% 03/05/20 09:55:46 31KCY5807001 ‘ 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 Tl +l+ l@ 2004 Honda XR400R OWNER’S MANUAL J l 03/05/20 09:55:54 31KCY5807003 ‘ 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 prac ‘al or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own goodjudgment. You will find important safety information in a variety of forms, including: {7} ' Safety Labels v on the motorcycle. - Safety Messages 7 preceded by a safety alert symbolAand one of three signal words: DANGER, WARNING, or CAUTION. These signal words mean: Safety Messages +HI? J I 03/05/20 09:56 : 01 31KC‘16807004 A Few Words About Safety m You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. N You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. A C UTION You CAN be HURT If you don t follow Instructions. ' Safety Headings i such as Important Safety Reminders or Impoltant Safety Precautions. ' Safety Section 7 such as Motorcycle Safety. ' Instructions 7 how to use this motorcycle correctly and safely. This entire book is filled with important safety information i please read it carefully. Safety Messages L 03/05/20 09:56:14 31KCY5807005 Contents These pages give an overview of the contents Basic Operation & Riding“ 27 of your owner's manual. The first page of each How to start and stop the engine hift section lists the topics covered in that section. gears, and brake. Also, riding precautions. Introduction Servicing Your Honda .. 41 Motorcycle Safety 4 Why your motorcycle need regular Important safety information, ' ' bout loading, ' cessories, and modific ions, and the location of safety labels. Operating Controls The location, function, and operation of the throttle, brakes, clutch, and other basic controls. Before Riding The importance of wearing a helmet and other protective gear, plus how to make sure you and your motorcycle are ready to ride. Contents 11 21 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 31KC‘15807006 Contents Tips.. . 137 How to transport and tore your motorcycle, and how to be an environinentally-responsible rider. Taking Care of the Unexpected“ 147 What to do if you have a flat tire, your engine won't start, etc. Technical Information. 4 155 ID numbers, technical and other technical facts. Consumer Information .. 171 Information on warranties and how to get Honda service manuals. Table of Contents... . 180 Sequential listing of topi owner’s manual. Index.. . 184 Quick Reference Handy facts about fuel, engine oil, tire sizes, and air pressures. Contents 03/05/20 09:56 : 33 31KCY5807007 Introduction Congratulations on choosing your Honda off- road 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 respons bility for keeping your motorcycle well maintained. Scheduled service is a must, of course. But it‘sjust as important to observe the break-in guidelin i, and perform all the pre- ride and other periodic checks detailed in this manual. Inlroduflion 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 ' ‘ 'on that is preceded by a symbol. This information is intended to p 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 31KCY5807008 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! Introduclinn 03/05/20 09:56:41 31KC‘15807009 03/05/20 09:56:46 31KC‘15807010 Motorcycle Safety This section presents some of the most important infoimation 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. lmponant Safety Information Loading, Accessories & Modi Loading . Accessone. Safety Labels Mom-cycle Safety 1 03/05/20 09:55 : 53 31KCY5807011 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 'gnificantly 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 3 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 signal 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 acro . J l 03/05/20 09:56 : 59 31KCY5807012 Important Safety Information Take Time to Learn and Practice Developing off-road riding skills a gradual, step-b \tep process Stan by prae icing at low . ee in a safe are d slowly build your sk s. 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 Tip: & Practicc Guide for thy Off-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 is another major cause of ents. 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 goodjudgments and ride safely. Motorcycle Safety 3 J l 03/05/20 09:57:03 31KC‘15807013 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 lime 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 31KC‘15807014 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. AWARNING 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 J l 03/05/20 09:57:23 31KCY5807015 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 discu“ed 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 common- sense 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. 0 Make sure that all cargo is tied down securely. ' Never exceed the maximum weight limit. 0 Check that both tires are inflated properly. 03/05/20 09:57:31 31KC‘15807016 Loading, Accessories & Modifications Accessories & Modifications Modifying your motorcycle or using non- Honda accessories can make your motorcycle unsafe. Before you consider making any modifications or adding an ac essory, be sure to read the following information. AWARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding modifications and accessories. 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 acc orie.. Check with your dealer for assistance and always follow this guideline: ' Make sure the accessory does not reduce ground clearance and lean angle, limit suspei "on travel or steering travel. alter your iding position, or interfere with operating any controls. (cont’d) Motorcycle Safety 7 J l 03/05/20 09:57:36 31KC‘1580701’7 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 iide. We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark airester or emission control system components) that would make the motorcycle illegal in your area. 8 Motorcycle Safety % 03/05/20 09:57:46 31KCY5307018 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. / or: with 0: mm was VEHICLE l5 DESIMD mu mnmnru Fun w nun: us: out. n was WV cww m renew mun vzmxz we" suwums mu Minna! w mu: swarm. was. an Him-ms is ILLEGAL. For your prutsclmn, always wear your helmet while ndlng Oneramr Duly No passengers Read me owner‘s manual cavelully. Motorcycle Safety 03/05/20 09:57:49 31KCY5807019 ‘ 10 Motorcycle Safety 7 \ +HI? J \ 03/05/20 09:57:54 31KCY580702D 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 refully before you ride. It describes the loc ion, function, and operation of all the basic controls on your motorcycle. Component Lo Fuel Valve ..... Choke Lever ...... Engine Stop Butto Front Brake Lever Throttle Clutch Leve Shift Lever . Rear Brake Peda Kickstarter.. Starter Deeompressor Side Stand Tripmeter ccxocxocqqqqmmn Operating Controls 11 % 03/05/20 09:57:58 31KCY5807021 Component Locations 44:» engine slop button clutch lever starter decompressor \ever 12 Operating Controls vipmeler from brake lever (h rattle % 03/05/20 09:58 : 03 31KCY5807022 44:» Component Locations fuel valve 4+ choke lever % 03/05/20 09:58 : 08 31KCY5807023 Component Locations 14 Operating Controls kickslaner rear brake pedal 4+ 03/05/20 09:58:17 31KC‘15807024 ‘ Operating Controls ON Fuel Valve Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. OFF Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor. k .9 RES a 2 Turning the fuel valve to RES allows fuel to The three—way fuel valve is used to control the flow from the reserve fuel supply to the flow of fuel from the fuel tank to the carburetor. carburetor. (cunt’d) Operating Controls 15 03/05/20 09:58:27 31KCY5807025 Operating Controls The reserve fuel supply is: 0.40 US gal (1.5 12) 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. 'Q‘ Choke Lever B detentposition C fully OFF (1) choke lever 16 Operating Controls 5 \ The choke lever is used for starting the engine (page 29 ). The choke increas ' the percentage of fuel in the fuel/air mixture delivered to the engine. 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 SSDC (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). J \ 03/05/20 09:58 : 36 31KC‘15807026 Operating Controls Engine Stop Button The engine stop button is sed to turn the engine off during normal riding situations. To operate, push the button in and hold it in until the engine stops completely. 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. Throttle 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. 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 31KC‘1580702’7 Operating Controls Shift Lever The shift lever is used to select the next higher or lower gear in the transin sion. 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 Shifting Gmrs, page 35 . 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 Conlmls Kickstarter 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 Starring Procedure, page 29. Starter Decompressor Lever 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 Starmr Dacampmsmr Levar, page 32 . % g \ 03/05/20 09:58 : 56 31KCY5807028 Operating Controls Side Stand The side stand is \ed to support your motorcycle while parked (page 39). To operate, use your foot to lower the stand. Before riding, raise the stand. Tripmeter FRONT (1) tripmeter (2) tripmeter reset knob FRONT (2) tripmeter reset knob The tripmeter( l) 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). Operating Controls 19 03/05/20 09:58:58 31KCY5807029 ‘ 20 Operating Comm]: 7 \ +HI? J l 03/05/20 09:59:03 31KC‘1580703D 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 nd how to perform the recommended pre-ride inspection of your Honda. Are You Ready to Ride 7 Protective Apparel .. Is Your Motorcycle Ready to Ride ‘7 Pre-ride Inspection ..... Before Riding 21 7 l 03/05/20 09:59:13 31KCY5807031 Are You Ready to Ride? Before you ride your motorcycle for the first time, we strongly recommend that you: . read this owner's manual . mak 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-sleevedjersey, shin, orjacket 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. J l 03/05/20 09:59:23 31KC‘15807032 Are You Ready to Ride? AWARNING 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. 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 (USA only). Always wear a face shield or goggles to protect your eyes and help your vision. Add nal Riding Gear ln add on to a helmet and eye protection, we also recommend: 0 Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. ' Off-road motorcycle gloves to help protect your hands. 