add the recommended engine oil before starting the engine to check the engine oil level. RIGHT SIDE (4) (4) check bolt 68 Servicing Your Honda Changing Engine Oil & Filter Your motorcycle’s oil filter has very specific performance requirements. Use a new genuine Honda oil filter specified for your model or a filter of equal quality. Using the wrong oil f ilter may result in leaks or premature engine damage. 03/05/20 10:06:33 31KCY680_078 Engine Oil Changing the oil requires a torque wrench. If you do not have it and the necessary skill, we recommend that you have your Honda dealer perform this service. If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly. FRONT LEFT SIDE (1) (1) drain bolt (down tube) (2) drain bolt (left crankcase) Drain the Engine Oil: 1. Park your motorcycle on a firm, level surface. 2. If the engine is cold, start it and let it idle for 3-5 minutes. Turn the engine off. Wait 2-3 minutes for the oil to settle. 3. Remove the oil filler cap/dipstick from the top of the frame. 4. Place a drain pan under the crankcase. 5. Remove the oil drain bolt ( 1 ) on the down tube, and the drain bolt ( 2 ) on the left crankcase. 6. After the oil has drained, check the sealing washers on the drain bolts. Replace, if necessary. (2) (cont’d) Servicing Your Honda 69 03/05/20 10:06:44 31KCY680_079 Engine Oil 7. Pour the drained oil into a suitable container and dispose of it in an approved manner (page 145 ). Install a New Engine Oil Filter: Improper disposal of drained f luids is harmf ul to the environment. 9. Remove the oil filter bolts ( 3 ) and oil filter cover ( 4 ). 8. Install the oil drain bolts and tighten to the specified torque: Crankcase drain bolt: 18 lbf·ft (25 N·m , 2.5 kgf·m) Frame drain bolt: 29 lbf·ft (39 N·m , 4.0 kgf·m) RIGHT SIDE Change the oil filter after draining the engine oil. (3) (4) (3) oil filter bolts (4) oil filter cover 70 Servicing Your Honda 03/05/20 10:06:54 31KCY680_080 Engine Oil 10. Remove the oil filter ( 5 ) from the cover. (6) (9) (5) oil filter (6) O-ring (7) spring (8) rubber seal (9) OUT-SIDE mark (5) (7) 13. Position the spring ( 7 ) against the engine crankcase and install a new oil filter with the rubber seal (8 ) facing out, away from the engine. You should see the ‘‘OUT-SIDE’’ mark (9 ) on the filter body, near the seal. Improper installation of the oil f ilter can cause serious engine damage. (8) 11. Discard the oil filter in an approved manner (page 145 ). 14. Reinstall the oil filter cover, making sure the bolts are tightened securely to the specified torque. Oil filter bolt: 9 lbf·ft (12 N·m , 1.2 kgf·m) Improper disposal of drained f luids is harmf ul to the environment. 12. Check that the oil filter cover O-ring (6 ) is in good condition. (cont’d) Servicing Your Honda 71 03/05/20 10:07:06 31KCY680_081 Engine Oil Add Engine Oil: If the oil filter was replaced: 1.9 US qt (1.8 ) If the oil filter was not replaced, use approximately: 1.8 US qt (1.7 ) 72 Servicing Your Honda To fill the oil tank to the upper level, oil should be added in two steps. 15. Pour the recommended oil into the oil tank, up to the upper level mark. 16. Install the oil filler cap/dipstick securely. 17. Start the engine. Let it idle 5 minutes. During idling, support your motorcycle in an upright position on a firm, level surface to assure an accurate oil level reading. 18. Stop the engine. Remove the oil filler cap/ dipstick. 19. Add the recommended oil up to the upper level mark. (Do not overfill.) 20. Reinstall the oil filler cap/dipstick. 21. Check for oil leaks. 03/05/20 10:07:14 31KCY680_082 Air Cleaner Refer to Saf ety Precautions on page 45 . Proper air cleaner maintenance is very important for off-road vehicles. A dirty, watersoaked, worn-out, or defective air cleaner will allow dirt, dust, mud, and other impurities to pass into the engine. Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions. Using the wrong air cleaner can result in premature engine damage. Proper air cleaner maintenance can prevent premature engine wear or damage, expensive repairs, low engine power, poor gas mileage, and spark plug fouling. Improper or lack of proper air cleaner maintenance can cause poor perf ormance and premature engine wear. Your motorcycle’s air cleaner has very specific performance requirements. Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality. Servicing Your Honda 73 03/05/20 10:07:24 31KCY680_083 Air Cleaner Cleaning LEFT SIDE (2) (1) (1) set spring (2) air cleaner 1. Remove the air cleaner housing cover (page 59 ). 2. Unhook the set spring ( 1 ). 3. Remove the air cleaner assembly (2 ). 4. Remove the air cleaner from its support. Wipe the support clean. 74 Servicing Your Honda 5. Gently wash the air cleaner in clean, nonflammable (high flash point) solvent such as kerosene−not gasoline. After cleaning, gently squeeze out the remaining solvent. Avoid twisting or wringing the air cleaner. This can tear the foam. 6. Inspect for tears or cracks in the foam or seams of the air cleaner. Replace the air cleaner if it is damaged. 7. Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil. 03/05/20 10:07:32 31KCY680_084 Air Cleaner 8. Pour clean Pro Honda Foam Filter Oil or an equivalent (Canada: Honda Foam Filter Oil or an equivalent) over the entire surface of the air cleaner. Use both hands to evenly spread the oil into the air cleaner. Gently squeeze out any excess oil. (To keep your hands dry, place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner.) 9. Install the air cleaner on its support. 10. Apply a thin coat of grease to the sealing surface of the air cleaner assembly. 11. Install the air cleaner with the lug on the holder aligned with the hole in the air cleaner. 12. Hook the set spring. 13. Install the air cleaner housing cover. Servicing Your Honda 75 03/05/20 10:07:39 31KCY680_085 Crankcase Breather (California only) Refer to Saf ety Precautions on page 45 . Service more frequently if your motorcycle is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube. LEFT SIDE (1) (1) crankcase breather tube plug 76 Servicing Your Honda 1. Remove the crankcase breather tube plug ( 1 ) from the tube and drain deposits. 2. Reinstall the crankcase breather tube plug. 03/05/20 10:07:52 31KCY680_086 Throttle Refer to Saf ety Precautions on page 45 . Throttle Freeplay Upper Adjustment Minor adjustments are generally made with the upper adjuster. RIGHT SIDE RIGHT SIDE (1) (2) (3) (1) (1) freeplay Inspection Check freeplay ( 1 ). Freeplay: 1/16−1/4 in (2−6 mm) If necessary, adjust to the specified range. (1) rubber dust cover (2) upper lock nut (3) upper adjuster 1. Pull the rubber dust cover ( 1 ) back. 2. Loosen the upper lock nut ( 2 ) on the throttle cable mechanism. 3. Turn the upper adjuster ( 3 ). (cont’d) Servicing Your Honda 77 03/05/20 10:08:03 31KCY680_087 Throttle 4. Tighten the lock nut. Return the dust cover to its normal position. 5. After adjustment, check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions. Lower Adjustment The lower adjuster is used for major freeplay adjustment, such as after replacing the throttle cables or removing the carburetor. It is also used if you can not get the proper adjustment with the upper adjuster. LEFT SIDE (5) (4) (4) lower lock nut (5) lower adjuster 1. Loosen the lower lock nut ( 4 ) on the cable. 2. Turn the lower adjuster ( 5 ). 3. Tighten the lock nut on the adjuster. If you can’t get the freeplay within the specified range, contact your Honda dealer. 78 Servicing Your Honda 03/05/20 10:08:12 31KCY680_088 Throttle Throttle Inspection (1) (2) 3. Inspect the condition of the throttle cables ( 2 ) from the throttle grip down to the carburetor. If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commerciallyavailable cable lubricant to prevent premature rust and corrosion. (1) throttle (2) throttle cables 1. Check that the throttle assembly is positioned properly and the securing bolts are tight. 2. Check for smooth rotation of the throttle ( 1 ) from fully open to fully closed in all steering positions. If there is a problem, see your Honda dealer. Servicing Your Honda 79 03/05/20 10:08:26 31KCY680_089 Clutch System Refer to Saf ety Precautions on page 45 . Clutch Freeplay LEFT SIDE Upper Adjustment Minor adjustments are generally made with the upper clutch cable adjuster. LEFT SIDE (1) (3) (4) (2) (−) (＋) (1) clutch lever Inspection Check freeplay. Freeplay: 3/8−13/16 in (10−20 mm) If necessary, adjust to the specified range. Improper freeplay adjustment can cause premature clutch wear. 80 Servicing Your Honda (2) dust cover (＋) increase freeplay (3) upper lock nut (−) decrease freeplay (4) upper clutch cable adjuster 1. Pull the rubber dust cover (2 ) back. 2. Loosen the upper lock nut ( 3 ). 3. Turn the upper clutch cable adjuster ( 4 ) to obtain the specified freeplay. 03/05/20 10:08:38 31KCY680_090 Clutch System 4. Tighten the lock nut and check the freeplay again. Lower Adjustment The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out near its limit−or the correct freeplay cannot be obtained. RIGHT SIDE (6) (＋) 1. Loosen the upper lock nut ( 3 ) and turn the upper clutch cable adjuster ( 4 ) all the way in (to provide maximum freeplay). 2. Tighten the upper lock nut and pull the dust cover ( 2 ) back to its normal position. 3. Hold the lower adjusting nut ( 5 ) and loosen the lower lock nut ( 6 ) at the lower end of the cable. 4. Turn the lower adjusting nut to obtain the specified freeplay. 5. Hold the lower adjusting nut and tighten the lower lock nut. Check the adjustment. (5) (−) (5) lower adjusting nut (6) lower lock nut (＋) increase freeplay (−) decrease freeplay (cont’d) Servicing Your Honda 81 03/05/20 10:08:46 31KCY680_091 Clutch System 6. Start the engine, pull the clutch lever in, 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. Your motorcycle should move smoothly and accelerate gradually. If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the official Honda Service Manual (page 172 ). 82 Servicing Your Honda Other Inspections & Lubrication Check that the clutch lever assembly is positioned properly and the securing bolts are tight. Check the clutch cable for kinks or signs of wear. If necessary, have it replaced. Lubricate the clutch cable with a commercially-available cable lubricant to prevent premature wear and corrosion. 03/05/20 10:08:57 31KCY680_092 Engine Idle Speed Refer to Saf ety Precautions on page 45 . LEFT SIDE (1) 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 The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-and-go riding is sufficient. (＋) increase rpm (−) decrease rpm 1. Warm up the engine, shift to neutral and place the motorcycle on its stand. 2. Connect a tachometer, following the tachometer manufacturer’s instructions. 3. Adjust idle speed with the throttle stop screw ( 1 ). Idle Speed: 1,300 ± 100 rpm Servicing Your Honda 83 03/05/20 10:09:07 31KCY680_093 Spark Plug Refer to Saf ety Precautions on page 45 . Use only the recommended type of spark plugs in the recommended heat range. Spark Plug Recommendation The recommended standard spark plug is satisfactory for most riding conditions. However, if you plan to ride for extended periods at high speeds or near maximum power (high engine rpm) in hot climates, or plan extended riding in cold climates, a different plug may be recommended. Standard For extended high speed riding DPR8Z (NGK) or X24GPR-U (DENSO) DPR9Z (NGK) or X27GPR-U (DENSO) Using spark plugs with an improper heat range can cause engine damage. (3) (2) (4) (1) (1) multi-purpose wrench (2) center electrode (3) side electrode (4) spark plug gap 1. Clean any dirt from around the spark plug base. 84 Servicing Your Honda 03/05/20 10:09:18 31KCY680_094 Spark Plug 2. Disconnect the spark plug cap. 3. Remove the spark plug with the multipurpose wrench ( 1 ) provided with your motorcycle. 