é HONDA OWNER’S MANUAL MANUAL DEL PROPIEI'ARIO CRFBOF Honda CRFSOF OWNER’S MANUAL MANUAL DEL PROPIETARIO © Honda Motor (20.. Ltd. 2007 IMPORTANT INFORMATION ' OPERATOR ONLY. NO PASSENGER This motorcycle is designed and constructed as an operatomnly model. The sealing configuration does not safely permit the carrying of a passenger. Do not exceed the maximum weight capacity. ‘ FOR OFF -ROAD USE ONLY This motorcycle is designed and manulactured for off-road use only, 0 PARENTS : READ IMPORTANT MESSAGE 0N PAGE 1 . 0 READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual. These messages are fully explained in the “A Few Words About Satety" section which appears before the Contents page. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold. Honda CRFSOF OWNER’S MANUAL All information in this publication is based on the latest production infommtion available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. WELCOME Your new motorcycle presents you with an invitation to adventure and a challenge to master the machine. Your salety depends not only on your own alertness and familiarity with the motorcycle, but also the motorcycle‘s mechanical condition. A preride inspection before every outing and regular maintenance are essential. To help meet the challenges safely and enjoy the adventure fully, become thoroughly familiar with this Owner's Manual BEFORE YOU RIDE THE MOTORCYCLE. As you read this manual, you will find iniormation that is preceded by a symbol. This information is intended to help you avoid damage to your motorcycle, other property. or the environment. When service is required. remember that your Honda dealer knows your motorcycle best. If you have the required mechanical ‘know-how" and tools, your dealer can supply you with an official Honda Shop Manual to help you perform many maintenance and repair tasks. Pleasant riding, and thank you for choosing a Honda ! OThe following codes in this manual indicate each country. I U ‘ Australia MX Mexico t The specifications may vary with each locale. m You WILL be KILLED or SERIOUSLV HURT II you don'l follow Instructions. AA WARNING Longsc‘ll‘onb: KILLED or SERIOUSLY HURT II you don't follow A C AUTIO N You CAN be HURT It you don‘t Iollow lnstructlons. 0 Safety Headings —— such as Important Salety Reminders or Important Salety Precautions 0 Safety Section — such as Motorcycle Salety. 0 Instructions — how to use this motorcycle correctly and safely, This entire manual is filled with important safety information — please read it carefully, A FEW WORDS ABOUT SAFETY Your satety, and the safety of others. is very important. And operating this motorcycle saiely is an important responsibility. To help you make intormed decisions about salety, we have provided Operating procedures and other information on labels and in this manual. This infonnation alerts you to potential hazards that could hurt you or others. 0! course. it is not practical or possible to wam you about all hazards associated with operating or maintaining a motorcycle. You must use your own good judgment You will find imponant safety inlormation in a variety oi Iorms, including: 0 Safety Labels — on the motorcycle. 0 Salety Messages —— preceded by a saiety alert symbol A and one of three signal words: DANGER, WARNING, OI‘ CAUTION. These signal words mean: OPERATION page page 1 MOTORCYCLE SAFETY 32 ESSENTIAL INDIVIDUAL 1 IMPOKTANT MESSAGE TO COMPONENTS PARENTS 32 IGNITION SWITCH 3 IMPOKTANT SAFETY 33 ENGINE STOP BU'I'TON INFORMATION 5 PROTECTIVE APPAREL 7 LOAD LIMITS AND GUIDELINES 1 l PARTS LOCATION 14 MAJOR COMPONENTS (Information you need to Operate this motorcycle) 14 BRAKES 19 CLUTCH 22 FUEL 26 ENGINEOIL 27 TYRES page page 34 FEATURES 35 OPERATION (Not required for operation) 35 PRE-RIDE INSPECTION 34 SIDE COVER 37 STARTING THE ENGINE 40 RUNNING—IN 41 RIDING 43 HIGH ALTITUDE RIDING (Except Mexico) 43 DOW ALTITUDE RIDING (Mexico only) 44 BRAKING 45 PARKING 45 ANTI-THEFT TIPS MAINTENANCE page 46 MAINTENANCE 46 THE IMPORTANCE OF MAINTENANCE 47 MAINTENANCE SAFETY 48 SAFETY PRECAUTIONS 49 MAINTENANCE SCHEDULE 52 TOOL KIT 53 SERIAL NUMBERS 54 COLOUR LABEL 55 AIR CLEANER 56 ENGINE OIL 61 SPARK PLUG 63 IDLE SPEED 64 THRUIT LE OPERATION 66 SPARK ARRESTER 67 