0 Riding pants with knee and hip pads, a riding jersey with padded elbows, and a chest/ shoulder protector. Before Riding 23 3 03/05/20 09:59:34 31KC‘16807033 Is Your Motorcycle Ready to Ride? Before each ride, it's important to inspect your motorcycle and make ure any problem you find is conected. A pie—tide 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. AWARNING 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: Tirrs Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damage or excessive wear (page 118 ). Spa/(ex & Make sure the spokes and rim Rimx locks are tight. Also check the rims for damage (page 112 ). Lmkx Look under the motorcycle for signs of leaking fluids (fuel, engine oil, brake fluid). J \ 03/05/20 09:59:52 31KCY5807034 Is Your Motorcycle Ready to Ride? Engine Oil Fuel Drive Chain Cab/ts Nurx & Balm Check the level and add oil if needed (page 67 ). Check the level and add fuel (page 61 ) if needed. Also make sure the fuel fill cap is securely fastened. 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). Check the cable housings for wear. Check the fittings for looseness. Replace or tighten as needed. Use a wrench to make sure all ac ssible nuts, bolts, and fasteners are tight. Spark Plug & Cap Check for looseness (page 84 ). Check these items after you get on the motorcycle: Throttle Bra/(ex Check the freeplay and adjust if needed. Rotate the throttle to make sure it moves smoothly without icking, and snaps shut automatically when it is released, in all steering positions (page 77). 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 31KC‘15807035 ‘ Is Your Motorcycle Ready to Ride? Clutch Check for smooth operation and Lever adjust if needed (page 80 ). Head/{gm Check for proper operation. Remember, be sure to take care of any problem you find or have your Honda dealer oorreel it before you ride. 26 Before Riding fl J l 03/05/20 10:00:08 31KCY5807036 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 informationihow to make turns, ride on hills, etc., see the Tips & Practice Guide/hr the Off-Highway Motorcyclist booklet that came with your Honda (USA only). 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 . Safe Riding Precautions. Starting & Stopping the Engine Preparation Starting Procedure Starter Decompr Flooded Engine How to Stop the ngme. Shifting Gea Braking Parking Post-ride nspec ion Basic Operation & Riding 27 03/05/20 10:00:15 31KCY580703’7 Basic Operation & Riding Safe Riding Precautions Before riding your motorcycle for the first time, please review the Important Safety Information beginning on page 2 and the previous section, titled Befom 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 i ze and weight. For your safety, avoid starting or operating the engine in an enclosed area such a, garage. Your motorcycle’s exha :t cont ns poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death. 28 Basic Operation & Riding J l 03/05/20 10:00:26 31KCY5807038 Starting & Stopping the Engine Always follow the proper starting procedure described below. Your motorcycle can be kic tarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter. Preparation Make sure that the transmission is in neutral. Turn the fuel valve ON. (1) choke lever fully ON (A). Starting Procedure Normal Air Temperature 1()°* 35‘“C (50“ *QSDF) §Ag lully ON B detent posttion (C) lully OFF 1. Pull the choke lever ( l ) up all the way to To restart a warm engine, follow the procedure for High Air Tempcramrc. (cont’d) Basic Operalinn & Riding 29 n l 03/05/20 10:00:35 31KCY5807039 Starting & Stopping the Engine . Keep the throttle fully closed. . 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. MN Allowing the kit/(starter to map bar/(freely agaimt 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 Ex en e me of the choke may impair pixtart and cylinder wall lubrication and damage IliL’ engine. 5. Warm up the engine by opening and closing the throttle s 'ghtly. 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. J l 03/05/20 10:00:49 31KCY5807040 High Air Temperature 35°C (9501;) o bove 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/'ail.r to restart: 1. Pull the starter deoompressor lever (page 32) in, open the throttle fully, and operate the kickstaner 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). Starting & Stopping the Engine Low Air Temperature 10°C (50°F) or below 1. Follow steps 1 7 3 under Norma/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 ( l ) is pushed down all the way to fully OFF (c). Extended are of the choke may impair pixtari and cylinder wall lubrication and damage the engine. Basic Operation & Riding 31 03/05/20 10:00:59 31KCY6807041 Starting & Stopping the Engine Starter Decompressor Lever An automatic engine decompression system is interlocked with the kic tarter to make starting easier, but if you have d 'ficulty starting the engine, you may use the manually-operated starter decompressor lever. (1) staner decompressor lever 32 Basic Operation & Riding fl . 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. 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 startior the engine will not start and the rear tire will skid. J l 03/05/20 10:01:11 31KCY6807042 Starting & Stopping the Engine If the rear tire SkidS.‘ 3 m4; . Pull the starter decompressor lever in. This will release engine compression and allow the rear wheel to roll while turning the engine over. . Release the starter decompressor lever. . If the engine does not start, pull the starter decompressor lever in again. Wait until the motorcycle gains speed and release the lever. l. 2. 3. 4. 5. 6. Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine: Push the choke lever down all the way to OFF. Pull and hold the starter decompressor lever. Open the throttle fully. While pushing the engine stop button, crank the engine several times with the kickstarter. Release the starter decompressor lever and engine stop button. Follow the High Air Tampvmmre starting procedure (page 31). Basic Operalinn & Riding 33 03/05/20 10:01:16 31KC‘16807043 l 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 steps. 34 Basic Operation & Riding fl J l 03/05/20 10:01:26 31KC‘15807044 Shifting Gears 2345 1 Your motorcycle has five foiward gears. 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. 3. Depress the shift lever from neutral down to 4. u. first gear. Release the front brake. Gradually open the throttle while you slowly release the clutch lever. It' engine rpm (speed) is too low when you release the clutch lever, the engine will stall. It' engine rpm is too high or you release the clutch lever too quickly, your motorcycle may lurch forward. . When you attain a moderate speed, close the throttle, pull the clutch lever in, and raise the shift lever. At‘ter shifting, release the clutch lever and apply the throttle. (cont Basic Operalinn & Riding id) 35 J l 03/05/20 10:01:35 31KCY5807045 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. lmprope hifting may damage [116 engind, 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 31KCY5807046 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 afety, exer ’se extreme caution when braking, accelerating, or turning. (cont’d) Basic Operalion & Riding 37 03/05/20 10:01:47 31KC‘1580704’7 Braking When descending u 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 ? l J l 03/05/20 10:01:51 31KC‘16807048 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 2t level place to park. Basic Operalion & Riding 39 03/05/20 10:01:56 EIKCYSBDJMB 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 ? l 03/05/20 10:02 : 02 31KCY580705D 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 instruction. ‘or specific maintenance ta . You’ll al find important safety precautions, information on oils, and tips for keeping your Honda looking good. For information about the exhaust emission and noise emission requirements of the US. Environmental Protection Agency (EPA) and the California Air Resources Board (CARB), see page 165 . Before You SEVVICE Your Honda The Importance of Maintenance ..... Maintenance Safety... Important Safety Pre utio Maintenance Schedule Maintenance Record . Competition Inspection Servicing Your Honda 41 J l 03/05/20 10:02 : o7 31KC‘15807051 Servicing Your Honda Service Preparations Component Locations ............ Tools ............ Side Cover Reino a1 Air Cleaner Housing Cover Removal. Seat Removal . S erviL‘e Procedures Fluids & Filters mwbw Crankease Breather (Californi only). 42 Servicing Your Honda Engine Throttle Clutch System Engine ldle Speed Spark Plug .. Spark Arrester Side Stand Drive Chain Headlight & Al 1;, Appearance Care ................ 03/05/20 10:02:15 31KC‘15807052 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 pre— ride 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 ection of the manual provid a Maintenance Schedule. The servi intervals in this schedule are based on average riding conditions. More frequent service is needed it' you subject your motorcycle to severe use (see the Competition Inspection checkli . page 52 ) or ride in unusually wet or dusty are s. 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. AWARNING 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 31KC‘15807053 ‘ 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 fl 03/05/20 10:02:26 31KC‘15807054 Maintenance Safety The maintenance section includes instructions on how to perform some important maintenance ta. Some of the most imponant safety precautions follow. However, we cannot want you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. AWARNING 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. 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. 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 31KC‘15807055 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 x .r‘ flash point) solvent such as keroseneinot gasoline’to clean parts. Keep cigarettes, sparks, and flames away from all fuel- relaled pans. 46 Servicing Your Honda ? l 03/05/20 10:02 : 39 31KCY5807056 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 . 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 schedule 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 cap' ble of performing a given task or need a tance, 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 31KCY5807057 Maintenance Schedule Perform the pre—ride inspection (page 24) at each scheduled maintenance period. 