4. Inspect the spark plug electrodes for wear. The center electrode ( 2 ) should have square edges. The side electrode ( 3 ) should not be eroded. The insulator should not be cracked or chipped. 5. Check the spark plug gap ( 4 ), using a wiretype feeler gauge. If adjustment is necessary, bend the side electrode carefully. The gap should be: 0.024−0.028 in (0.60−0.70 mm) Make sure the plug washer is in good condition. If you have to install a new plug, first check the gap. 6. With the plug washer attached, thread the spark plug in by hand (to prevent crossthreading). 7. Tighten the spark plug: about 1/8-1/4 turn after it seats (if the old plug is good). about 1/2 turn after it seats (if installing a new plug). Improperly tightened spark plugs can damage the engine. Too loose, you can burn a piston. Too tight, you can damage the threads. Servicing Your Honda 85 03/05/20 10:09:28 31KCY680_095 Spark Arrester Refer to Saf ety Precautions on page 45 . RIGHT REAR (1) (3) The spark arrester must be serviced every 100 operating hours to maintain its efficiency. Regular servicing prevents carbon buildup (which can diminish engine performance) and also complies with USDA regulations for regular maintenance to assure proper function. The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment. (4) (2) (1) spark arrester (2) bolts (3) gasket (4) muffler 1. Allow the engine and muffler to cool. 2. Remove the three bolts ( 2 ), the spark arrester ( 1 ), and the gasket ( 3 ) from the muffler ( 4 ). 86 Servicing Your Honda 03/05/20 10:09:34 31KCY680_096 Spark Arrester 3. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary. 4. Install the spark arrester and the gasket in the muffler and tighten the three bolts securely. Servicing Your Honda 87 03/05/20 10:09:42 31KCY680_097 Suspension Refer to Saf ety Precautions on page 45 . Front Suspension Inspection Loose, worn, or damaged suspension components may adversely affect the handling and stability of your motorcycle. If any suspension components appear worn or damaged, see your Honda dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts or repairs are needed. FRONT (1) (1) (1) (1) mounting bolts 1. Check fork operation. Pull the front brake lever in, to lock the brake. Then pump up and down on the fork legs several times. The suspension should function smoothly. There should be no oil leakage. 88 Servicing Your Honda 03/05/20 10:09:51 31KCY680_098 Suspension 2. Check the security of all handlebar and fork mounting bolts ( 1 ). If any front suspension components appear worn or damaged, see your Honda dealer for further inspection. RIGHT SIDE (2) Rear Suspension Inspection LEFT SIDE (1) (1) (3) (1) swingarm bearing (2) shock absorber attachment points (3) suspension linkage attachment points 1. Place the motorcycle on a maintenance stand. Push hard against the side of the rear wheel and feel for any freeplay which indicates worn swingarm bearings ( 1 ). (1) swingarm bearing (cont’d) Servicing Your Honda 89 03/05/20 10:09:56 31KCY680_099 Suspension 2. Check that the fasteners for the shock absorber attachment points ( 2 ) and rear suspension linkage attachment points ( 3 ) are secure. 3. Check for oil leaks in the shock absorber. If any rear suspension components appear worn or damaged, see your Honda dealer for further inspection. 90 Servicing Your Honda 03/05/20 10:10:09 31KCY680_100 Suspension Condition Front Suspension Adjustment The front suspension can be adjusted for the rider’s weight and riding conditions by changing the oil volume and the rebound and compression damping. Use the following chart to determine the correct adjustment for you. Entire range of travel is too hard. Entire range of travel is too soft (bottoming). Initial travel is good, but the final stages of travel are too soft (bottoming). The initial stages of travel are good, but the final stages are hard. The initial stages of travel are too soft, but the final stages are good. The initial stages of travel are too hard, but the final stages are good. Oil Rebound. Comp. Volume Damp. Damp. − softer softer − stiffer stiffer increase − − reduce − − reduce stiffer stiffer increase softer softer Servicing Your Honda 91 03/05/20 10:10:15 31KCY680_101 Suspension FRONT Front Suspension Air Pressure (2) The standard air pressure is 0 psi (0 kPa, 0 kgf/cm2). You may relieve accumulated air pressure in the fork legs by using the pressure release screws. The front wheel should be off the ground before you release the pressure. (1) (1) pressure release screws (2) fork caps 92 Servicing Your Honda 03/05/20 10:10:25 31KCY680_102 Suspension 1. Raise the front wheel off the ground by placing a support block under the engine. 2. Remove the pressure release screws ( 1 ). 3. Check that the O-ring is in good condition. 4. Install the pressure release screws. Front Suspension Oil Volume (1) (1) fork caps (2) (2) oil level (cont’d) Servicing Your Honda 93 03/05/20 10:10:36 31KCY680_103 Suspension Low oil levels provide a soft ride. Use a low oil level for easy terrain and smooth riding conditions. High oil levels provide a firm ride. Use a high oil level for heavy loads and rough riding conditions. 1. Raise the front wheel off the ground by placing a support block under the engine. 2. Remove the pressure release screws to release any accumulated air pressure. 3. Remove the fork caps ( 1 ) and springs from the fork tubes. Inspect the O-rings on the fork caps and replace them if they are damaged. The fork caps are under extreme spring pressure. Use care when removing the caps and wear eye and face protection. 94 Servicing Your Honda 4. Compress the fork all the way and measure the oil level (2 ) from the top of the tubes. Standard oil level: 4.6 in (116 mm) To lower the oil level (decrease volume), use a syringe. Add oil with a graduated beaker for accurate measurements. The recommended oil level range is: 3.4−5.1 in (87−129 mm) Increase or decrease oil in increments of: 0.08 US oz (2.5 cm ) 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. 03/05/20 10:10:45 31KCY680_104 Suspension 5. Be sure the oil level is the same in both fork tubes. 6. Clean and dry the fork springs with a lintfree cloth. Install the fork springs. Oil the fork cap O-rings and install the fork caps. Torque the fork caps to: 16 lbf·ft (22 N·m , 2.2 kgf·m) Front Suspension Damping Rebound Damping The rebound damping adjuster has at least 12 positions. Turning the adjuster screw one full turn advances the adjuster 6 positions. Always start with the full hard position when adjusting damping. (cont’d) Servicing Your Honda 95 03/05/20 10:10:52 31KCY680_105 Suspension 1. Turn the adjuster ( 1 ) clockwise until it will no longer turn (lightly seats). This is the full hard position. 2. Turn the adjuster counterclockwise 3 clicks until the punch mark ( 2 ) on the adjuster aligns with the reference mark ( 3 ). 3. Make sure that both fork legs are adjusted to the same position. To adjust to the standard position: (3) (2) (1) (1) rebound damping adjuster (2) punch mark (3) reference mark 96 Servicing Your Honda 03/05/20 10:11:02 31KCY680_106 Suspension Compression Damping Compression damping affects how quickly the fork compresses. The fork compression damping adjuster has at least 14 positions (clicks). Turning the adjuster screw one full turn advances the adjuster 4 positions. To adjust to the standard position: LEFT FRONT (1) Always start with the full hard position when adjusting damping. (1) compression damping adjuster (cont’d) Servicing Your Honda 97 03/05/20 10:11:09 31KCY680_107 Suspension 1. Turn the adjuster ( 1 ) clockwise until it will no longer turn (lightly seats). This is the full hard position. 2. Turn the adjuster counterclockwise 8 clicks. This is the standard position. 3. Make sure that both fork legs are adjusted to the same position. Rear Suspension Adjustment The rear suspension can be adjusted for the rider’s weight and riding conditions by changing the spring pre-load and the rebound and compression damping. Use the following chart to determine the correct adjustment for you. The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assembly only. 98 Servicing Your Honda 03/05/20 10:11:24 31KCY680_108 Suspension Condition Bottoming Step 1 shorten the spring length (to increase preload) Soft turn the compression adjuster to a stiffer position (to increase damping force) increase the spring length (to decrease preload) Hard Excessive Sinking Step 2 turn the compression adjuster to a stiffer position (to increase damping force) shorten the spring length (to increase preload) turn the compression adjuster to a softer position (to decrease damping force) Step 3 turn the rebound adjuster to a stiffer position (to increase damping force) turn the rebound adjuster to a softer position (to decrease damping force) shorten the spring length (to increase preload) Make changes one step at a time. Test ride your motorcycle after each adjustment. If necessary, proceed to the next step. Servicing Your Honda 99 03/05/20 10:11:34 31KCY680_109 Suspension Rear Suspension Spring Pre-Load Pre-load should be adjusted when the engine is cold because it is necessary to remove the muffler. RIGHT SIDE (4) (2) (3) An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre-load. 1. Remove the seat (page 60 ). 2. Remove the right side cover (page 58 ). 3. Remove the muffler by loosening the muffler clamp bolt ( 2 ) and removing the lower ( 3 ) and upper muffler bolts ( 4 ). Pull the muffler away from the exhaust pipe. 100 Servicing Your Honda (1) (1) side cover bolts (2) muffler clamp bolt (3) muffler bolt (lower) (4) muffler bolt (upper) 03/05/20 10:11:42 31KCY680_110 Suspension 4. Loosen the screw (5 ) on the air cleaner connecting tube clamp and remove the air cleaner connecting tube from the carburetor. 5. Disconnect the electrical connectors (6 ). (10) (7) (6) Be careful not to allow dust into the carburetor. Severe engine damage could result. RIGHT SIDE (8) (9) (5) (6) electrical connectors (7) rubber band and clip (9) subframe lower side bolt (10) subframe upper bolt (5) screw (8) subframe lower side bolt (cont’d) Servicing Your Honda 101 03/05/20 10:11:52 31KCY680_111 Suspension 6. Loosen the rubber band and clip ( 7 ). 7. Remove the three subframe mounting bolts ( 8 ) ( 9 ) (10 ). 8. Remove the subframe by pulling it straight back. 9. Raise the rear wheel off the ground by placing a support block under the engine. 10. Measure the spring length ( 1 ). Standard: 8.36 in (212.3 mm) Minimum: 8.08 in (205.3 mm) Maximum: 8.56 in (217.3 mm) (−) (1) (2) (＋) (3) (1) spring length (2) lock nut (3) adjusting nut 102 Servicing Your Honda (＋) increase preload (−) decrease preload 03/05/20 10:12:03 31KCY680_112 Suspension 11. To increase spring pre-load: Loosen the lock nut ( 2 ) with the optional pin spanner and turn the adjusting nut ( 3 ) to shorten the spring length. Do not shorten to less than: 8.08 in (205.3 mm) (2) To decrease spring pre-load: Loosen the lock nut ( 2 ) with the optional pin spanner and turn the adjusting nut ( 3 ) to increase the spring length. Do not increase to more than: 8.56 in (217.3 mm) Each turn of the adjuster changes spring length and spring pre-load. One turn equals: spring length/spring pre-load: 0.06 in (1.5 mm) / 33.1 lbs (15.0 kg) 12. Tighten the lock nut and install the removed parts. (3) (2) lock nut (3) adjusting nut (cont’d) Servicing Your Honda 103 03/05/20 10:12:16 31KCY680_113 Suspension To install the removed parts: 1. Install the subframe. Tighten the three bolts to the specified torque: Subframe upper bolt (10 ): 20 lbf·ft (26 N·m , 2.7 kgf·m) Subframe lower side bolts ( 8 ) ( 9 ): 31 lbf·ft (42 N·m , 4.3 kgf·m) If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly. 2. Connect the electrical connectors by matching the cable colors. 