DRIVE CHAIN 72 WHEEL RIMS AND SPOKES 73 WHEEL REMOVAL 76 BRAKE SHOE WEAR 77 FRONT SUSPENSION 78 REAR SUSPENSION 79 SIDE STAND page 80 83 83 85 86 CLEANING STORAGE GUIDE STORAGE REMOVAL FROM STORAGE SPECIFICATIONS MOTORCYCLE SAFETY IMPORTANT MESSAGETO PARENTS Your child’s salety is very important to Honda. That's why we urge you to read this message before you let any young person ride this motorcycle. Off-road riding can be fun. But as with riding a bicycle, bad judgements can result in injuries, and we don’t want that to happen l As a parent, you can help prevent accidents by making good decisions about it, when, and how your youngster rides this motorcycle. Riding Readiness The first decision you‘ll need to make is whether your youngster is ready to ride. Riding readiness varies widely from one person to another, and age and size are not the only factors. PHYSICAL ABILITY is an important consideration. For example, riders must be big enough to hold the motorcycle up, get on, and comtortably sit on the seat with both feet touching the ground. They should also be able to easily reach and work the brakes, the throttle and all other controls. ATHLETIC ABILITY is necessary [or riding a motorcycle. Generally speaking, your youngster should be good at riding a bicycle before getting on a motorcycle. Can your youngster judge speeds and distances on a bicycle and react with proper hand and foot actions? Anyone who does not have good coordinationbalance, and agility is not ready to ride this motorcycle. MENTAL AND EMOTIONAL MATURITY are requirements {or sate riding. Does your youngster think through problems and come to logical solutions? On a bicycle, does your youngster obey sate riding rules ? Be honest 1 Young people who take unnecessary risks. make bad judgements and don’t obey rules are not ready to ride this motorcycle. Instruction and Supervision If you decide that your youngster is ready to safely operate this motorcycle, make sure both oI you carefully read and understand the Owner‘s Manual before riding Also be sure that your youngster has a helmet and other appropriate riding equipment and always wears it when operating the vehicle or sitting on it. GOOD INSTRUCTION is an important part OI hands—on twining. The teacher can either be you or another responsible adult who has experience with off-road motorcycle riding. (For help in finding a qualified instructor. talk with your Honda dealer.) Even if you’re not the main teacher, it’s up to you to ensure your youngster‘s safety. Remember. learning to ride a motorcycle is a gradual stepby—step process. It takes time, patience and practice 7 many hours over a period of weeks or months. SUPERVISION is another important obligation of parents. Even after youngsters have become skilled off-road riders, they should always ride with adult supervision. It helps to regularly remind young riders of basic safety rules and cautions. And remember, it’s your responsibility to see that the vehicle is properly maintained and kept in sate operating condition. SAFE AND RESPONSIBLE RIDING must be an ongoing commitment—by you and your youngster. When you both put safety first, you can enjoy more peace of mind, and your youngster can enjoy more hours of safe offiroad riding. For your convenience. this CRFSOF comes with an ignition switch and key. Remove the key when the motorcycle is parked to help prevent unauthorized use. IMPORTANT SAFETY INFORMATION Your motorcycle can provide many years of service and pleasureiif you take responsibility for your own safety and understand the challenges you can meet while riding. This motorcycle has been designed [or younger riders, as well as for smaller adults. However, not all youngsters are physically or emotionally ready to ride. Therefore. before parents allow any youngster to ride this motorcycle, we urge them to carefully read the Important Message to Parents on page 1 . There ls much that you can do to protect yourself when you ride. You‘ll find many helpful recommendations throughout this manual. Following are a few that: we consider most important. Always Wear a Helmet It’s a proven fact: helmets significantly reduce the number and severity 01 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 