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. ‘ Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and 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 Summary of Maintmance Schedulc Norm and Pracedurex: 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. Maintenance Procedures: 1: inspect and clean adjust, lubricate, or replace, if nece sary clean adjust lubricate replace FLT??? A 03/05/20 10:03:12 31KC‘16807058 ‘ Maintenance Schedule thchcvcr 1“.qu chulur Munu. numul Frcqucmy Comes le Mum. Rem r> um Mm 6m) 1.200 mm 2.400 [0 km 150 1.000 2.000 3.000 4.000 pugs: ch Mmuh | u 12 I8 24 . Fucl anc l 1 7 - « Fucl Slmmchcrccn c c 7 ’ Thmu|c()pcr.\m\n l 1 77 A" Clcuncr Nola l c c C 73 Cmnkcmc Emma Nola 2 l l l 1 7a Spurk Plug l l l 1 84 . Vulvc Clcuruncc l l l l 1 7 A En mcou R R R R R m x J En mc on film R R R R R as a 2 « Engchxl Strmnchuccn c c 7 m Down Tnhc ’ Dcwmprcamr. mm 1 l l l 1 7 . « En mcmu pcud l l l l 1 83 ' Should he scn‘xccd h) your Houdu dculcr. unlc» ma mmcr has the propcr mob and >crvmc dam .md 1s mcuhuumuu) quulmed Rem to ma omcml Hundu *rx Muuuul npugc I72 ), "In mc mum of mu), we rcwmmcnd mm xmm he xmmcd only by your HmuJu dculcr Koonl'dl ng Your Honda 49 A 03/05/20 10:03:32 31KC‘15807059 ‘ Maintenance Schedule A WhIclIcvcr lmml Ragnm Mnnn. Inmvnl Frcqucncy Comes Fm: Mnm Rem um Mm 6m) 1.200 mm 2.400 [0 [mm km 150 1.000 2.000 3.000 4.000 page: , ch Mnnm | n 12 I8 24 Dnvc Chum Nola l I, L I L c\ an 300 “II «500 klm nr ‘» mmuh~ I23 2 Dnvc cmm SlIdcr I I I I IE 3 mm FluId Nola 3 I I I I ma 3ka F.1d Wcm' I I I I | In E Bmkc s slcm I I I I I m7 E .. chdllplu Ann I I m 3 Clumh Swlcm I I I I I so A 5 Suit 5an I I I22 , , \ x J g » Smpcnsmn I I 88 a J g . Spnk Anew c: every mm) .n. 1 [.600 kxm (It 85 :. cvcr mu opcmnn noun g » Mus. Bulls. chncn I I I 7 a ‘ th S/TIrcS I I I I I HZ. H8 . SIccnn chd Bcunn s I I I 7 ’ Should he scn‘Iccd h) ynur Honda dealer. unlc» th mmcr Inn Ihc propcr mob and mmc duu .Ind n Incchm nu) quulmcd Rem m ma omcml I-Inndn Scrvmc Mnnun Ipngc I72 7, "In mc nncmn of men, we rcmmmcnd mm Imm he mum only by your I-Innun dcnlc: 50 Servicing Your Honda +HI? 7 I 03/05/20 10:03 : as 31KC‘1680706D 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 name Performed By: Notes Months 600 (1,000) or 0 1.200 (2,000) or 12 1.800 (3,000) or tea 2.400 (4,000) or 24 1') 3.000 (5,000) or 30 3.600 (0,000) or 30 4.200 (7,000) or 42 4.800 (8,000) or 43 5.400 (9,000) or 54 Servicing Your Honda 51 A 03/05/20 10:03 i 51 31KC‘15807061 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: Refer to the Maintenance Schedule (page 48) for regular service intervals. No Item Inspect For: Action Rctcr In Page: t 1 tin prerrtde inspection 24 llfima 2 engine oil contaminanls change 64 3 fuel line deterioration, damage, or leakage replace , 4 valve clearance correct clearance adjusl 7 5 engine idle speed correct idle speed adjusl x3 6 carburetor choke proper operation 7 7 52 Servicing Your Honda 777:? 03/05/20 10:04:03 31KC‘15807062 ‘ Competition Inspection No Item Inspect For: Action Refer In Page: 7 decompr ssion mechanism proper freepl' , adprsl , 8 clulch di proper operation. see worn 1 replace , 9 air cleaner contamination or tears clean or 73 replace 10 spark pl ug gap, tightness. proper heat range. highr tighten, 85 tension terminal security replace or secure 1 1 steering head bean’ngs rree rotation of handlebar and steering adprsl or , {:1 stem nut tightness relighlen {V} 12 front suspension smoolh openllnn, air pressure. oil capacity. replace or 88. 91 no oil leaks. good bool eondillon adprsl 13 rear suspenoion smoolh openllnn, no oil leaks. proper replace or 89. 98 spring height adjusl NOTE 1: Competition use may cause more rapid clutch disc wear. Refer to the official Honda Service Manual. or see your Honda dealer for elutch di, asembly and wear inspection. (cunl’d) Servicing Your Honda 53 03/05/20 10:04:15 31KC‘16807063 Competition Inspection No Item Inspect For: Action Refer In Page: 14 awingarm bearings smunlh cpernnnn replace xv 15 rear suspension linkage wear replace xv bushings ln brnke pads wear beyond service limil replace 1 lo 17 drivechain’ 67.2 in (1,707 mmi/ 108 pins replace [25 max. length/pin 18 apmckela wear and secure inalallanan replace or [26 lighlen C» 19 aen security liplnen no 20 headlight proper benrn arm adpnl 130 2 l lripmeler proper nperalion replace 1‘} 22 cnnlrnl cables smunlh opemllnn, kinks and correct lubricate or , muting replace 23 engine monnling bolls lighlne» lighlen 7 54 Servicing Your Honda 7 l +HI? % 03/05/20 10:04:22 31KCY5807064 A? Component Locations dutch lever oil filler cap/ rear suspension dipstick sreering head luel tank from brake hose Iron! suspension lrame 0H drain boll crankcase oil drain bo‘l crankcase breather lube p‘ug (CaHlornia only) side stand 4+ aircleaner lell side cover chain slipper drive chain rearwhee‘ ax‘e chain slider Servicing Your Honda 55 03/05/20 10:04:27 31KCY5807065 ‘ Component Locations kickslarter fuel lill cap lhroltle lronl brake lever spark plug lower clulch adjusting nut ‘Et’: front wheel axle 46‘57 rim lock carburelor rear brake pedal rim lock 56 Servicing Your Honda Tl l l@ 03/05/20 10:04 : 33 31KCY5807066 Refer to Safery Pracamimzs on page 45 . (1) mum-purpose wrench 2 plug wrench 3 tool bag Tools 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. Servicing Your Honda 57 03/05/20 10:04:44 31KCY5807067 ‘ Side Cover Removal Refer to Safery Pracamimzs on page 45 . Removal 1. Remove the right seat bolt (page 60 ). RIGHT SIDE 2. Use a hex wrench to remove the two bolts (1 ). 3. Pull the side cover out. 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. ‘1 3' 4. Tighten the seat bolt. Use the same procedure to remove and install the left side cover. (1) bolts 58 Servicing Your Honda fl 03/05/20 10:04:52 31KCY5807068 i Air Cleaner Housing Cover Removal Refer to Safety Pracamimzs on page 45 . The air cleaner housing cover must be removed to service the air cleaner. LEFT SIDE Removal 1. Lift the D-ring on each quick—release fastener ( 1 ) and turn it counterclockwise until it releases. Installation 1. A gn the air cleaner housing cover with the . air cleaner housing. ‘1 3' 2. Push each quick-releas fastener into it lift its D-ring, and turn it clockwise until secure. (1) quick release fastener Servicing Your Honda 59 03/05/20 10:05:04 31KCY5807069 Seat Removal Refer to Safery Pracamimzs on page 45 . 1 bolts 2 slot (3) pin E4; prongs 5 hooks 60 Servicing Your Honda The seat must be removed to adjust rear suspension pre-load. Removal 1. Remove the two bolts ( 1) securing the seat. 2. Slide the seat back. lnst‘ . Align the locating slot (2 ) under the front of ation the seat with the pin (3) on the rear of the fuel tank. . Align the locating prongs (4) on the bottom of the seat with the hooks (5 ) on the frame. . Slide the seat into position. . Install the bolts and tighten them. 03/05/20 10:05:14 31KCY580707D Fuel Refer to Safety Pracamions on page 45. Fuel Recommendation Type unleaded Pump Octane 91 (or higher! Number 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. Use of lower octane gasoline can cause persistent “pinging" or ‘ park 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.) 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 g ohm or an oil/gasoline mixture. Avoid getting dirt, dust, or water in the fuel tank. Servicing Your Honda 61 03/05/20 10:05:26 31KC‘15807071 Fuel Refueling Procedure Fuel Tank Capacity, including reserve: 2.51 US gal (9.5 0) Reserve Capacity: 0.40 US gal (1.5 12) (1) luei fill cap (3) steering stern nut (2) breather tube (4) liiier neck 62 Servicing Your Honda a i 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 overt‘illing the tank. There should be no fuel in the filler neck. AWARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. 0 Stop the engine and keep heal, sparks and flame away. - Handle fuel only outdoors. - Wipe up spills immediately. 03/05/20 10:05:31 31KC‘158070’72 ‘ 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 7 \ 03/05/20 10:05:40 31KC‘158070’73 Engine Oil Refer to Safery Pracamimzs on page 45 . 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 diny oil can damage your engine. Running the engine with insuffi “ent oil can cause serious damage to the engine and transmission. 64 Servicing Your Honda Oil Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label viscosity (weight) SAE 20W-50‘/’|0W-40 JASO T 903 standard MA suggested oil“ Pro Honda GN4 or HP4 iwithout molybdenum additivesl 4-stroke oil lUSA & Canadal, or Honda 4-stroke oil iCanada only), or an equivalent motorcycle oil J \ 03/05/20 10:05:52 31KCY5807074 Engine Oil ‘ For normal air temperatures. Use SAE 1()W-4() when the outside temperature is below 0°C (32°F). See next age for additional temperature/vi ity 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. 0 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. i’ $35.; ,- {3/ NOT RECOMMENDED OK ' Do not use non-detergent, vegetable, or castor based racing oils. Servicing Your Honda 65 03/05/20 10:06:66 slacysauiu/s Engine Oil Olher viscosilies shown in the following chart JASO T 903 sizindurd may be used when the average lemperulure in The JASO T 903 sizindurd is an index lo choose your riding urea is wilhin the indicated runge. engine oils for 4-slmke motorcycle engines. There are two classes: MA and MB. Oil conforming 10 [he standard has [he following classil'ieulion on the oil eunluiner. PRODUCT MEETNG JASO T 903 COMPANV GUARANTEEWG TH‘S MA PERFORMANCE (1) code number of the sales company 0! the oil (2) oil classlflcatlon 66 Servicing Your Honda w J l 03/05/20 10:06 : 12 31KCY5807076 Engine Oil Checking & Adding Oil FRONT (1) (1) oil ltHer 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 ( l) 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. . Hold the motorcycle upright. Insert the dipstick until it seats, but do not screw it in. . Remove the dipstick and check the oil level. 0 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. (Do not overfill.) (cont’d) \IQU. Servicing Your Honda 67 J \ 03/05/20 10:06:21 31KCY5807077 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 lush with the lower edge of the hole. If it is, ins a 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) 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. Ur rig the wrong ailfiller may rem/t in leaks or prematurc enginz damagc. % 03/05/20 10:06 : 33 31KCY5807078 4):» 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 LEFI' SIDE (1) drain bolt (down tube) (2) drain bolt (left crankcase) Drain 1hr Engint 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 nec (cont’d) Servicing Your Honda 69 3 03/05/20 10:05:44 31KCY5807079 Engine Oil 7. Pour the drained oil into a suitable container and dispose of it in an approved manner (page 145 ). Improper disparal of drained fluids ix harmful to the environment. 