3. Reinstall the band and the clip. 4. Tighten the air cleaner connecting tube clamp and the rear brake fluid reservoir stay mount bolt. 104 Servicing Your Honda 5. Install the muffler and tighten the bolts. Be careful not to damage the packing installed inside the muffler clamp. Tighten to the specified torque: Muffler clamp bolt (2 ): 14 lbf·ft (20 N·m , 2.0 kgf·m) Muffler bolt (lower) ( 3 ): 24 lbf·ft (32 N·m , 3.3 kgf·m) Muffler bolt (upper) (4 ): 24 lbf·ft (32 N·m , 3.3 kgf·m) If a torque wrench is not used for installation, see your Honda dealer as soon as possible to verify proper assembly. 6. Reinstall the side cover and seat. 03/05/20 10:12:27 31KCY680_114 Suspension To adjust to the standard position: Rear Suspension Damping Rebound Damping The rebound damping adjuster is located at the lower end of the shock absorber. It has at least 16 positions. Turning the adjuster one full turn advances the adjuster 4 positions. To avoid damage to the damping adjuster, do not keep it in the full hard position. LEFT SIDE (3) (2) (1) (1) rebound damping adjuster (2) punch mark (3) reference mark 1. Turn the adjuster ( 1 ) clockwise until it will no longer turn (lightly seats). This is the full hard position. 2. Turn the adjuster counterclockwise 10 clicks until the punch mark (2 ) on the adjuster aligns with the reference mark ( 3 ) at the lower end of the shock absorber. (cont’d) Servicing Your Honda 105 03/05/20 10:12:35 31KCY680_115 Suspension Compression Damping The compression damping adjuster has at least 14 positions. Turning the adjuster one full turn advances the adjuster 6 positions. To adjust to the standard position: LEFT SIDE (1) (3) (2) (1) compression damping adjuster (2) punch mark (3) reference mark 106 Servicing Your Honda 1. Turn the adjuster ( 1 ) counterclockwise until it will no longer turn (lightly seats). This is the full soft position. 2. Turn the adjuster clockwise 12 clicks until the punch mark ( 2 ) on the adjuster aligns with the reference mark ( 3 ). 03/05/20 10:12:46 31KCY680_116 Brakes Refer to Saf ety Precautions on page 45 . Front Brake Lever Adjustment Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop. RIGHT SIDE (2) (3) (1) Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect the brake fluid level and the brake pads for wear. If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding, check the brake pads. If they are not worn beyond the recommended limit (page 110 ), there is probably air in the brake system. See your Honda dealer to have the air bled from the system. (1) front brake lever (2) lock nut (3) adjuster Never use adjusters other than those designed for this motorcycle. Install a new adjuster from the lever side with the lock nut under the head of the adjuster. (cont’d) Servicing Your Honda 107 03/05/20 10:12:56 31KCY680_117 Brakes 1. Loosen the lock nut (2 ). 2. To position the brake lever farther away from the handgrip, turn the adjuster ( 3 ) clockwise. To position the brake lever closer to the handgrip, turn the adjuster counterclockwise. 3. Tighten the lock nut. 4. Apply the brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times. 5. Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage. Freeplay: 3/8−13/16 in (10−20 mm) If brake lever freeplay is not within this range, see your Honda dealer. 108 Servicing Your Honda Fluid Level Inspection Front Brake Fluid Level RIGHT HANDLEBAR (1) (1) LOWER level mark With the motorcycle in an upright position, check the fluid level. It should be above the LOWER level mark ( 1 ). If the level is at or below the LOWER level mark, check the brake pads for wear (page 110 ). 03/05/20 10:13:09 31KCY680_118 Brakes Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an equivalent. With the motorcycle in an upright position, check the fluid level. It should be between the UPPER ( 1 ) and LOWER ( 2 ) level mark. If the level is at or below the LOWER level mark, check the brake pads for wear (page 110 ). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. Rear Brake Fluid Level RIGHT SIDE (1) (2) The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an equivalent. Other Inspections Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. (1) UPPER level mark (2) LOWER level mark Servicing Your Honda 109 03/05/20 10:13:19 31KCY680_119 Brakes RIGHT REAR Brake Pad Wear Brake pad wear depends on the severity of usage, the type of riding, and riding area conditions. (Generally, the pads will wear faster on wet and dirty riding terrain.) Inspect the pads at each regular maintenance interval (page 50 ). (2) (3) (2) cutout (3) rear brake caliper LEFT FRONT (1) Check the cutout ( 2 ) in each pad. If either pad is worn to the cutout, replace both pads as a set. See your Honda dealer for this service. Other Inspections (2) (1) front brake caliper (2) cutout 110 Servicing Your Honda Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight. 03/05/20 10:13:24 31KCY680_120 Brakes More About: Brake Fluid Brake fluid should be added and replaced by your Honda dealer. The recommended brake fluid is Honda DOT 4 Brake Fluid, or any brake fluid of equal equality and performance. Use fresh brake fluid from a sealed container. Servicing Your Honda 111 03/05/20 10:13:33 31KCY680_121 Wheels Refer to Saf ety Precautions on page 45 . Wheel Rims & Spokes Maintenance of spoke tension and wheel trueness (roundness) is critical to safe motorcycle operation. During the first 100 miles (150 km), spokes will loosen more rapidly due to the initial seating of the parts. Excessively loose spokes may result in instability at high speeds and the possible loss of control. It’s also important that the rim locks are secure to prevent tire slippage. It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule. However, information for wheel removal is provided for emergency situations. REAR (1) (2) (3) (1) wheel rim (2) spoke (3) rim lock 1. Inspect the wheel rims ( 1 ) and spokes ( 2 ) for damage. 2. Tighten any loose spokes or rim locks ( 3 ). 112 Servicing Your Honda 03/05/20 10:13:46 31KCY680_122 Wheels 3. Rotate the wheel slowly to see if it appears to ‘‘wobble.’’ If it does, the rim is out of round or not ‘‘true.’’ If the wobble is noticeable, see your Honda dealer for inspection. Front Wheel Removal RIGHT FRONT (2) (1) (3) (3) (5) (4) (3) (3) (1) tripmeter cable set screw (2) tripmeter cable (3) axle holder nuts Removal 1. Raise the front wheel off the ground by placing a maintenance stand or support block under the engine. Secure the rear of the motorcycle with tie-down straps. 2. Remove the tripmeter cable set screw ( 1 ) and disconnect the tripmeter cable ( 2 ). 3. Remove the front axle holder nuts ( 3 ) and the front axle holder ( 4 ). 4. Unscrew and remove the axle ( 5 ). Remove the wheel. Avoid depressing the brake lever and brake pedal when the wheel is off the motorcycle. This will force the caliper pistons out of the cylinders. The result will be loss of brake fluid. If this occurs, the brake system will require service. See your Honda dealer for this service. (4) axle holder (5) front axle (cont’d) Servicing Your Honda 113 03/05/20 10:13:56 31KCY680_123 Wheels Installation RIGHT FRONT (6) (7) (8) (6) tang (7) tang (8) UP mark 1. Reverse the removal procedure. Insert the axle through the wheel hub and left fork leg. Make sure the tang ( 6 ) on the tripmeter gearbox is located behind the tang ( 7 ) on the right fork leg. 114 Servicing Your Honda 2. Torque the axle to: 65 lbf·ft (88 N·m , 9.0 kgf·m) 3. Install the axle holder with the UP mark ( 8 ) upward and first tighten the upper holder nuts to the specified torque, then tighten the lower axle nuts to the same torque: 9 lbf·ft (12 N·m , 1.2 kgf·m) 4. 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. Check front brake adjustment (page 107 ). If a torque wrench was not used to install the wheel, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. 03/05/20 10:14:04 31KCY680_124 Wheels Rear Wheel Removal RIGHT REAR LEFT REAR (2) (2) (1) (1) rear axle nut (2) adjuster (3) (2) adjuster (3) rear axle (cont’d) Servicing Your Honda 115 03/05/20 10:14:15 31KCY680_125 Wheels Removal 1. Raise the rear wheel off the ground by placing a maintenance stand or support block under the engine. Secure the front of the motorcycle with tie-down straps. 2. Remove the brake hose guide. 3. Loosen the rear axle nut ( 1 ) while holding the axle. 4. Turn both adjusters ( 2 ) so the rear wheel can be moved all the way forward for maximum drive chain slack. 5. Move the rear wheel forward. Derail the drive chain from the driven sprocket. 6. Move the rear axle ( 3 ) back all the way to the swingarm end. Pull down on the rear axle. 116 Servicing Your Honda 7. Remove the rear wheel with the rear axle. Avoid depressing the brake lever and brake pedal when the wheel is off the motorcycle. This will force the caliper pistons out of the cylinders. The result will be loss of brake fluid. If this occurs, the brake system will require service. See your Honda dealer for this service. 03/05/20 10:14:25 31KCY680_126 Wheels Installation RIGHT REAR (4) (5) 2. Torque the axle nut to: 65 lbf·ft (88 N·m , 9.0 kgf·m) 3. Adjust the drive chain (page 126 ). 4. Apply the rear brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times. If a torque wrench was not used to install the wheel, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. (6) (4) lug (5) slot (6) swingarm 1. Reverse the removal procedure. Make sure the lug ( 4 ) on the brake caliper is located in the slot ( 5 ) in the swing arm ( 6 ). Check that the chain adjusters are installed properly. Servicing Your Honda 117 03/05/20 10:14:34 31KCY680_127 Tires & Tubes Refer to Saf ety Precautions on page 45 . To safely operate your motorcycle, the tires must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated. Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding tire inflation and maintenance. and our recommendations on tire repair and replacement. Air Pressure Properly inflated tires provide the best combination of handling, tread life, and riding comfort. Generally, underinflated tires wear unevenly, adversely affect handling, and are more likely to fail from being overheated. Underinflated tires can also cause wheel damage in rocky terrain. Overinflated tires make your motorcycle ride more harshly, are more prone to damage from surface hazards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install a new cap. The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, 118 Servicing Your Honda 03/05/20 10:14:44 31KCY680_128 Tires & Tubes Always check air pressure when your tires are ‘‘cold.’’ If you check air pressure when your tires are ‘‘warm’’−even if your motorcycle has only been ridden for a few miles−the readings will be higher. If you let air out of warm tires to match the recommended cold pressures, the tires will be underinflated. The correct ‘‘cold’’ tire pressures are: Front Rear 15 psi (100 kPa , 1.0 kgf/cm ) 15 psi (100 kPa , 1.0 kgf/cm ) If you decide to adjust tire pressures for a particular riding condition, make changes a little at a time. Inspection A flat tire or blowout is inconvenient and may even cause an accident. Take time to inspect your tires and wheels before you ride. For more information about handling flat tires, see page 150 . (1) (2) (3) (1) tire tread depth (2) spoke nut (3) rim lock nut (cont’d) Servicing Your Honda 119 03/05/20 10:14:54 31KCY680_129 Tires & Tubes Inspect carefully for bumps or bulges in the side of the tire or the tread. Replace any tire that has a bump or bulge. Look closely for cuts, slits, or cracks in the tires. Replace a tire if you can see fabric or cord. Check for rocks or other objects embedded in the tire or tread. Remove any objects. Measure tread depth ( 1 ). Replace the tire before depth at the center reaches 0.12 in (3 mm), or any time you notice a reduction in traction. Check the position of both valve stems. A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim. See your Honda dealer. 