5 ). Never Carry 3 Passenger Your motorcycle is designed {or one person only. There are no handholds. footrests. or seat for a second person—so never cany a passenger. A passenger could interIere 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 tyres are not made [or pavement, and the motorcycle does not have turn signals and other features required [or use on public roads. It you need to cross a paved or public road» get off and walk your motorcycle across. Take Time to Learn and Practice Developing off-road riding skills is a gradual. stepby«step process. Start by practicing at low speeds in a safe area and slowly build your skills. Personal instruction from an experienced rider can also be valuable. If you need assisLanoe, ask your dealer about riding groups in your area. BeAlert for Off-Road Hmrds The terrain can present a variety of challenges when you ride off-road. Continually “read" the terrain for unexpected turns. drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards. Ride Within Your Limits Pushing the limits is another major cause of motorcycle accidents. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol. drugs. fatigue and inattention can significantly reduce your ability to make good judgements and ride safely. Don‘t Drink and Ride Alcohol and riding don‘t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don't drink and ride. and don‘t let your friends drink and ride either. Keep Your Bike in Safe Condition For safe riding, it's important to inspect your motorcycle before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by Honda for this motorcycle. See page 7 for more details. Others IThis motorcycle is not equipped with lights. Don’t ride at night. PROTECTIVE APPAREL For your safety. we strongly recommend that you always wear an approved motorcycle helmet. eye protection, boots, gloves. long pants, and a long-sleeved jersey. shirt or jacket whenever you ride, Although complete protection is not possible, wearing proper gear can reduce the chance oi injury when you ride. Following are suggestions to help you choose proper gear. AWARNING Not wearing a helmet increases the chance oi 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 otters the best prolection against head lrflufles. A helmet should {it your head comonably and have a chin strap that can be tightened securely. An open-lace helmet offers some protection. but a lull-face helmet offers more. Always wear a face shield or goggles to protect your eyes and help your vision, Additional Riding Gear In addition to a helmet and eye protection» we also recommend: ' Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. 0 Oil-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. LOAD LIMITS AND GUIDELINES 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 aocessories or making modifications that change this motorcycles design and performance can also make it unsafe Also, the weight of any accessories will reduce the maximum load the motorcycle can carry. The [allowing pages give more specific intomiation on loading, accessories and modifications Loading How much weight you put on your motorcycle, and how you load it. are important to your saletyt If you decide to carry cargo. you should be aware oi 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, Load Limits Following are the load limits [or your motorcycle: Maximum weight capadty: 100 kg (220 lbs) Includes the weight of the rider and any accessories loading Guidelines As discussed on page 7. 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: 0 Keep cargo small and light Make sure it cannot easily be caught on bnish or other objects, and that it does not interfere with your ability to shift position to maintain balance and stability. 0 Place weight as close to the center of the motorcycle as possible I Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebar, fork, or front tender 0 Make sure that all cargo is tied down securely 0 Never exceed the maximum weight limit. 