8. Install the oil drain bolts and tighten to the specified torque: Crankouse 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) 70 Servicing Your Honda Imtall a New Engine Oil Filter: Change the oil filter after draining the engine oil. 9. Remove the oil filter bolts (3 ) and oil filter cover (4). 3 oil filter bolts 4 oil filtercover 03/05/20 10:06 : 54 31KCY5807080 Engine Oil 10. Remove the oil filter (5 ) from the cover. (6) (9) (5) (7) (5) oil Mar (6) O-ring k ‘1 (7; spring 8 (9) rubber seal (a) OUT-SIDE mark 11. Discard the oil filter in an approved manner (page 145 ). Improper dispaxal of drained fluids ix harmful to the environment. 12. Check that the oil filter cover O-ring (6 ) is in good condition. A 1 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 ailfilter can came Seriaux engine damage. 14. Reinstall the oil filter cover, making sure the bolts are tightened securely to the specified torque. Oil filter bolt: 9 Ibf-f‘t (12 N-m , 1.2 kgf-m) (cont’d) Servicing Your Honda 71 03/05/20 10:07:06 31KCY5807081 Engine Oil Add Engine Oil: If the oil filter was replaced: 1.9 US qt (1.8 13) If the oil filter was not replaced, use approximately: 1.8 US qt (1.7 12) 72 Servicing Your Honda ? 1 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 pus on 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.) 2t). Reinstall the oil filler cap/dipstick. 21. Check for oil leaks. 03/05/20 10:07:14 31KCY5807082 Air Cleaner Refer to Safety Precautions on page 45 . Proper air cleaner maintenance is very important for off-road vehicle . A dirty, water- soaked, 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. Your motorcycle“ 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. 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 performance and premature engine wear. Servicing Your Honda 73 03/05/20 10:07:24 31KCY5807083 i Air Cleaner 5. Gently wash the air cleaner in clean, non- Cleaning flammable (high f sh point) solvent such as kerosene inot gasoline. After cleaning, LEFT SIDE 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 ‘1 3' 8 set slpring not fully absorb the oil. all' C eaner 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 J \ 03/05/20 10:07:32 31KCY5807084 Air Cleaner 10. 11. 12. . 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 exce oil. (To keep your hands dry, place the air cleaner in a clean pl tic bag before spreading the oil into the air cleaner.) . Install the air cleaner on its support. Apply a thin coat of grea surface of the air cleaner : Install the air cleaner with the lug on the holder aligned with the hole in the air cleaner. Hook the set spring. 13. Install the air cleaner housing cover. Servicing Your Honda 75 J \ 03/05/20 10:07:39 31KCY5807085 Crankcase Breather (California only) Refer to Safety Pracamimzs 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) 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. J \ 03/05/20 10:07:52 31KC‘15807086 Throttle Refer to Safety Pracamimzs on page 45. Throttle Freeplay RIG HT SIDE (1) lreeplay Inspection Cheek freeplay (1). Freeplay: 1/16*1/4 in (2*6 mrn) If necessary, adjust to the specified range. Upper A nent upper adjuster. RIGHT SIDE 1 rubberdustcover 2 upperlock nut (3) upper adjuster 1. Pull the rubber dust cover (1 ) back. tments are generally made with the 2. Loosen the upper lock nut (2 ) on the throttle cable mechanism. 3. Turn the upper adjuster (3 ). (cunt’d) Servicing Your Honda 77 % 03/05/20 10:08 : 03 31KCY5807087 Throttle as 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 s after replacing the throttle cables or removing the carburetor. It ' also used if you can not get the proper adjustment with the upper adjuster. 78 Servicing Your Honda LEFI' SIDE (4) lower lock nut (5) lower adjuster l. Loosen the lower lock nut (4) on the cable. 2. Turn the lower adjuster (5 ). 3. Tighten the lock nut on the adjuster. If y 't get the freeplay within the speeit d range, contact your Honda dealer. J \ 03/05/20 10:08 : 12 31KCY5807088 Throttle Inspection (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. Throttle 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 cable steering position . 5. Lubricate the cables with a commercially— available cable lubricant to prevent premature rust and Corrosion. ‘or tension or stress in all Servicing Your Honda 79 J \ 03/05/20 10:08:26 31KCY5807089 Clutch System Refer to Safety Pracamimzs on page 45. Clutch Freeplay LEFT SIDE 4; Check freeplay. Freeplay: 3/8* 13/16 in (10*20 mrn) If necessary, adjust to the specified range. Improper freeplay adjustment can cause premature clutch wear. 80 Servicing Your Honda Upper Adj \tment Minor adj tments are generally made with the upper clutch cable adjuster. LEFT SIDE (2) dust cover (+) increase freeplay 3 upper lock mu (7) decrease lreepiay 4 upperciutch 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. J l 03/05/20 10:08:38 31KCY580709D Clutch System 4. Tighten the lock nut and check the freeplay again. Lower Ad’ ent 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) (5; lower adjusting nut 6 lower lock nut (+) increase freeplay (7) decrease lreeplay . Loosen the upper lock nut (3) and turn the upper clutch cable adjuster (4) all the way in (to provide maximum freeplay). . Tighten the upper lock nut and pull the dust cover (2) back to normal position. . Hold the lower adjusting nut (5) and loosen the lower lock nut (6) at the lower end of the cable. .Tum the lower adjusting nut to obtain the specified freeplay. . Hold the lower adjusting nut and tighten the lower lock nut. Check the adjustment. (cont’d) Servicing Your Honda 81 J \ 03/05/20 10:08:46 31KCY5807091 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 Scs may be worn. See your Honda dealer or refer to the official Honda Service Manual (page 172 ). 82 Servicing Your Honda Other Inspections & Lubrication 0 Check that the clutch lever a, embly 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 31KCY5807092 a Engine Idle Speed Refer to Safety Pracamimzs on page 45. LEFT SIDE (1) throttle slop screw (+) increase rpm (7) decrease rpm 4 \ The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop—and-go riding is sufficient. Do not attempt to compensate for faults in other. stems by adjusting idle speed. See your Honda dealer for regularly scheduled carburetor adjustments. 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 i 100 rpm Servicing Your Honda 83 03/05/20 10:09:07 31KCY5807093 Spark Plug Refer to Safety Pracamimis on page 45 . Spark Plug Recommendation The recommended standard spark plug is sati ‘lury 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 DPRBZ(NGK| or X24GPR-U1DENSOi For extended high DPRQZ (NGKl or speed riding X27GPR-U {DENSOD 84 Servicing Your Honda Use only the recommended type of spark plugs in the recommended heat range. Using .vpark plug: with an improper heat range can mum engilw damage. (1) mum-purpose wrench 2 centerelectrode 3 side electrode (4) spark plug gap 1. Clean any dirt from around the spark plug base. J \ 03/05/20 10:09:18 31KCY5807094 Spark Plug mix: . Disconnect the spark plug cap. . Remove the spark plug with the multi- purpose wrench ( 1) provided with your motorcycle. . 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. . Check the spark plug gap (4 ), using a wire- type feeler gauge. If adjustment is necessary, bend the side electrode carefully. The gap should be: 0.024i0.028 in (050,010 mm) Make sure the plug washer is in good condition. If you have to install a new plug, first check the gap. . With the plug washer attached, thread the spark plug in by hand (to prevent cross- threading). 7. Tighten the spark plug: a about 1/8-1/4 turn after it seats (if the old plug is good). u about 1/2 turn after it seats (if installing a new plug). Improperly tightened Spark plugs can damage the engine. T00 lame, you can burn a pixton. T00 tight, you can damage the threadx. Servicing Your Honda 85 J l 03/05/20 10:09:28 31KCY5807095 Spark Arrester Refer to Safery Pracamimzs on page 45 . 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. 86 Servicing Your Honda RIGHT REAR (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 ). % 03/05/20 10:09:34 31KCY6807096 ‘ Spark Arrester 3. Use a brush to remove carbon deposits from 4. Install the spark arrester and the gasket in the the spark arrester screen. Be careful to avoid muffler and tighten the three bolts securely. damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necel ry. Check the gasket. Replace, if nee Servicing Your Honda 87 03/05/20 10:09:42 31KCY5807097 i Suspension Refer to Safety Pracamimzs on page 45 . Front Suspension Inspection Loose, worn, or damaged suspension components may adversely affect the handling FRONT and stability of your motorcycle. If any , ension 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. (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 fl % g l 03/05/20 10:09:51 31KCY5807098 44:» 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. Rear Suspension Inspection LEFT SIDE (1) swingarrn bearing RIGHT SIDE (1) swlngarm 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). (cont’d) Servicing Your Honda 89 7 l 03/05/20 10:09:56 31KC‘15807099 Suspension 2. 90 Check that the fasteners for the shock absorber attachment points (2) and rear suspension linkage attachment points (3) are secure. . Check for oil leaks in the shock absorber. If any rear suspension components appear worn or damaged, see your Honda dealer for further inspection. Servicing Your Honda 03/05/20 10:10:09 31KC‘15807100 ‘ Suspension Cnndilitm Oil Reboundr Campr Front Suspension Adjustment Volume Damn Damn Entire range of travel is lot) 7 tone: sol-[er The front suspension can be adjusted for the hard- rider’s weight and riding Conditions by Entire range of travel is lot) 7 differ suffer changing the oil volume and the rebound and WT! (bt‘lmmingl compression dumping. Use the following chart lulliflllm\€1i>gt‘°d-bul "meme ’ ’ to determine the correct adjustment for you. the final 51311850“le are too soft tbutmmmg), 'llte mtual ttage» of traxel reduce , 7 C] are gout], bul the fmal g ; xluges are hard 'llte mtual ttage» of traxel reduce uiffer suffer are too soft. but the final urge» are good 'llte mtual ttage» of traxel Infleflw mfter softer are too hard, but [he final urge» are good Servicing Your Honda 91 03/05/20 10:10:15 31KCY5807101 Suspension Front Suspension Air Pressure The standard air pressure is () psi (0 kPa, 0 kgf/eml). 