120 Servicing Your Honda Tube Replacement If a tube is punctured or damaged, you should replace it as soon as possible. A repaired tube may not have the same reliability as a new one, and it may fail while you are riding. For information on making a temporary repair, see page 150 . Use a replacement tube equivalent to the original. We recommend that tubes be replaced by your Honda dealer. Replacing a tube requires removing and reinstalling the wheel. Any time a tube is replaced, carefully inspect the tire as described on page 119 . 03/05/20 10:15:04 31KCY680_130 Tires & Tubes Tire Replacement The tires that came on your motorcycle were designed to provide a good combination of handling, braking, durability, and comfort across a broad range of riding conditions. Installing improper tires on your motorcycle can affect handling and stability. This can cause a crash in which you can be seriously hurt or killed. Front Rear 80/100-21M/C 51M 110/100-18M/C 64M Use a replacement tire equivalent to the original. Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Have the wheel balanced after a new tire is installed. We recommend that tires be replaced by your Honda dealer. Always use the size and type of tires recommended in this owner’s manual. Servicing Your Honda 121 03/05/20 10:15:12 31KCY680_131 Side Stand Refer to Saf ety Precautions on page 45 . LEFT SIDE 1. Check the side stand spring ( 1 ) for damage and loss of tension. 2. Check the side stand assembly for freedom of movement. If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with clean engine oil. (1) (1) side stand spring 122 Servicing Your Honda 03/05/20 10:15:22 31KCY680_132 Drive Chain Refer to Saf ety Precautions on page 45 . Inspection The service life of the chain depends on proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain or sprockets. LEFT SIDE (1) Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary. Before servicing your drive chain, turn the engine OFF, lower the side stand, and check that your transmission is in neutral. (1) drive chain It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule. 1. Check slack in the lower drive chain ( 1 ) run midway between the sprockets. Drive chain slack should allow the following vertical movement by hand: 1 3/8−1 3/4 in (35−45 mm) (cont’d) Servicing Your Honda 123 03/05/20 10:15:32 31KCY680_133 Drive Chain 2. Check drive chain slack at several points along the chain. The slack should remain constant. If it isn’t, some links may be kinked and binding. Lubricating the chain will often eliminate binding and kinking. Excessive chain slack may allow the drive chain to damage the engine cases. 3. Inspect the drive chain for: damaged rollers loose pins dry or rusted links kinked or binding links excessive wear damaged or missing O-rings Replace the drive chain (page 128 ) if it has damaged rollers, loose pins, or kinks that cannot be freed. Lubricate the drive chain (page 127 ) if it appears dry or shows signs of rust. Lubricate any kinked or binding 124 Servicing Your Honda links and work them free. Adjust chain slack if needed. 4. Check the chain slipper ( 2 ), chain guide slider ( 3 ) and chain roller ( 4 ) for wear. If the depth ( 5 ) of the groove in the chain slipper exceeds the depth limit, have your Honda dealer replace the slipper. Chain slipper depth limit: 0.3 in (8 mm) Replace the chain guide slider if the chain is visible through the wear inspection window ( 6 ). Replace the chain roller if it is smaller than 1 in (25 mm). 03/05/20 10:15:41 31KCY680_134 Drive Chain LEFT SIDE (5) (3) To check the chain’s service limit, remove the drive chain (page 128 ). Then measure the distance between a span of 108 pins, from pin center to pin center. If the distance exceeds the service limit, the drive chain is worn out and should be replaced. (2) (4) (6) (2) chain slipper (3) chain guide slider (4) chain roller (5) depth (6) wear inspection window 5. Replace the drive chain if chain slack is excessive when the rear axle is moved to the farthest limit of adjustment. Excessive slack indicates the chain is worn beyond its service limit. Measure a span of 108 pins New Chain: Service Limit: 66.9 in (1,699 mm) 67.2 in (1,707 mm) (cont’d) Servicing Your Honda 125 03/05/20 10:15:50 31KCY680_135 Drive Chain 6. Inspect the front and rear sprocket teeth for excessive wear or damage. If necessary, have your Honda dealer replace a worn sprocket. Adjustment LEFT SIDE Damaged Sprocket Teeth Worn Sprocket Teeth (4) (3) REPLACE REPLACE (5) (1) RIGHT REAR Normal Sprocket Teeth GOOD (2) Use of a new chain with worn sprockets will cause rapid chain wear. 126 Servicing Your Honda (1) axle (2) axle nut (3) chain adjuster (4) index mark (5) stopper pin 03/05/20 10:16:04 31KCY680_136 Drive Chain 1. Hold the axle ( 1 ) and loosen the rear axle nut (2 ). 2. Turn both the right and left adjusters (3 ) equally to increase or decrease chain slack. 3. After adjusting, be sure the same adjuster index marks (4 ) align with the stopper pins (5 ) on both sides of the swingarm. 4. Turn the axle end bar to the lower edge of the swing arm. 5. Torque the rear axle nut to: 65 lbf·ft (88 N·m , 9.0 kgf·m) If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly. 6. Recheck drive chain slack. Lubrication Lubricate every 300 miles (500 km) or sooner if chain appears dry. The O-rings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents. (cont’d) Servicing Your Honda 127 03/05/20 10:16:15 31KCY680_137 Drive Chain Lubricate only with SAE 80 or 90 gear oil. Commercial chain lubricants may contain solvents which could damage the rubber O-rings. Removal, Cleaning & Replacement LEFT SIDE (1) (1) master link retaining clip 128 Servicing Your Honda When the drive chain becomes extremely dirty, it should be removed and cleaned prior to lubrication. 1. Remove the master link retaining clip ( 1 ) with pliers. Do not bend or twist the clip. Remove the master link and O-rings. Remove the drive chain. 2. Clean the side surfaces of the chain with a dry cloth. Do not brush the rubber O-rings. Brushing will damage them. Use of a solvent may also damage the O-rings. 3. Inspect the drive chain for possible wear or damage. Replace the drive chain if it has damaged rollers, loose fitting links, or otherwise appears unserviceable. Replacement chain: D.I.D. 520V8 or RK 520MOZ6 03/05/20 10:16:23 31KCY680_138 Drive Chain 4. Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. 5. Lubricate the drive chain. 6. Pass the chain over the sprockets and join the ends of the chain with the master link. Master links with O-rings have four O-rings fitted between the rollers and master link plates. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. Install the master link retaining clip so that the closed end of the retaining clip will face the direction of forward wheel rotation. 7. Adjust the drive chain and rear brake pedal freeplay. More About: Drive Chain The master link is the most critical element of drive chain security. Master links are reusable, as long as they remain in excellent condition. We recommend installing a new master link retaining clip when the drive chain is reassembled. You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets. Servicing Your Honda 129 03/05/20 10:16:34 31KCY680_139 Headlight & Taillight Refer to Saf ety Precautions on page 45 . (3) Headlight Bulb (5) (4) FRONT (1) (2) (1) headlight mount bands (2) number plate 1. Remove the two headlight mount bands ( 1 ) and remove the front number plate ( 2 ). 2. Disengage the socket ( 3 ) from the headlight case ( 4 ). Remove the bulb ( 5 ) from the socket. 130 Servicing Your Honda (3) socket (4) headlight case (5) bulb 3. Install a new bulb, aligning the tab on the bulb with the groove on the headlight case. 4. To install the headlight, reverse the removal procedure. 03/05/20 10:16:40 31KCY680_140 Headlight & Taillight Headlight Aim FRONT (5) (5) adjusting screw The headlight beam can be raised or lowered. Turn the adjusting screw ( 5 ) to move the headlight up or down to the proper adjustment. Servicing Your Honda 131 03/05/20 10:16:48 31KCY680_141 Headlight & Taillight REAR (3) Taillight Bulb LEFT REAR (1) (2) (3) bulb 1. Remove the two screws ( 1 ). 2. Pull the lens off. Replace the bulb ( 3 ) with a new one. 3. Reinstall the lens. (1) screws (2) lens 132 Servicing Your Honda 03/05/20 10:16:57 31KCY680_142 Appearance Care Refer to Saf ety Precautions on page 45 . General Recommendations Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values your motorcycle. A clean motorcycle is also easier to inspect and service. While you’re cleaning, be sure to look for damage, wear, and gasoline or oil leaks. To clean your motorcycle, you may use: −water −a mild, neutral detergent and water −a mild spray and wipe cleaner/polisher −a mild spray and rinse cleaner/degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your motorcycle. If your motorcycle is still warm from recent operation, give the engine and exhaust system time to cool off. (cont’d) Servicing Your Honda 133 03/05/20 10:17:09 31KCY680_143 Appearance Care We recommend the use of a garden hose to wash your motorcycle. High pressure washers (like those at coin-operated car washes) can damage certain parts of your motorcycle. If you use a high pressure washer, avoid spraying the following areas: wheel hubs muffler outlet area under seat engine stop button brake master cylinders under fuel tank drive chain carburetor instruments 134 Servicing Your Honda High pressure water (or air) can damage certain parts of your motorcycle. Washing Your Motorcycle with a Mild Detergent 1. Rinse your motorcycle thoroughly with cool water to remove loose dirt. 2. Fill a bucket with cool water. Mix in a mild, neutral detergent, such as dish washing liquid or a product made especially for washing motorcycles or automobiles. 03/05/20 10:17:20 31KCY680_144 Appearance Care 3. Wash your motorcycle with a sponge or a soft towel. As you wash, check for heavy grime. If necessary, use a mild cleaner/ degreaser to remove the grime. 4. After washing, rinse your motorcycle thoroughly with plenty of clean water to remove any residue. 5. Dry your motorcycle with a chamois or a soft towel. 6. Lubricate the drive chain to prevent rusting. 7. Start the engine and let it idle for several minutes. The engine heat will help dry moist areas. 8. As a precaution, ride at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance. 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. Servicing Your Honda 135 03/05/20 10:17:23 31KCY680_145 136 Servicing Your Honda 03/05/20 10:17:27 31KCY680_146 Tips Here’s helpful advice on how to prepare for an off-road adventure, how to transport and store your Honda, and how to be an environmentally responsible motorcycle owner. Preparing for a Ride ......................................138 Transporting Your Honda .............................140 Storing Your Honda ......................................142 You & the Environment................................145 Tips 137 03/05/20 10:17:38 31KCY680_147 Preparing for a Ride A safe and enjoyable ride begins with good planning and preparation. Always ride with at least one other person in case you have trouble, and let someone know where you’re going and when you expect to return. Before riding in an unfamiliar area, find out in advance if you need special permits, get maps so you can study the terrain, and talk to other riders who know the area. The Forest Service and the Bureau of Land Management (USA only), the Ministry of Natural Resources (Canada only), riding clubs, and off-road magazines are good sources of information. 