0 Check that both tyres are properly inflated (page 27). Accessories and Modifications Modifying your motorcycle or using non- Honda accessories can make your motorcycle unsafe. Before you consider making any modifications or adding an accessory, 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 accessories and modifications. Accessories We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation and use of non-Honda accessories. Check with your dealer for assistance and always follow these guidelines: 0 Make sure the accessory does not reduce ground clearance and lean angle, limit suspension travel or steering travel. alter your riding position or interfere with opemting any controls. 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 5 handling. stability and bmking making it unsafe to ride. Removing or modifying your exhaust system (such as the spark arresters or mufflers) or other equipment can also make your motorcycle illegaL 10 PARTS LOCATION Clutch lever Front brake lever Throttle grip Fuel fill cap 1| 12 Kickslaner wapez Rear brake pedal Ignition switch Shifl lever Fuel valve Choke lever Side stand 13 MAJOR COMPONENTS (Information you need to operate this motorcycle) BRAKES Front Brake Brakes are items of personal safety and should always be maintained in proper adjustment. The distance the front brake lever or rear brake pedal moves before the brake starts to engage is called freeplay. Measured at the tip of the front brake lever (1), freeplay should be maintained at: 20*30 mm (0.3713 in) Adjust the freeplay of the brake lever with the front wheel pointed straight ahead. Ad ustment Harm the rubber dust cover (2) Loosen the lock mu (3) and turn the cable adjuster (4). Tighten the lock nut and check the adjustment. 14 (2) Rubber dust cover (3) lock mu (4) Cable adjuster (A) Decrease freeplay (B) Increase freepIay 2, H the adjuster is threaded out near its 4. Loosen the lock nut (6) at the lower end limit or the correct freeplay cannot be of the cable. Turn the atfiusting nut (7) to obtained using the cable adjuster , loosen obtain the specified freeplay. Tighten the the lock nut and turn in the cable adjuster lock nut and check the adjustment. completely Tighten the lock nut and install the rubber dust cover. It proper adjustment cannot be obtained by 3‘ {.oosen the front brake cable guide bolt this method, see your Honda dealer‘ 5 , (6) Lock nut (A) Decrease freeway (5) (kble guide bolt (7) Adjusting nut (B) Increase lreeplay 15 5. Apply the brake several times and check for free wheel rotation after the brake lever is released. Tighten the front brake cable guide bolt. Alter adjustment, push the brake arm (8) to confirm that there is proper freeplay. (8) (8) Brake arm Alter adjustment, confirm the ireeplay of the brake lever. 16 Other Checks: Check the Brake cable for kinks or signs of wear that could cause sticking or lailure. Lubricate the brake cable with a commercially available cable lubricant to prevent premature wear and corrosion, Make sure the brake arm. spring and fasteners are in good condition. Brake Adiustment: 1r Plaoe the motorcycle on its side stand. its side stand 2. Measure the distance the rear brake 2, The stopper bolt (1) IS provided to allow pedal (3) moves before the brake starts adjustment of the pedal height to lake holdl To adjust the pedal height, loosen the Freeplay should be: lock nut (2) and turn the stopper bolt. 20-30 mm (0'3,"2 in) Tighten the lock nut. 3‘ II adjustment is necessary, turn the rear (2) brake adjusting nut (4 )i (l) Stopper bolt (3) Rear brake pedal (4) Adjusting nut (A) Decrease freeplay (2) Lock mu (5) Brake arm pin (B) Increase [reeplay 17 Adjust by [timing the rear bmke adjusting nut a hall-tum at a time. Make sure the cut- out on the adjusting nut is seated on the brake arm pin (5) alter making final treeplay adjustment. 4‘ Apply the brake several times and check for tree wheel rotation alter the brake pedal is released It proper adjustment cannot be obtained by this method. see your Honda dealer: Atter adjustment. push the bmke arm (6) to confirm that there is a gap between the adjusting nut (7) and the brake arm pin(5). 18 (5) Brake arm pin (6) Bmkeann <7) Adjusting nut After adjustment, confirm the freeplay o! the brake pedal. Other Checks: MaEe sure the brake rod» brake arm. spring and fasteners are in good condition. CLUTCH Clutch adjustment may be required if the motorcycle stalls when shifting into gear or tends to creep: or it the clutch slips. causing acceleration to lag behind engine speed. Minor adjustments can be made with the clutch cable adjuster (4) at the clutch lever ( 1). Normal clutch lever freeplay is: 10 g 20 mm (0.4703 in) (1) Clutch lever ll Pull back the rubber dust cover (2). 