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. 92 Servicing Your Honda ? l (1) pressure release screws (2) fork caps % 03/05/20 10:10:25 31KCY5807102 ‘ Suspension 1. Raise the front wheel off the ground by placing a support block under the engine. Front Suspension Oil Volume 2. Remove the pressure release screws (1 ). 3. Check that the O-ring is in good condition. 4. Install the pressure release screws. (1) fork caps (2) (2) oil level (cont’d) Servicing Your Honda 93 3 03/05/20 10:10:36 31KCY5807103 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 pre, ure. 3. Remove the fork caps ( l) 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 . 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: 14751 in (87* 129 mm) Increase or decrease oil in increments of: 0.08 US 02 (2.5 cm3) 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 31KC‘16807104 i Suspensmn 5. Be sure the oil level is the same in both fork tubes. Front Suspension Damping 6. Clean and dry the fork springs with a lint- free cloth. Install the fork springs. Oil the Rebound Dampinév fork cap O-rings and install the fork caps. The rebound damping adjuster has at least Torque the fork caps to: 12 positions. Turning the adjuster s 'ew one 16 lbf-ft (22 N-m , 2.2 kgf-m) full turn advances the adjuster 6 positions. Always star1 with the full hard position when adjusting damping. (cont’d) Servicing Your Honda 95 % 03/05/20 10:10:52 31KCY5807105 i Suspension To adjurl to the Standard pavilion: .Tum 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. (1) rebound damping adjuster 2 punch mark 3 reference mark 96 Servicing Your Honda J l 03/05/20 10:11:02 31KCY5807106 Suspension 'on Damping on damping affects how quickly the fork compresses. The fork compre 'on damping adjuster has at least 14positions (clicks). Turning the adjuster screw one full tum advances the adjuster 4 positions. Always start with the full hard position when adjus mg damping. To adjust 10 [hr .mmdard position: LEFT FRONT (1) compresston damping adjuster (cont’d) Servicing Your Honda 97 03/05/20 10:11:09 31KCY680710’7 ‘ Suspenswn 1. Turn the adjuster (l ) clockwise until it will no longer tum (lightly seats). This is the full Rear Suspension Adjustment hard position. 2. Turn the adjuster counterclockwise 8 clicks. The rear suspension can be adjusted for the This is the standard position. rider‘s weight and riding conditions by 3. Make sure that both fork legs are adjusted to changing the spring pre-load and the rebound the same position. and compression damping. Use the following chart to determine the correct adjustment for you. The rear shock absorber assembly includes a ‘1 3' damper unit that contains high pressure nitrogen gas. Do not attempt to di emble, 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. 9s Servicing Your Honda Tl 03/05/20 10: .24 31KC‘15807108 length (to decrease pt‘er load) adjuster to a softer position (to decrease damping force) Suspensmn Condition Step 1 Step 2 Step 3 Bottoming shorten the spring turn the compression length (to increase prer adjuster to a stitt‘er load) position (to increase damping force) Soft lum the compression shorten the spring turn the rebound adjuster to a , rrer lenglh (to increase prer adjuster to a stiffer position (to increase load) position (to increase damping force) damping force) Hard increase the spring turn the compression turn the rebound 11d] uster to a softer position ( to decrease damping force) Excessive Sinking shorten the spring length (to increase prer load) Make changes one step at a time. Test ride your motorcycle after e' h adjustment. If necessary, proceed to the next step. Servicing Your Honda 99 J l 03/05/20 10:11:34 31KCY6807109 Suspension Rear Suspension Spring Pre-Load Pre-load should be adjusted when the engine is cold because it is necessary to remove the muffler. 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 RIGHT SIDE (1) side cover bolts 2 mufflerclam bolt 3 mufflerbolt lower) (4) muffler bolt (upper) % g l 03/05/20 10:11:42 31KCY6307110 4% Suspension 4. Loosen the screw (5 ) on the air cleaner connecting tube clamp and remove the air cleaner connecting tube from the carburetor. Be careful not to allow dust into the carburetor. Severe engine damage could result. RIGHT SIDE (5) screw (8) subframe lower side boll 5. Disconnect the electrical connectors (6 ). (6) (10) (7) (9) (6) electrical connectors 7 rubber band and clip 9 subframe lower side bolt (10) sublrame upper bolt (cont’d) Servicing Your Honda 101 03/05/20 10:11:52 31KC‘15807111 Suspension 6. Loosen the rubber band and clip (7 ). 7. Remove the three subframe mounting bolts (8)(9)(1())- 8. Remove the subframe by pulling it straight back. 9. R' 'e the rear wheel off the ground by placing a support block under the engine. 102 Servicing Your Honda 4 l 1(). Measure the spring length ( 1 ). 3.36 in (212.3 mm) Minimum: 8.08 in (205.3 mm) Maximum: 8.56 in (217.3 mm) Standard: 1 spring length 2 look nut (3) adjustmg nut l 1 l increase preload decrease preload % 03/05/20 10:12 : 03 31KCY5807112 Suspensron 11. To increase spring pre-load: To decrease spring pre-load: Loosen the lock nut (2) with the optional pin Loosen the lock nut (2) with the optional pin spanner and turn the adjusting nut (3) to spanner and turn the adjusting nut (3) to shorten the spring length. Do not shorten to increase the spring length. Do not increase to less than: more than: 8.08 in (205.3 mm) 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. (2) look nut (3) adjusting nut (cont’d) Servicing Your Honda 103 J l 03/05/20 10:12:16 31KCY6807113 Suspension To install the removtd partr: l. at» 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 as \embly. . Connect the electrical connectors by matching the cable colors. . Reinstall the band and the clip. . Tighten the air cleaner connecting tube clamp and the rear brake fluid reservoir stay mount bolt. 104 Servicing Your Honda . 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 Ibf-ft (20 N-m , 2.0 kgf-m) Muffler bolt (lower) (3 ): 24 Ibf-ft (32 N-m , 3.3 kgf-m) Muffler bolt (upper) (4 ): 24 Ibf-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 ' mbly. 6. Reinstall the si e cover and seat. J l 03/05/20 10:12:27 31KCY5807114 Suspension Rear Suspension Damping Rebound Damping The rebound damping adjuster is located at the lower end of the shock absorber. It has at least 16positions. Turning the a ' ter one full turn advances the adjuster 4 positions. To avoid damage to the damping adjuster, do not keep it in the full hard position. To adjust 10 [hr standard position: LEFT SIDE (1) rebound damping adjuster (2) punch mark (3) reierence 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 J l 03/05/20 10:12:35 31KCY5807115 Suspension Compres 'on Damping The compr sion damping adjuster has at least ions. Turning the adjuster one full tum \ the adjuster 6 positi s. To adjuxt to the Standard pmition: LEFT SIDE (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 tum (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 ). J l 03/05/20 10:12:46 31KCY5807116 Brakes Refer to Safery Pracamimzs on page 45. 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. Frequently inspect the s tem 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. Front Brake Lever Adjustment RIGHT SID E (1) front brake lever 2 look nut 3 adjuster Never use adjusters other than those designed for this motorcye e. Install a new adjuster from the lever side with the lock nut under the head of the adjuster. (cont’d) Servicing Your Honda 107 J l 03/05/20 10:12 : 56 31KCY5807117 Brakes . Loosen the lock nut (2 ). 2. To position the brake lever farther away from the handgrip, tum the adjuster (3) clock ' To pot ion the brake lever closer to the handgrip, tum the adjuster counterclockwise. . Tighten the lock nut. . Apply the brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several time. 5. Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage. Freeplay: 3/8713/16 in (10*20 mm) at» 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) 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 31KCY5807118 i Brakes Worn brake pads should be replaced. If the With the motorcycle in an upright position, pads are not worn, have your brake system check the fluid level. inspected for leaks. It should be between the UPPER ( 1) and LOWER (2) level mark. If the level is at or The recommended brake fluid is Honda DOT 4 below the LOWER level mark, check the brake brake fluid from a sealed container, or an pads for wear (page 110). equivalent. Worn brake pads should be replaced. If the Rear Brake Fluid Level pads are not worn, have your brake system /\ inspected for leaks. . t ‘1 RIGHT SIDE <:} The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an (1) equivalent. Other lnsp ‘tions ' 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 31KCY6807119 Brakes 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 ). C» LEFT FRONT (2) (1) lront brake caliper (2) cutout 110 Servicing Your Honda ? l RIGHT REAR (2) cutout (3) rear brake caliper Check the cutout (2) in each pad. If either pad is worn to the cutout, replace both pad, as a set. See your Honda dealer for this service. Other Inspections Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight. J \ 03/05/20 10:13:24 31KC‘1580712D 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 J \ 03/05/20 10:13 : 33 31KCY6807121 Wheels Refer to Safety Pracamimzs on page 45 . 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. Exce ' ely 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. 112 Servicing Your Honda Wheel Rims & Spokes REAR (1) wheat 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 ). J l 03/05/20 10:13:46 31KCY5807122 Wheels 3. Rotate the wheel slowly to see i‘ ' appears to “wobble." If it does, the rim is out of round or not ”true." If the wobble is noticeable, see your l-londa dealer for inspection. Front Wheel Removal (3) (3) E1; tripmeter cable set screw 2 tripmeter cable (3) axle holder nuts (4) axle holder (5) lront axle Removal 1. R 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. (cont’d) Servicing Your Honda 1 13 % g \ 03/05/20 10:13 : 56 31KCY5807123 Wheels 4.} Installation RIGHT FRONT (6) tang E7; tang UP mark . lReverse 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: 65lbf-f1188 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 Ibf‘ft (12 Nm , 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 31KCY5307124 Wheels Rear Wheel Removal RIG HT REAR 1 rearaxle mu 2 adjusler LEFI' REAR (3) 2 adjuster 3 rear axle (2) (cont’d) Servicing Your Honda 1 15 J i 03/05/20 10:14:15 31KCY5807125 Wheels Removal ' 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. J \ 03/05/20 10:14:25 31KCY5807126 Wheels Installation RIGHT HEAR (4) lug E5; slot 6 swingarrn 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. 