138 Tips What to Take to the Riding Area Along with your motorcycle and riding gear, you should take along some tools and supplies in case you have a problem. For some of the difficulties you might encounter, see Taking Care of the Unexpected, which begins on page 147 . We recommend that you always take water, food, a first aid kit, and your owner’s manual. Other items you should consider loading on your truck or trailer include: a tool kit tire repair supplies and tools, tubes, and tires extra parts, such as a drive chain and master links, control levers, cables, and spark plugs wire, duct tape, and rope extra gasoline 03/05/20 10:17:43 31KCY680_148 Preparing for a Ride For safety, all refueling should be done at a gas station on the way to the riding area or at your base camp. If you decide to take some tools, spare parts, or other supplies on the trail, be sure you can carry them safely and know how to use them. Also, be sure to follow the loading guidelines and weight limit (page 6 ). What to Take on the Trail What you take with you during a ride depends on the kind of terrain, how long you expect to ride, how far you might go from your base camp or help, and how experienced you or your companions are in making repairs. Tips 139 03/05/20 10:17:51 31KCY680_149 Transporting Your Honda If you use a truck or motorcycle trailer to transport your Honda, we recommend that you follow these guidelines: Use a loading ramp. Make sure the fuel valve is off. Secure the motorcycle in an upright position, using motorcycle tie-down straps. Avoid using rope, which can loosen and allow the motorcycle to fall over. To secure your motorcycle, brace the front wheel against the front of the truck bed or trailer rail. Attach the lower ends of two straps to the tie-down hooks on your vehicle. Attach the upper ends of the straps to the handlebar (one on the right side, the other on the left), close to the fork. 140 Tips 03/05/20 10:17:56 31KCY680_150 Transporting Your Honda Check that the tie-down straps do not contact any control cables or electrical wiring. Tighten both straps until the front suspension is compressed about half-way. Too much pressure is unnecessary and could damage the fork seals. Use another tie-down strap to keep the rear of the motorcycle from moving. We recommend that you do not transport your motorcycle on its side. This can damage the motorcycle, and leaking gasoline could be a hazard. Tips 141 03/05/20 10:18:01 31KCY680_151 Storing Your Honda If you won’t be riding for an extended period, such as during the winter, thoroughly inspect your motorcycle and correct any problem before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your motorcycle running again. 142 Tips For more information about storage, refer to the Honda Motorcycle Winter Storage Guide, available from your Honda dealer (USA only). We suggest you perform the following procedures to keep your motorcycle in top condition. These storage procedures will reduce the deterioration that can occur during storage. 03/05/20 10:18:10 31KCY680_152 Storing Your Honda Preparation for Storage 1. Change the engine oil and filter (page 68 ). 2. Fill the fuel tank. Make sure the fuel fill cap is properly installed. 3. Check that the fuel valve is OFF. 4. Drain the carburetor into an approved gasoline container and dispose of it in an approved manner (page 145 ). If storage will last longer than one month, carburetor draining is important, to assure proper performance after storage. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately. 5. Wash and dry your motorcycle. (cont’d) Tips 143 03/05/20 10:18:22 31KCY680_153 Storing Your Honda 6. Lubricate the drive chain. 7. Inflate the tires to their recommended pressures (page 119 ). 8. Store your motorcycle in an unheated area, free of dampness, away from sunlight, with a minimum of daily temperature variation. 9. Cover your motorcycle with a porous material. Avoid using plastic or similar nonbreathing, coated materials that restrict air flow and allow heat and moisture to accumulate. 144 Tips Removal from Storage 1. Uncover and clean your motorcycle. 2. If your motorcycle has been stored for more than four months−change the engine oil (page 68 ). 3. If your motorcycle has been stored for more than two months−drain and replace the fuel. 4. Lubricate the drive chain. 5. Perform a pre-ride inspection (page 24 ), then test-ride your motorcycle at low speeds. 03/05/20 10:18:29 31KCY680_154 You & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally-responsible motorcycle owner. Choose Sensible Cleaners. Use a biodegradeable detergent when you wash your motorcycle. Avoid aerosol spray cleaners that contain chloroflurocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Don’t throw cleaning solvents away; see the following guidelines for proper disposal. Tread Lightly. Stay on existing roads and trails, avoid surfaces that are easily damaged, and ride only in areas approved for off-road vehicles. Keep the Noise Down. Loud motorcycles can be offensive. Ride as quietly as possible, don’t remove your spark arrester, and don’t modify the muffler or any other part of your air intake and exhaust systems. Such modifications not only increase noise, they also reduce engine performance and may be illegal. (cont’d) Tips 145 03/05/20 10:18:33 31KCY680_155 You & the Environment Recycle Wastes. It’s illegal and thoughtless to put used engine oil in the trash, down a drain, or on the ground. Used oil, gasoline, and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water, lakes, rivers, and oceans. Before changing your oil, make sure you have the proper containers. Put oil and other toxic wastes in separate sealed containers and take them to a recycling center. Call your local or state office of public works or environmental services to find a recycling center in your area and get instructions on how to dispose of non-recyclable wastes. 146 Tips 03/05/20 10:18:38 31KCY680_156 Taking Care of the Unexpected With all the challenges you can encounter offroad, there’s a chance that sometime something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride. Also review the tips in Preparing f or a Ride (page 138 ). General Guidelines........................................148 If Your Engine Quits or Won’t Start ............149 If You Have a Flat Tire.................................150 If You Crash..................................................151 If a Component Fails ....................................152 Taking Care of the Unexpected 147 03/05/20 10:18:46 31KCY680_157 Taking Care of the Unexpected General Guidelines If something goes wrong during a ride, the first thing to do is stop as soon as you safely can. Do not continue riding if you have a flat tire, or you hear an unusual noise, or your motorcycle just doesn’t feel right. If you continue riding, you could cause more damage and endanger your own safety. After a stop, take time to assess the situation. Carefully inspect your motorcycle to identify the problem, then consider your options before you decide what to do. If a problem is relatively minor and you have the tools, supplies, and skills to make a permanent repair, you may be able to fix it on the trail and continue riding. Or, you may be able to make a temporary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help. When a problem is more serious−or you don’t have the tools, supplies, experience, or time to deal with it−you need to choose the safest way to get yourself and your motorcycle back to base. For example, if you are close enough, you (or you and another person) might be able to push it back. Whatever the problem, the most important rules are: Always put personal safety first. 148 Taking Care of the Unexpected 03/05/20 10:18:57 31KCY680_158 Taking Care of the Unexpected If the problem is relatively minor and you have the tools, supplies, and skills to make a temporary repair, be sure to have permanent repairs made as soon as possible. Do not continue riding if you are hurt or your motorcycle is not in safe riding condition. Additional recommendations for specific problems follow. If Your Engine Quits or Won’t Start If the engine wasn’t making any unusual noises before it quit running, and it feels normal when you operate the kickstarter, you can probably rule out a major mechanical problem. The next area to check is the fuel system: Make sure there is enough gas in the tank and the fuel valve is at the ON or RESERVE position. Check the fuel fill cap vent tube to see if it is pinched or obstructed. Turn the fuel valve OFF, disconnect the fuel line that goes from the fuel valve to the carburetor, then momentarily turn the fuel valve ON. If fuel does not flow out, there is an obstruction in the fuel tank or the fuel valve. If the fuel system appears to be okay, check the ignition system (this requires a spark plug wrench): (cont’d) Taking Care of the Unexpected 149 03/05/20 10:19:08 31KCY680_159 Taking Care of the Unexpected Check that the spark plug cap isn’t loose or disconnected. Disconnect the spark plug cap and remove the spark plug. Connect the spark plug cap to the spark plug and ground the threaded portion of the spark plug on the cylinder head. Operate the kickstarter while you watch the spark plug. If it sparks, the ignition system is probably working. If there is no spark, install a new spark plug, if you have one with you. If there is still no spark, there is a problem in the ignition system. If you cannot identify or correct the problem, you will have to push your motorcycle back to your base or get some help. 150 Taking Care of the Unexpected If You Have a Flat Tire How you handle a flat tire on the trail depends on how serious the tube or tire damage is, and what tools and supplies you have with you. If you have a slow leak or a minor puncture, there are two ways to try making a temporary repair: Use an aerosol tire sealer to seal the puncture and inflate the tube. (This can be done without removing the tire or wheel.) Use a tube patch kit to repair the puncture. (This requires removing the tire.) 03/05/20 10:19:16 31KCY680_160 Taking Care of the Unexpected If the leak is more serious, or a temporary repair doesn’t hold, the tube must be replaced. The tire will also need to be replaced if it is damaged (page 120 ). Replacing a tube or tire involves removing and re-installing the wheel (pages 113 , 115 ). If you are unable to repair a flat tire on the trail, you will need to push the motorcycle back to your base or send for help. We strongly recommend that you do not try to ride with a flat tire. The motorcycle will be hard to handle, and if the tire comes off the rim, it may lock up the wheel and cause you to crash. If You Crash Personal safety is your first priority after an accident. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. If you cannot ride safely, send someone for help. Do not ride if you will risk further injury. If you decide you are capable of riding safely, carefully inspect your motorcycle for damage and determine if it is safe to ride. Check the tightness of critical nuts and bolts securing such parts as the handlebar, control levers, brakes, and wheels. (cont’d) Taking Care of the Unexpected 151 03/05/20 10:19:23 31KCY680_161 Taking Care of the Unexpected If there is minor damage, or you are unsure about possible damage but decide to try riding the motorcycle back to your base, ride slowly and cautiously. Sometimes, crash damage is hidden or not immediately apparent. When you get home, thoroughly check your motorcycle and correct any problems you find. Also, be sure to have your Honda dealer check the frame and suspension after any serious crash. 152 Taking Care of the Unexpected If a Component Fails The drive chain, master link, brake lever or pedal, control cables, and other components can be damaged as you ride in dense brush or over rocky terrain. Making a trailside repair depends on how serious the damage is and what tools and supplies you have with you. If the drive chain comes off because the master link clip gets knocked off, you may be able to put the chain back on with a new master link. However, if the chain breaks or does other damage when it comes off, you may not be able to make a trailside repair. 