2. Torque the axle nut to: 65 Ibf-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. Servicing Your Honda 117 03/05/20 10:14 : 34 31KC‘15807127 Tires & Tubes Refer to Safety Prccamimzs 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. AWARNING 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. 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 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 haLards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install a new cap. 03/05/20 10:14:44 31KCY5807128 i Tires & Tubes Always check air pressure when your tires are “cold." It‘ you check air pressure when your Inspection tires are “warm"ieven if your motorcycle has only been ridden for a few miles’the A flat tire or blowout is inconvenient and may readings will be higher. If you let air out of even cause an accident. Take time to inspect warm tires to match the recommended cold your tires and wheels before you ride. For more pressures, the tires will be underinflated. information about handling flat tires, see The correct “cold" tire pressures are: page 150. Front 15 psi (100 kPa , 1.0 kgf/cmzl Rear 15 psi (100 kPa,1.0 kgf/cmzl If you decide to adjust tire pressures for a particular riding condition, make changes a little at a time. (1) tire tread depth 2 spoke nut 3 rlm lock nut (cont’d) Servicing Your Honda 119 03/05/20 10:14 : 54 31KCY5807129 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 cr \ 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. 0 Check the position of both valve stems. A tilted valve stem indicates the tube \ slipping inside the tire or the tire is . lipping 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 31KC‘1680713D 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. AWARNING 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. Always use the size and type of tires recommended in this owner‘s manual. Front 80/100-21M/C 51M Rear 110/100-18M/C 64M ' Use a replacement lire equivalent to the original. I 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. I Have the wheel balanced after a new tire is installed. ' We recommend that tires be replaced by your Honda dealer. Servicing Your Honda 121 03/05/20 10:15:12 31KCY6807131 Side Stand Refer to Safety Pracamimzs on page 45 . LEFT SIDE (1) side stand spring 122 Servicing Your Honda 3 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 iff or squeaky, clean the pivot area and lubriLate the pivot bolt with clean engine oil. 03/05/20 10:15:22 31KC‘15807132 Drive Chain Refer to Safety Pracamimzs on page 45. 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. 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. It is not nec ary to remove or replace the drive chain to peiform the recommended service in the Maintenance Schedule. Inspection LEFT SIDE (1) drive chain 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 3/8i‘l 3/4 in (35*45 mm) (cont’d) Servicing Your Honda 123 J l 03/05/20 10:15:32 31KCY5807133 Drive Chain 2. Check drive chain slack at several points along the ch' n. The slack should remain constant. If it isn’t, some links may be kinked and binding. Lubr' ing the chain will often eliminate binding and kinking. EA zve chain Slack may allow the drive chain to damagd the engine casex. 3. Inspect the drive chain for: . damaged rollers - loose pins - dry or rusted links - kinked or binding links - excessive wear Replace the drive c ain (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. . 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). J l 03/05/20 10:15:41 31KCY5807134 Drive Chain LEFT SIDE (2)0hai s (3)0hai guideslider 4 chain roller 5 (6) depth 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. 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. Measure a span of 108 pins New Chain: Service Limit: 66.9in (1,699 mm) 67.2in (1,707 mm) (ccnt’d) Servicing Your Honda 125 03/05/20 10:15:50 31KC‘15807135 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. Damaged Sprocket Worn Sprocket Teeth Teeth «25: Normal Sprocket Teeth GOOD Uxe of a naw chain with worn sprockets will came rapid chain wear. 126 Servicing Your Honda Adjustment LEFT SIDE (2) (1) axle (2) axle nut $33 chain adjuster 4 Index mark (5) stopper pm J l 03/05/20 10:16:04 31KC‘15807136 ‘ Drive Chain . Hold the axle ( l ) and loosen the rear axle nut (2 ). Lubrication 2. Turn both the right and left adjusters (3 ) equally to increase or dee e 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 p ,sible to verify proper ssembly. 6. Recheek drive chain slack. 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 J l 03/05/20 10:16:15 31KCY5807137 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) master link retaining clip 128 Servicing Your Honda When the drive chain becomes extremely dirty, it should be removed and cleaned prior to lubrication. l. w 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. . 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. . 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. 520V80r RK 520M026 03/05/20 10:16:23 31KCY5807138 Drive Chain 4. Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. . Lubricate the drive chain. . 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 in adjacent rear sprocket teeth while in. rting the master link. Install the master link retaining clip so that the closed end of the retaining clip will f‘ e the direction of forward wheel rotation. 7. Adjust the drive chain and rear brake pedal freeplay. awn More About: Drive Chain 0 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 inst la 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 J \ 03/05/20 10:16 : 34 31KCY5807139 Headlight & Taillight Refer to Safety Pracamimzs on page 45. Headlight Bulb FRONT 1 headlight mount bands 2 number mate 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 headhght 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. J \ 03/05/20 10:16:40 31KC‘15807140 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. Headlight & Taillight Servicing Your Honda 131 03/05/20 10:16:48 31KC‘15807141 Headlight & Taillight Taillight Bulb LEFT REAR (1) screws (2) lens 132 Servicing Your Honda 7 \ REAR (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. 03/05/20 10:16 : 57 31KCY5807142 Appearance Care Refer to Safery Pracamimzs on page 45. 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. General Recommendations - To clean your motorcycle, you may use: 7 water 7 a mild, neutral detergent and water 7 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 p1' tic on your motorcycle. If your motorcycle . . operation, give the engine and exhaust system time to cool off. ill warm from recent (cont’d) Servicing Your Honda 133 03/05/20 10:17:09 31KCY5807143 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 ng 1pmsxure water (or air) can damage certain parrx of your motorcycla. 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 d‘ h washing liquid or a product made especially for washing motorcycles or automobiles. 03/05/20 10:17:20 31KCY5807144 Appearance Care . 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. . After washing, rinse your motorcycle thoroughly with plenty of clean water to remove any residue. . Dry your motorcycle with a chamois or a soft towel. . Lubricate the drive chain to prevent rusting. . Start the engine and let it idle for several minutes. The engine heat will help dry moist are . 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 31KCY5807145 136 Servicing Your Honda J l 03/05/20 10:17:27 31KCY5807146 Here‘s helpful advice on how lo prepare for an off—road advenlure, how lo transpon and Store your Honda. and how lo be an environmentally responsible motorcycle owner. Preparing for a Ride... Transporting Your Hond Storing Your Honda... You & the Environment. Tips 137 03/05/20 10:17:38 31KCY5807147 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 d 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 Unexpacred, 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: 0 a tool kit - tire repair supplie and tools, tubes, and tires - extra parts, such ' a drive chain and master links, control levers, cables, and spark plugs - wire, duct tape, and rope - extra gasoline J l 03/05/20 10:17:43 31KC‘15807148 ‘ Preparing for a Ride For safety, all refueling should be done at a gas If you decide to take some tools, spare parts, or station on the way to the iiding area or at your other supplies on the trail, be sure you can base camp. cairy 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 ‘1 3' companions are in making repairs. Tips 139 03/05/20 10:17:51 31KCY5807149 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, ing motorcycle tie-down straps. Avoid using rope, which can loosen and allow the motorcycle to fall over. 140 Tips A l 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. 03/05/20 10:17:56 31KC‘1580715D 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 ide. Thit n damage the motorcycle, and leaking gasoline could be a hazard. Tips 141 03/05/20 10:18:01 31KCY5807151 ‘ Storing Your Honda If you won’t be riding for an extended period, For more information about storage, refer to such as during the winter, thoroughly inspect the Honda Motorcycle Winter Storage Guida, your motorcycle and correct any problem available from your Honda dealer (USA only). before storing it. That way, needed repairs won't be forgotten and it will be easier to get We suggest you perform the following your motorcycle running again. procedures to keep your motorcycle in top condition. These storage procedures will reduce the deterioration that can occur during storage. 142 Tips 03/05/20 10:18:10 31KC‘16807152 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. J l 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. AWARNING Gasoline is highly flammable and explosive. You can be burned or a; seriously injured when handling fuel. - Stop the engine and keep heal, 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 31KCY5807153 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 non- breathing, 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 ). . If your motorcycle has been stored for more than two monthsidrain and replace the fuel. . Lubricate the drive chain. . Perform a pre-n'de inspection (page 24 ), then test—ride your motorcycle at low speeds. J l 03/05/20 10:18:29 31KCY6807154 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. - 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 exhaus . stems. Such modifications not only increase noise, they also reduce engine performance and may be illegal. - 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. (cont’d) Tips 145 03/05/20 10:18:33 31KCY5807155 ‘ 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 . (J your local or state office of public works or t: 3' environmental services to find a recycling center in your area and get instructions on how to dispose of non-recyclable wastes. 146 Tips J l 03/05/20 10:18 : as 31KC‘15807156 With all the challenges you can encounter off- road, 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 Preparingfor a Ride (page 138 ). If Your Engine Qu If You Have a Flat Tire If You Crash...... If a Component Fa Taking Care of Ihc Unexpected 147 03/05/20 10:18:46 31KCY6807157 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. 148 Taking Care of the Unexpected If a problem is relatively minor and you have the tools, suppli , 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 seriousior you don‘t have the tools, supplies, experience, or time to deal with itiyou 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: 0 Always put personal safety first. J l 03/05/20 10:18 : 57 31KCY5807158 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 a on \sible. 0 Do not continue riding 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. 0 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 31KCY5807159 Taking Care of the Unexpected - Check that the spark plug cap isn’t loose or disconnected. - Disconnect the spark plug cap and remove the . ark 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 kit. starter while you watch the spark plug. It'i arks, the ignition system is probably working. If there is no spark, install k .r‘ a new spark plug, if you have one with you. If there i '11 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 g l 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: 0 Use an aerosol tire sealer t eal 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.) J l 03/05/20 10:19:16 31KCY5807160 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, the severity of the injuries 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 it is safe to ride. Check the tightnes. f 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 31KCY5807161 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. J l 03/05/20 10:19:28 31KCY5807162 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 t'or slowing or stopping. 0 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 31KCY5807163 154 Taking Care of Ihc Unexpected J \ 03/05/20 10:19:35 31KC‘15807164 Technical Information This section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your motorcycle. ion . Vehicle ldentit Specit utions Break-in Guidelines High Altitude Carburetor Adjut nent Emission Control Sy em Technical Information 155 % 03/05/20 10:19:44 31KCY5807165 ‘ Vehicle Identification RIGHT SIDE Serial Numbers The frame and engine serial numbers are (1 , required when you register your motorcycle. 9? ' They may also be required when ordering / replacement parts. You may record these / numbers in the Quick Refarmre section at the rear of the manual. (1) frame number I I ‘Et?’ The frame number ( 1) is stamped on the right 4% side of the steering head. LEFI' SIDE The engine number (2) is stamped on the left crankcase. (2) engine number 1 56 Technical Infomation 03/05/20 10:19:51 31KCY5807166 Color Label & Code The color label ( l ) 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 Refermce section at the rear of the manual. (1) color \abel Technical Information 157 03/05/20 10:20:05 31KC‘16807167 Spec1f1cat10ns Dimensions Fuel & Lubricants Overall length 83.9 in 12,130 mm) Fuel tank capacity 2.51 US gal (3.5 0) Overall width 33.1 in 1840 mml Overall height 48.8 in 11,240 mm) including reserve Wheelbase 56.1 in 11,425 mm) Fuel tank reserve 0.40 US gal (1.5 12) Weight Fuel unleaded gasoline, Dry weight 256.8 lbs 1116.5 kgl recommendation pump octane 158 Technical Information number 0191 or higher Engine oil capacity 1.5 USqt11.7 a) after draining 1.9 US qt (1.5 2) after draining 81 oil filter change 2.3 US qt (2.2 a) after disassembly 03/05/20 10:20:20 31KC‘15807168 Spec1f1cat10ns Fuel & Lubricants Fuel & Lubricants (cont' d) Engine oil API Service Aircleaner oii Pro Honda (USA recommendation Classification 86 or only) or Honda higher except oils (Canada only) Foam labeled as energy Filter Oil or an conserving on the equivalent circular API service label, SAE ZOW-SO/ Capacities 10W-40,JASO T 303 Passenger operator only: standard MA, capacity no passenger Pro Honda GN4 or HP4 Maximum weight 220 lbs (100 kgl (without molybdenum capacity additives) 4-stroke oil Cargo capacity none (USA & Canadai or Fork oil capacity 18.9 US oz Honda 4-stroke oil (each side) (559 cm“ (Canada onlyl, or an equivalent motorcycle Engine Specification oil Displacement 24.2 cu-in (397 cm” Drive chain SAE 80 or 30 gear oil Bore & stroke 3.3 X 2.8 in iubricant (85 X 70 mmi Compression ratio 9.3: 1 Technical Information 159 03/05/20 10:20:33 31KC‘16807169 Specifications Engine Specifications Power Transmission Valve clearance Intake: 0.004 in Priman/ reductlon 2.826 (cold) (0.10 mml Gear ratio,1st 2.615 Exhaust: 0.005 in 2nd 1.842 10.12 mml 3rd 1.400 Spark plug DPREZ (NGKl or 4th 1.120 (standard) X2AGPR-U (DENSOl 5th 0.926 Spark plug DPRQZ (NGKl or Flnal reduction 3.000 (extended high speed riding) X27GPR-U (DENSOl Standard sprocket sizes drive (engine) sprocket: 15 teeth Spark plug gap 002470.028 in driven (rear wheel) (0.607070 mml sprocket: 45 teeth Idle speed 1,300 L 100 rpm Flnal drlve chain 1 60 Technical Information D.|.D. 520V8 or RK 520M026 03/05/20 10:20:46 31KC‘1680717D Power Transmission Drive chain lreeplay 1 3/871 3/4in 135*45 mml Specifications Chassis & Suspension Caster 25°15' Trail 3.7 in 194 mml New chain length 66.9 in 11,693 mm) distance between a span of 108 pins Tire size, front 80/100-21M/C 51M Tire size, rear 110/100-18M/C 64M Tire pressure, front 15 psi (100 kPa , 1.0 Used chain service 67.2 in 11,707 mm) (cold) kgf/cm‘l limit length distance between a Tire pressure, rear 15 psi (100 kPa,1.0 span of 108 pins (cold) kgf/cmzl Suspension, front 11.0 in (280 mm) cushion stroke Suspension, rear 11.8 in (300 mm) axle travel Technical Information 161 03/05/20 10:20:57 31KC‘16807171 Speuflcatlons Electrical Torque Specilicalions Allemalor 1 0.074 kW/5,000 rpm Fork caps 16 Ibf-fl 122 N~m. 2.2 kgf~ml Lights Crankcase dram 18 Ibf-fl 125 N~m. Headlighl 12V-35W bo1l 2.5 kgf~ml Taillight 12V-5W Frame dram boll 29 Ibf-fl 139 N~m. 4.0 kgf~ml Oil fllter bolt 9 Ibf-fl 112 N-m , 1.2 kgf~ml Rear wheel axle 65 Ibf-fl 188 N~m. C» 9.0 kgf~m) Front wheel axle 65 Ibf-fl 188 N~m. 9.0 kgf~ml Front wheel axle 9 Ibf-fl 112 Mm, ho1der nuts 1.2 kgf~ml 162 Technical Information J \ 03/05/20 10:21:01 31KC‘15807172 Break-in Guidelines Help assure your motorcycle's future reliability and perfmmance 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 J t 03/05/20 10:21:06 31KC‘158071’73 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 retumed to standard factory . altitude riding is desired. See your Honda dealer for high altitude modification. Sitxtazne operation at altitudex below 5,000feet (1,500 m) with high altitude carburetor modificationr may cause engine overheating and damage. 1 64 Technical Information J t 03/05/20 10:21:12 31KCY6807174 Emission Control Systems Exhaust Emission Requirements The California Air Resources Board (CARB) requires that your motorcycle comply with ' pl’ able exhaust emissions standards during i useful life, when operated and maintained according to the instructions provided. (California only) 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) The Vehicle Emi ion Control Information Label ( 1) is attached to the rear fender. (1) vehlele emlsston controt Inlormation label Technical Information 165 03/05/20 10:21:18 31KCY5807175 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 emi ion 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 emi“ion ntrol system is \eparate from the crankcase em on control system. 1 66 Technical Information Crankcase Emission Control System (California only) The engine is equipped with a closed crankcase system to prevent di' arging crankcase em ons into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and the carburetor. J \ 03/05/20 10:21:24 31KCY5807176 Emission Control Systems Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U. S. federal law prohibits, or C' ian provincial la 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 d ign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purch er 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 1 67 J \ 03/05/20 10:21:28 31KC‘158071’7’7 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 staning 2. Rough idle 3. Misfiring orbackfiri during acceleration 4. After-burning (bac ing) 5. Poor performance (driveability) and poor fuel economy 1 68 Technical Information J 1 03/05/20 10:21:36 31KCY5807178 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 1 69 03/05/20 10:21:42 31KCY58071’79 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. 1 70 Technical Information 0A3gma a fuelx can damaga paint and plastic. Damage causcd by Spillcdfuel is not covered under warranty. 03/05/20 10:21:47 31KC‘15807180 Consumer Information This section contains information on your wairanty and how to get an official Honda service manual. 4 l AuthoriLed Manua Warranty Coverag Warranty Service Contacting Honda The Honda Rider’s Club (USA only). Your Honda Deale Consumer Information 171 03/05/20 10:21:55 31KC‘16807181 Authorized Manuals The Service Manual (Publication Item No. 61KCY()8 ) used by your authorized l-Ionda 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. 