03/05/20 10:19:28 31KCY680_162 Taking Care of the Unexpected If any component of the front brake system is damaged, you may be able to ride carefully back to your base using the rear brake for slowing or stopping. If the clutch lever breaks, you may be able to temporarily switch the front brake lever to the clutch side, then ride carefully back to base using the rear brake for slowing or stopping. If you damage a throttle cable or other critical component, your motorcycle may be unsafe to ride. Carefully assess the damage and make any repairs that you can. But if there is any doubt, it’s best to be conservative and safe. Taking Care of the Unexpected 153 03/05/20 10:19:31 31KCY680_163 154 Taking Care of the Unexpected 03/05/20 10:19:35 31KCY680_164 Technical Information This section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your motorcycle. Vehicle Identification ...................................156 Specifications ................................................158 Break-in Guidelines ......................................163 High Altitude Carburetor Adjustment ..........164 Emission Control Systems ............................165 Oxygenated Fuels..........................................169 Technical Information 155 03/05/20 10:19:44 31KCY680_165 Vehicle Identification RIGHT SIDE Serial Numbers The frame and engine serial numbers are required when you register your motorcycle. They may also be required when ordering replacement parts. You may record these numbers in the Quick Ref erence section at the rear of the manual. (1) (1) frame number The frame number ( 1 ) is stamped on the right side of the steering head. LEFT SIDE The engine number ( 2 ) is stamped on the left crankcase. (2) (2) engine number 156 Technical Information 03/05/20 10:19:51 31KCY680_166 Vehicle Identification Color Label & Code The color label ( 1 ) is attached to the frame behind the left side cover (page 58 ). The color code is helpful when ordering replacement parts. You may record the color and code in the Quick Ref erence section at the rear of the manual. (1) (1) color label Technical Information 157 03/05/20 10:20:05 31KCY680_167 Specifications Dimensions Overall length Overall width Overall height Wheelbase 83.9 in (2,130 mm) 33.1 in (840 mm) 48.8 in (1,240 mm) 56.1 in (1,425 mm) Weight Dry weight 256.8 lbs (116.5 kg) Fuel & Lubricants Fuel tank capacity 2.51 US gal (9.5 ) Fuel tank reserve including reserve 0.40 US gal (1.5 ) Fuel recommendation Engine oil capacity unleaded gasoline, pump octane number of 91 or higher 1.8 US qt (1.7 ) after draining 1.9 US qt (1.8 ) after draining & oil filter change 2.3 US qt (2.2 ) after disassembly 158 Technical Information 03/05/20 10:20:20 31KCY680_168 Specifications Fuel & Lubricants Engine oil recommendation Drive chain lubricant API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label, SAE 20W-50/ 10W-40, JASO T 903 standard MA, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (USA & Canada) or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil SAE 80 or 90 gear oil Fuel & Lubricants (cont’ d) Pro Honda (USA Air cleaner oil only) or Honda (Canada only) Foam Filter Oil or an equivalent Capacities Passenger capacity Maximum weight capacity Cargo capacity Fork oil capacity (each side) operator only; no passenger 220 lbs (100 kg) none 18.9 US oz (559 cm ) Engine Specifications Displacement 24.2 cu-in (397 cm ) Bore & stroke 3.3 × 2.8 in (85 × 70 mm) Compression ratio 9.3 : 1 Technical Information 159 03/05/20 10:20:33 31KCY680_169 Specifications Engine Specifications 0.004 in Intake: Valve clearance (0.10 mm) (cold) Exhaust: 0.005 in (0.12 mm) DPR8Z (NGK) or Spark plug X24GPR-U (DENSO) (standard) DPR9Z (NGK) or Spark plug X27GPR-U (DENSO) (extended high speed riding) 0.024−0.028 in Spark plug gap (0.60−0.70 mm) 1,300 ± 100 rpm Idle speed 160 Technical Information Power Transmission Primary reduction Gear ratio, 1st 2nd 3rd 4th 5th Final reduction Standard sprocket sizes Final drive 2.826 2.615 1.842 1.400 1.120 0.926 3.000 drive (engine) sprocket: 15 teeth driven (rear wheel) sprocket: 45 teeth chain D.I.D. 520V8 or RK 520MOZ6 03/05/20 10:20:46 31KCY680_170 Specifications Power Transmission Drive chain freeplay New chain length Used chain service limit length 1 3/8−1 3/4 in (35−45 mm) 66.9 in (1,699 mm) distance between a span of 108 pins 67.2 in (1,707 mm) distance between a span of 108 pins Chassis & Suspension Caster Trail Tire size, front Tire size, rear Tire pressure, front (cold) Tire pressure, rear (cold) Suspension, front Suspension, rear 25°15’ 3.7 in (94 mm) 80/100-21M/C 51M 110/100-18M/C 64M 15 psi (100 kPa , 1.0 kgf/cm ) 15 psi (100 kPa , 1.0 kgf/cm ) 11.0 in (280 mm) cushion stroke 11.8 in (300 mm) axle travel Technical Information 161 03/05/20 10:20:57 31KCY680_171 Specifications Electrical Alternator 0.074 kW/5,000 rpm Lights Headlight Taillight 12V-35W 12V-5W 162 Technical Information Torque Specifications Fork caps 16 lbf·ft (22 N·m , 2.2 kgf·m) 18 lbf·ft (25 N·m , Crankcase drain 2.5 kgf·m) bolt 29 lbf·ft (39 N·m , Frame drain bolt 4.0 kgf·m) 9 lbf·ft (12 N·m , Oil filter bolt 1.2 kgf·m) 65 lbf·ft (88 N·m , Rear wheel axle 9.0 kgf·m) 65 lbf·ft (88 N·m , Front wheel axle 9.0 kgf·m) 9 lbf·ft (12 N·m , Front wheel axle 1.2 kgf·m) holder nuts 03/05/20 10:21:01 31KCY680_172 Break-in Guidelines Help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. Technical Information 163 03/05/20 10:21:06 31KCY680_173 High Altitude Carburetor Adjustment When operating this motorcycle at high altitude, the air-fuel mixture becomes overly rich. Above 6,500 feet (2,000 m), driveability and performance may be reduced and fuel consumption increased. The carburetor can be modified to compensate for this high altitude richness. However, the carburetor must be returned to standard factory specifications when lower altitude riding is desired. See your Honda dealer for high altitude modification. Sustained operation at altitudes below 5,000 f eet (1,500 m) with high altitude carburetor modif ications may cause engine overheating and damage. 164 Technical Information 03/05/20 10:21:12 31KCY680_174 Emission Control Systems Exhaust Emission Requirements The California Air Resources Board (CARB) requires that your motorcycle comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided. (California only) The Vehicle Emission Control Information Label ( 1 ) is attached to the rear fender. (1) Noise Emission Requirements The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 1,865 miles (3,000 km) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. (USA only) (1) vehicle emission control information label Technical Information 165 03/05/20 10:21:18 31KCY680_175 Emission Control Systems Source of Emissions The combustion process produces carbon monoxide (CO) and hydrocarbons (HC). Control of hydrocarbons is very important because under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings and other systems to reduce carbon monoxide and hydrocarbons. Exhaust Emission Control System (California only) The exhaust emission control system is composed of lean carburetor settings, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. 166 Technical Information Crankcase Emission Control System (California only) The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and the carburetor. 03/05/20 10:21:24 31KCY680_176 Emission Control Systems Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U. S. federal law prohibits, or Canadian provincial laws may prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing the muffler, baffles, header pipes, or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. Technical Information 167 03/05/20 10:21:28 31KCY680_177 Emission Control Systems Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your Honda Motorcycle Dealer: 1. Hard starting or stalling after starting 2. Rough idle 3. Misfiring or backfiring during acceleration 4. After-burning (backfiring) 5. Poor performance (driveability) and poor fuel economy 168 Technical Information 03/05/20 10:21:36 31KCY680_178 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/ provinces require this information to be posted on the pump. The following are the EPA-approved percentages of oxygenates: ETHANOL (ethyl or grain alcohol) 10% by Volume You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name ‘‘Gasohol’’. MTBE (Methyl Tertiary Butyl Ether) 15% by Volume You may use gasoline containing up to 15% MTBE by volume. METHANOL (methyl or wood alcohol) 5% by Volume You may use gasoline containing methanol containing up to 5% methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system. (cont’d) Technical Information 169 03/05/20 10:21:42 31KCY680_179 Oxygenated Fuels If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty. Oxygenated fuels can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank. Wipe up any spills immediately. 170 Technical Information Oxygenated f uels can damage paint and plastic. Damage caused by spilled f uel is not covered under warranty. 03/05/20 10:21:47 31KCY680_180 Consumer Information This section contains information on your warranty and how to get an official Honda service manual. Authorized Manuals ......................................172 Warranty Coverage .......................................175 Warranty Service...........................................176 Contacting Honda .........................................177 The Honda Rider’s Club (USA only) ...........178 Your Honda Dealer .......................................179 Consumer Information 171 03/05/20 10:21:55 31KCY680_181 Authorized Manuals The Service Manual (Publication Item No. 61KCY08 ) used by your authorized Honda dealer is available from Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals.) Also available, but not necessary, to service your model is the Honda Common Service Manual (Publication No. 61CM001 ), which explains theory of operation and basic service information for various systems common to all Honda motorcycles, motor scooters and ATVs. These Honda manuals are written for the professional technician, but most mechanically-capable owners should find them easy to use if they have the proper tools and observe proper safety standards. Special Honda tools are necessary for some procedures. Publication Item No. Description 61KCY08 2004 XR400R Service Manual 61CM001 Common Service Manual 31KCY680 2004 XR400R Owner’s Manual ＊ Prices are subject to change without notice and without incurring obligation. 172 Consumer Information Price Each＊ $48.00 $48.00 $16.00 03/05/20 10:22:06 31KCY680_182 Order On-Line: www.helminc.com Order Toll Free: 1-888-CYCLE93 (1-888-292-5393) (NOTE: For Credit Card Orders Only) Monday − Friday 8:00 AM − 6:00 PM EST OR By completing this form you can order the materials desired. You can pay by check or money order, or charge to your credit card. Mail to Helm, Inc. at the address shown on the back of this order form (USA only). Canada: See your Honda dealer to order authorized manuals. Publication Item No. ＊ Item Description Prices are subject to change without notice and without incurring obligation. Orders are mailed within 10 days. Please allow adequate time for delivery. Qty. Price Each＊ Sub Total Mich. Purchasers Add 6 % Sales Tax Handling Charge Grand Total Total Price $4.00 Consumer Information 173 03/05/20 10:22:22 31KCY680_183 S H I P T O NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person to whose attention the shipment should be sent. Customer Name Attention Street Address - No P. O. Box Number City State Daytime Telephone Number ( P A Y M E N T Apartment Number ) Check or money order enclosed payable to Helm Inc. U.S. funds only. Do not send cash. MasterCard Zip Code Check here if your billing address is different from the shipping address shown above. Account Number Expiration: Mo. Yr. − VISA Discover Customer Signature Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery. On returns, a restocking fee may be applied against the original order. HELM P.O. BOX 07280, DETROIT, MICHIGAN 48207 174 Consumer Information 03/05/20 10:22:29 31KCY680_184 Warranty Coverage Your new Honda is covered by these warranties: Motorcycle Limited Warranty Noise Control Warranty (USA only) There are responsibilities, restrictions, and exclusions which apply to these warranties. Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the time of purchase. Be sure to keep your Honda owner’s card (USA only) with your Warranties Booklet. Your warranty coverage will not be voided if you choose to perform your own maintenance. However, you should have the proper tools and service information and be mechanically qualified. Failures that occur due directly to improper maintenance or lack of maintenance are not covered. Almost all of your warranty coverage can be extended through the Honda Protection Plan (USA only). For more information, see your Honda dealer. It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship. Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle. Consumer Information 175 03/05/20 10:22:35 31KCY680_185 Warranty Service Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items (such as brakes, tires, etc.). If you believe you have a problem with your Honda, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. Remember, as the owner of the motorcycle, you will be asked to authorize that inspection. Your dealer will give you the results of the inspection. If the problem is covered under warranty, your dealer will perform the warranty repairs for you. If you have questions about warranty coverage or the nature of the repair, it is best to talk to the service manager of your Honda dealer. 176 Consumer Information Sometimes, in spite of the best intentions of all concerned, a misunderstanding may occur. If you aren’t satisfied with your dealer’s handling of the situation, we suggest you discuss your problem with the appropriate member of the dealership’s management team. If the problem has already been reviewed with the Service Manager, Parts Manager, Sales Manager, etc., contact the Owner of the dealership or his designated representative. 03/05/20 10:22:43 31KCY680_186 Contacting Honda Your owner’s manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner’s manual can be answered by your Honda dealer. If he doesn’t have the answer right away, he will get it for you. If you have a difference of opinion with your dealer, please remember that each dealership is independently owned and operated. That’s why it’s important to work to resolve any differences at the dealership level. If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O. Box 2220, Torrance, CA 905092220, mailstop: 100-4W-5B, telephone: (310) 532-9811. Canada: Refer to the warranty booklet that was supplied with your vehicle. Please include the following information in your letter: name, address, and telephone number product model, year, and frame/VIN serial number date of purchase dealer name and address We will likely ask your Honda dealer to respond, or possibly acknowledge your comments directly. Consumer Information 177 03/05/20 10:22:54 31KCY680_187 The Honda Rider’s Club (USA only) One of the best ways to get the most enjoyment from owning and riding your Honda is to join the Honda Rider’s Club of America (HRCA). Your purchase of a new motorcycle, scooter or ATV from a participating Honda dealer entitles you to a complimentary one-year membership. The HRCA has hundreds of dealer-sponsored chapters throughout the USA. Some of the HRCA membership benefits include: 24-hr. emergency roadside assistance for your Honda or transport vehicle. Transportation for your Honda or transport vehicle to the nearest Honda dealer or service facility if roadside assistance can’t get you going again. Reimbursement (to $75) for motorcycle and scooter rider training from the Motorcycle Safety Foundation. Free ATV rider training is available from the Specialty Vehicle Institute of America with the purchase of a new Honda ATV. 178 Consumer Information A subscription to Honda Red Rider, a bimonthly insider’s magazine for all members. Special members-only HRCA website. Discounts from HRCA partners for both on and off-road riding schools and adventure packages. Hospitality at national events. Optional insurance, club pin, patch, etc. Red Rider (MX) contingency and off-road support at selected events. Computerized trip routing, color maps, and special travel packages. Contact your Honda dealer for more information or call: 1-800-847-HRCA. For a complete list of all HRCA benefits and services, refer to your HRCA membership benefits manual or visit our website at www.honda.com. 03/05/20 10:23:01 31KCY680_188 Your Honda Dealer Once you purchase your new Honda, get familiar with the organization of your Honda dealer so you can utilize the full range of services available. The service department is there to perform regular maintenance and unexpected repairs. It has the latest available service information from Honda. The service department will also handle warranty inspections and repairs. The parts department offers Genuine Honda parts, Pro Honda products, Hondaline accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Genuine Honda replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department. The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage (USA only). Your dealer can inform you about competition and other riding events in your area. You’ll also find that your dealer is a source of information (USA only) about American Honda’s Rider Education Centers and the Honda Rider’s Club of America. We’re sure you’ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda. Consumer Information 179 03/05/20 10:23:05 31KCY680_189 Table of Contents The following presents the contents of each section of your owner’s manual. Side Stand .......................................................19 Tripmeter .........................................................19 MOTORCYCLE SAFETY ............................1 Important Safety Information ...........................2 Loading, Accessories & Modifications ............5 Loading .........................................................5 Accessories & Modifications........................7 Safety Labels.....................................................9 BEFORE RIDING ........................................21 Are You Ready to Ride？...............................22 Protective Apparel ......................................22 Is Your Motorcycle Ready to Ride？ .............24 Pre-ride Inspection ......................................24 OPERATING CONTROLS.........................11 Component Locations .....................................12 Fuel Valve .......................................................15 Choke Lever ....................................................16 Engine Stop Button .........................................17 Front Brake Lever ...........................................17 Throttle ............................................................17 Clutch Lever....................................................17 Shift Lever ......................................................18 Rear Brake Pedal .............................................18 Kickstarter .......................................................18 Starter Decompressor Lever ...........................18 180 Table of Contents 03/05/20 10:23:10 31KCY680_190 Table of Contents BASIC OPERATION & RIDING...............27 Safe Riding Precautions..................................28 Starting & Stopping the Engine ......................29 Preparation ..................................................29 Starting Procedure.......................................29 Starter Decompressor Lever .......................32 Flooded Engine ...........................................33 How to Stop the Engine ..............................34 Shifting Gears .................................................35 Braking ............................................................37 Parking ............................................................39 Post-ride Inspection ........................................40 SERVICING YOUR HONDA .....................41 Bef ore You Service Your Honda The Importance of Maintenance .....................43 Maintenance Safety.........................................45 Important Safety Precautions......................45 Maintenance Schedule ....................................47 Maintenance Record .......................................51 Competition Inspection ...................................52 Service Preparations Component Locations .....................................55 Tools................................................................57 Side Cover Removal .......................................58 Air Cleaner Housing Cover Removal .............59 Seat Removal ..................................................60 (cont’d) Table of Contents 181 03/05/20 10:23:15 31KCY680_191 Table of Contents SERVICING YOUR HONDA (cont’d) Service Procedures Fluids & Filters Fuel ..................................................................61 Engine Oil .......................................................64 Air Cleaner ......................................................73 Crankcase Breather (California only) .............76 Engine Throttle ............................................................77 Clutch System .................................................80 Engine Idle Speed ...........................................83 Spark Plug .......................................................84 Spark Arrester .................................................86 182 Table of Contents Chassis Suspension ......................................................88 Brakes............................................................107 Wheels ...........................................................112 Tires & Tubes................................................118 Side Stand .....................................................122 Drive Chain ...................................................123 Headlight & Taillight ....................................130 Appearance Care ...........................................133 TIPS ..............................................................137 Preparing for a Ride ......................................138 Transporting Your Honda .............................140 Storing Your Honda ......................................142 You & the Environment................................145 03/05/20 10:23:19 31KCY680_192 Table of Contents TAKING CARE OF THE UNEXPECTED ...........................................147 General Guidelines........................................148 If Your Engine Quits or Won’t Start ............149 If You Have a Flat Tire.................................150 If You Crash..................................................151 If a Component Fails ....................................152 CONSUMER INFORMATION ................171 Authorized Manuals ......................................172 Warranty Coverage .......................................175 Warranty Service...........................................176 Contacting Honda .........................................177 The Honda Rider’s Club (USA only) ...........178 Your Honda Dealer .......................................179 TECHNICAL INFORMATION ...............155 Vehicle Identification ...................................156 Specifications ................................................158 Break-in Guidelines ......................................163 High Altitude Carburetor Adjustment ..........164 Emission Control Systems ............................165 Oxygenated Fuels..........................................169 TABLE OF CONTENTS ...........................180 INDEX ..........................................................184 QUICK REFERENCE Table of Contents 183 03/05/20 10:23:25 31KCY680_193 Index A accessories .........................................................7 air cleaner ........................................................73 air pressure, front suspension ..........................................92 tires ............................................................118 altering your motorcycle ...................................8 arrester, spark ..................................................86 Authorized Manuals ......................................172 B brakes, fluid level ..................................................108 lever, front ...................................................17 lever, front adjustment ..............................107 pad wear ....................................................110 pedal, rear ....................................................18 braking ............................................................37 184 Index break-in guidelines ........................................163 button, engine stop ..........................................17 C capacity, fuel ...................................................62 carburetor, high altitude adjustment ............................164 idle speed.....................................................83 choke lever ......................................................16 cleaner, air .......................................................73 cleaning, appearance care .............................133 clutch system, adjustment ...................................................80 lever .............................................................17 color label ......................................................157 competition inspection ....................................52 consumer information ...................................171 controls, operating...........................................11 cover removal, side .........................................58 crankcase breather (California only) ..............76 03/05/20 10:23:32 31KCY680_194 Index customer service............................................177 D damping adjustments ..............................95, 105 decompressor lever ...................................18, 32 drive chain .....................................................123 E education, rider .........................................3, 179 emission control systems ..............................165 engine number ...............................................156 engine, flooded ........................................................33 idle speed.....................................................83 pinging ........................................................61 starting .........................................................29 stop button ...................................................17 stopping .......................................................34 won’t start .................................................149 environment, protecting ................................145 exhaust pipe maintenance .............................135 F filter, air.................................................................73 oil.................................................................68 flat tire ...........................................................150 flooded engine, starting ..................................33 fork ............................................................88, 91 frame number ................................................156 front brake lever freeplay .............................107 front suspension maintenance.........................88 front wheel removal ......................................113 fuel, recommendation..........................................61 oxygenated ................................................169 tank capacity ...............................................62 valve ............................................................15 Index 185 03/05/20 10:23:40 31KCY680_195 Index G gap, spark plug ................................................85 gasohol ..........................................................169 gasoline ...........................................................61 gears, shifting ..................................................35 pre-ride ........................................................24 K kickstarter ........................................................18 L H headlight ........................................................130 Honda, contacting .........................................177 Honda service manual ...................................172 I idle speed, engine ............................................83 inspection, competition .................................................52 post-ride ......................................................40 186 Index lever, clutch ...........................................................17 front brake ...................................................17 shift .............................................................18 starter decompressor .............................18, 32 limit, weight ......................................................6 loading ...............................................................5 03/05/20 10:23:48 31KCY680_196 Index M maintenance, record ..........................................................51 safety ...........................................................45 schedule.......................................................47 manual, service..............................................172 modifications ....................................................8 O oil, engine ..........................................................64 volume (fork) ..............................................93 operating controls............................................11 oxygenated fuels ...........................................169 P pad, brake ......................................................110 parking ............................................................39 pedal, rear brake ..............................................18 pinging, engine ................................................61 plug, spark .......................................................84 post-ride inspection .........................................40 pre-ride inspection...........................................24 pre-load, rear suspension ..............................100 R rear suspension maintenance...........................89 reserve capacity, fuel tank ..............................62 rider training..............................................3, 179 (cont’d) Index 187 03/05/20 10:23:53 31KCY680_197 Index riding, basic operation ............................................27 before ..........................................................21 clothing........................................................22 precautions ..................................................28 safety .............................................................2 rim lock .........................................................112 S schedule, maintenance ....................................47 seat, removal ...................................................60 service, customer ....................................................177 warranty ....................................................176 manuals .....................................................172 shifting gears ...................................................35 side cover, removal .........................................58 side stand .................................................19, 122 spark arrester ...................................................86 spark knock .....................................................61 188 Index spark plug ........................................................84 specifications ................................................158 spring pre-load, rear suspension ...................100 stand, side ................................................19, 122 starter decompressor lever ........................18, 32 starting, engine ................................................29 stop button, engine ..........................................17 stopping engine ...............................................34 storage ...........................................................142 suspension, front.......................................................88, 91 rear ........................................................89, 98 03/05/20 10:24:00 31KCY680_198 Index T taillight ..........................................................132 throttle freeplay .......................................................77 operation......................................................17 tires, air pressure ................................................118 flat .............................................................150 replacing ....................................................121 tool bag ............................................................57 towing..............................................................36 training, rider.............................................3, 179 transporting ...................................................140 tripmeter ..........................................................19 troubleshooting, starting ...............................149 V valve, fuel ..............................................................15 vehicle identification ....................................156 W warranty, coverage ....................................................175 extended ....................................................175 service .......................................................176 washing your motorcycle ..............................134 weight limit .......................................................6 wheels............................................................112 U unexpected problems ....................................148 Index 189 03/05/20 10:24:07 31KCY680_199 Quick Reference The following is a brief, but important collection of information you need to know about your Honda. You’ll also find space to record important notes. How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair. Proper maintenance, especially the use of the recommended fluids and filters, prevents premature wear and damage. Frequent causes of costly engine repairs are: Engine oil: insufficient quantity, improper oil. Air cleaner: dirty, leaking because of improper installation (poor seal). Quick Reference 03/05/20 10:24:11 31KCY680_200 Quick Reference Record important information here: Frame No. Engine No. Color Label Owner’s: Name Address City/State Phone Dealer’s: Name Address City/State Phone Service Mgr. Quick Reference 03/05/20 10:24:29 31KCY680_201 Quick Reference Initial Maintenance about 100 miles (150 km) or one month. Regular Maintenance Pre-ride Inspection about every 600 miles (1,000 km) or six months. Fuel/Capacity Engine Oil Maximum Weight Capacity Tires Tire Pressure (cold) Spark Plug Drive Chain Quick Reference Check the following items each time before you ride (page 24 ): tires, spokes & rims, leaks, engine oil, fuel, drive chain, cables, nuts & bolts, spark plug and cap, throttle, brakes, clutch lever, headlight. unleaded gasoline, pump octane number of 92 or higher tank: 2.51 US gal (9.5 ) reserve: 0.40 US gal (1.5 ) API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label, SAE 20W-50, 10W-40 (when outside temperature is below 0°C, 32°F), JASO T 903 standard MA, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent 220 lbs (100 kg) rider only (no passenger or cargo) and any accessories Front: 80/100-21M/C 51M 110/100-18M/C 64M Rear: Front: 15 psi (100 kPa , 1.0 kgf/cm ) 15 psi (100 kPa , 1.0 kgf/cm ) Rear: DPR8Z (NGK) or X24GPR-U (DENSO) D.I.D. 520V8 or RK 520MOZ6