61CM()()1 ), 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 profe ional 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 Price Each’ 61KCY08 2004 XR400R Servlce Manual $48.00 610M001 Common Servlce Manual $48.00 31KCY680 2004 XR400R Owner's Manual $16.00 172 Consumer Information ‘Prices are subject to change without notice and Without incurring obligation. +HI? 03/05/20 10:22 : as 31KC‘15807182 Order On-Line: www.helminc.com Order Toll Free: 1-888-CYCLE93 (1—888-292-5393) (NOTE. Fm Cram Curt! Orr/m Only) Monday 7 Friday 8:00 AM 7 6:00 PM EST OR By completing this form you can order the materials desired You can pay by check or money order. hown on the back of this order form or charge to your credit card. Mail to Helm, Inc. at the addre (USA only). Canada: See your Honda dealer to order authorized manuals. Publication Item Description Qty. Price Total (:7 Item No. Each‘ Price ‘Prices are subject to change without notice and Without Incurrlng Sub Total obligation. Mich. Purchasers Add 6 % Sales Tax Handling Charge $4.00 Orders are mailed within 10 days. Please allow adequate tlme for delivery. Grand Total 4 Consumer Information 03/05/20 10:22:22 llKC‘l6807183 ‘ NOTE: Dealers and Companies please provide dealerorcompany name, and also the name olthe person to 5 whose attention the shipment should be sent. Ii. Customer Name Attention F Street Address - No P. O. Box Number Apartment Numberi a City State Zip Code Daytime Telephone Number ( ) D fihsec'lrfloégngrnley orderenclosed payable to Helm Inc. B Check here it your billing address is dillerent P . y. Do not send cash. from the shipping address shown above. if?) VA D MasterCard Account Number Expiration: Mo Vr. {V} IEII D VISA CECE CECE CECE CECE |:| ¥ D Discover Customer Signature Date These Publications cannot be returned Iorcredit Without receiving advance authorization Within 14 days ol delivery. On returns, a restocking lee may be applied against the original order. HELM PO. BOX 07280, DETROIT, MICHIGAN 48207 174 Consumer Information 7 I +HI? 03/05/20 10:22:29 31KCY6807184 ‘ Warranty Coverage Your new Honda is covered by these Your warranty coverage will not be voided if warranties: you choose to perform your own maintenance. However, you should have the proper tools and ' Motorcycle Limited Warranty service information and be mechanically ' Noise Control Warranty (USA only) qualified. Failures that occur due directly to improper maintenance or lack of maintenance There are responsibilities, restrictions, and are not covered. exclusions which apply to these warranties. Please read the Honda Motorcycle Warranties Almost all of your warranty coverage can be Booklet given to you by your Honda dealer at extended through the Honda Protection Plan . the time of purchase. Be sure to keep your (USA only). For more information, see your ‘1 3' Honda owner’s card (USA only) with your Honda dealer. Warranties Booklet. 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 31KCY5807185 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 a appointment for an inspection and diagno, . 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 sfied with your dealer's handling of the situation, we suggest you discuss your problem with the appropriate member of the dealerships 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. J l 03/05/20 10:22:43 31KCY5807186 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., PO. Box 2220, Torrance, CA 90509- 2220, mailstop: l()()-4W-SB, telephone: (310) 532-9811. Canada: Refer to the warranty booklet that was supplied with your vehicle. Please include the following information in your letter: 0 name, address, and telephone number 0 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 po ibly acknowledge your comments directly. Consumer Information 177 3 03/05/20 10:22 : 54 31KCY5807187 The Honda Rider’s Club (USA only) One of the best ways to get the most enjoyment from owning and riding your Honda is tojoin the Honda Rider's Club of America (HRCA). Your purchase of new motorcycle, scooter or ATV from a partici ting 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: 0 24-hr. emergency roadside as stance 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. 0 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 Rad Rider, a bi- monthly insider‘s magazine for all members. - Special members-only HRCA website. ' Discounts from HRCA partners for both on and o -road riding schools and adventure package . ' Hospi ality 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 31KCY5807188 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 part , Pro Honda products, Hondaline acc sories (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 ac .sories and products available from the parts depanment. 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 i ource of information (USA only) about Ame ‘an 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 J l 03/05/20 10:23 : 05 31KCY5807189 Table of Contents The following presents the contents of each section of your owner's manual. MOTORCYCLE SAFETY . Important Safety Information Loading, Accessories & Modi Loading Accessories & Modific ions Safety Labels.. \D\lUIUINl-t OPERATING CONTROLS Component Lo tion Fuel Valve Choke Lever Engine Stop utto Front Brake Lever. Throttle.... Clutch Lever Shift Lever .. Rear Brake Peda Kickstarter... Starter Decompre. sor Lever ..... ._. mmxmqqqqamw— 180 Table of Conlcnls Side Stand Tripmeter BEFORE RIDING Are You Ready to Ride 7 Protective Appare Is Your Motorcycle Rea y o Pre-ride Inspection ..... J \ 03/05/20 10:23:10 31KCY580719D Table of Contents BASIC OPERATION & RIDIN Safe Riding Precautions. Starling & Stopping the Engine Preparation Starting Procedure Starter Decompres Flooded Engine. How to Stop the Engine. Shifting Gears Braking. Parking . Post—ride I pection . ecumbwwcccmq SERVICING YOUR HONDA“... Before You Service Your Honda The Importance of Maintenance Maintenance Safety. Important Safety Pre autio Maintenance Schedule Maintenance Record Competition Inspection Service Preparatiom Component Location Tools. Side Cover Removal Air Cleaner Housing Cover Remov Seat Removal (cont’d) Table of Contents 181 J \ 03/05/20 10:23:15 31KCY6807191 Table of Contents SERVICING YOUR HONDA (cont’d) Service Procvdures 1 4 3 Crankease Breather (Calitornia only). 6 Engine Throttle... Clutch System 0 Engine Idle Speed . 3 Spark Plug 4 Spark Arrester 182 Table of Conlcnts Cha is Suspension ........ Brakes Wheel Tires & Tub Side Stand Drive Chain Headlight & Tailligh Appearance Care TIPS.“ Preparing for a Ride Transporting Your l-lond Storing Your Honda... You & the Environment. 03/05/20 10:23:19 31KCY5807192 Table of Contents TAKING CARE OF THE UNEXPECTED General Guidelin If Your Engine Qu If You Have a Flat Tire If You Crash... If a Component TECHNICAL INFORMATION Vehicle Identification Specifications. Break—in Guideline High Altitude Carburetor Adjustmen Emission Control Systems Oxygenated Fuels.. CONSUMER INFORMATIO AuthoriLed Manual Warranty Coverage Warranty Service Contacting Hond The Honda Rider Club (USA only) Your Honda Dealer ........................ TABLE OF CONTEN INDEX ....... QUICK REFERENCE Table of Contents 183 J l 03/05/20 10:23:25 31KC‘15807193 Index A ' cessori cleaner air pressure, front suspension tires... altering your motoi arrester, spark. Authorized Manua B brakes, fluid level lever, fron lever, front a Justment pad wea pedal, re braking ........ 184 Index break-in guidelines button, engine stop C capacity, fuel ..... carburetor, high altitude adjustment. idle speed choke lever. cleaner, ai cleaning, appe ance are clutch system, adjustment. lever. color label competition inspec on consumer information. controls, operating cover removal, sid crankcase breather (California only) .............. 76 J l 03/05/20 10:23 : 32 31KC‘16807194 Index customer service ........... D won't start ..... 149 environment, protecting. exhaust pipe maintenance ..... damping adjustments decompressor lever drive chain... E education, rider ..... em , , engine number... engine, flooded idle speed. stoppin g ...... on control system flat ire. flooded engine, . fork ...... front brake lever ieep a front suspension maintenance front wheel removal.... fuel, recommendation oxygenated tank capacity . valve .............. J l 03/05/20 10:23:40 31KC‘15807195 Index C pre-ride .......... 1 gap. spark plug ..85 K gasohol . gasoline kickstaiter gears, shi mg. 5 L H lever, headlight.. clutch. Honda, contacting. 177 Honda service manua 172 I limit. weight loading... idle speed. engine ..... inspection. competition post-ride ..... 186 Index J l 03/05/20 10:23:48 31KC‘15807196 Index M maintenance, record manual, servrce mudifi lions . 0 pre-ride inspection pre-loud, rear suspension oil. engine ...... volume (fork) operating control oxygenated fuels R rear suspension muintenanc reserve capu y, fuel tank. rider training (cunl’d) Index 187 J \ 03/05/20 10:23 : 53 31KCY580719’7 Index riding, spark plug basic operation ..... specification S side cover, removu side stand. spark arrests spark knock 188 Index spring pro-load, rear suspension and, side ...... starting, engin stop button, engin stopping engine . storage. suspension, front. rear J l 03/05/20 10:24 : oo 31KC‘15807198 Index T V taillight ........ valve, throttle freeplay operatio tool bag. towing training, ride transporting . tripmeter .. troubleshooting, U unexpected problems warranty, coverage. extended . servic . washing your motorcye weight limit wheels...... Index 189 03/05/20 10:24:07 31KC‘15807199 ‘ Quick Reference The following is a brief, but important collection of information you need to know How To Avoid Costly Repairs about your Honda. You'll also find space to record important notes. 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 03/05/2 o 14: .11 Achysauizuu Quick Reference Record important information here: Frame N0. Enfiine N0. Culm Lube] Owner‘s Name Add|$3> Cily/Sule Phone Deuler' 3. Name Addt e» Cily/Sule Phone Semee Mgt Quick Reference 03/05/20 10:24:29 31KC‘15807201 Quick Reference lnilial Mainienance about 100 miles (150 km) or one monlh. Regular Mainlenunce nhoul eyery ooo mile» (1.000 km) or six monih», Prehde lnepeciiun Check lhe inllewing item.» each urne before you rule (page 24 )» lii‘es, spokes & rim». leaks, engine oil, iuel. drive ehnin. cables. nun & helu, apark plug and cap. ihi‘oille. brake». eluleh lever, headlighi. Fuel/Cupacuy unleaded gasoline. pump oclane number oi 92 or higher tank: 2.51 US gal 19.5 El reserve: 0.40 us gal 11.5 E) (7.7 Engine oil APl Seryiee Clasoil‘icalion 56 or higher except Oils labeled as energy comerving on ihe Circular APl service label, SAE ZOWVSO. [0W40 (when outside lenipei‘uiure is below 0°C. 32%), JASO T 903 omndui‘d MA. Pro Honda GN4 or HP4 (wilhoui molybdenum addilivm) Aroiroke uil or equivalent Maximum Weighl Capaciiy 220 |bs(100 kgl rider only (no pausenger or eugu) and any acre/55.01165. T ires From: 80/100-Z1M/C 51 M Rear: 110/100-18M/C 64M Tire Pressure (cold) From: 15 psi (100 kPa , 1.0 kgf/cmzl Rear: 15 psi (100 kPa,1.0 kgf/cmzl Spark Plug DPRBZ (NGKl or X24GPR-U (DENSOl Drive Chain D.|.D. 520V8 or RK 520M026 Quick Reference +HI?