2. Loosen the lock nut (3) and tum the clutch cable adjuster. Tighten the lock nut and check the adjustment. 3.1f the adjuster is threaded out near its limit or if the comet freeplay cannot be obtained, loosen the lock nut and turn in the clutch cable adjuster completely Tighten the lock nut and install the dust cover, (3) (2) Rubber dust cover (3) Lock nut (4) Clutch cable adjuster (A) Decrease ireeplay (B) Increase freephy 19 4. Loosen the lock nut (5) at the lower end 5. Clutch adjustment is made at the clumh oi the cable, Tum the adjusting nut (6) to housing according to the maintenance obtain the specified treeplayr Tighten the schedule (page 48) or when normal lock nut and check the adjustment. cable adjustment cannot obtain specified freeplay. Belore adjusting the clutch. turn the cable adjuster all the way in to provide maximum freeplay. Then loosen the lock nut (7) and turn the clutch adjuster (8) counterclockwise until a slight resistance is felt Turn the adjuster back clockwise 1/8 to 1/4 tum and tighten the lock nut, then readjust the lower cable adjuster (or proper treeplayr (5) Lock nut (A) Decrease ireeplay (s) Adjusting nut (B) Increase freeplay (8) W (7) Lock nut (8) Clutch adjuster 20 6. Start the engine, pull in the clutch lever and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. The motorcycle should begin to move smoothly and accelerate gmdually. If proper adjustment cannot be obtained or the clutch does not work correctly, see your Honda dealer. Other Checks: Check the Clutch cable {or kinks or signs of wear that could cause sticking or failure. Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion. 21 FUEL Fuel Valve The three way fuel valve (1) is on the left side near the carburetor. 01F With the fuel Valve in the OFF position, fuel cannot flow from the tank to the carburetor, Turn the valve OFF whenever the motorcycle is not in use. Wh the fuel valve in the ON position. fuel will flow from the main fuel supply to the carburetori With the fuel valve in the RES position, fuel will flow from the reserve fuel supply to the carburetor, Use the reserve fuel only when the main supply is gone Refill the tank as soon as possible after switching to RES. The reserve fuel supply is: 0.7 111018 US gal , 0.15 Imp gal) 22 Remember to check that the fuel valve is in the ON position each time you refuel If the valve is left in the RES position, you may mn out of fuel with no reserve. (1) Fuel valve Fuel Tank The fuel tank capacity including the reserve supplyis: 5‘0 11 (132 US gal , 1,10 Imp gal) To open the fuel til] cap ( 1). Pull the breather tube (2) from the front number plate (3 ) Turn the fuel fill cap counterclockwise. Do not overfill the tank There should be no fuel in the filler neck (4). After refueling, be sure to tighten the fuel fill cap firmly by tuming it clockwise. Insert the breather tube into the front number plate AWARNING Petrol is highly flammable and explosive. You can be burned or seriously injured when handling luel. - Stop the engine and keep heal. sparks. and flame away. 0 Reluel only outdoors. - Wipe up spills immediately. (1) Fuel fill cap (2) Breather tube (3) Front number plate (4) Filler neck 23 For U: Use unleaded or low-lead petrol with a research octane number of 91 or higher. We recommend that you use unleaded petrol because it produces lewer engine and spark plug deposits and extends the life of exhaust system components. For Mexico: Use unleaded or low-lead petrol with a research octane number of 88 or higher. Recommended - Extra petrol. 24 ll spark knock" or “pinking” occurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinklng persists. consult your Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda‘s Limited Warranty Occasionally you may experience light spark knock while operating under heavy loads. This is no cause {or concern, it simply means your engine is operating efficiently. Petrol Containing Alcohol If you decide to use a petrol containing alcohol (gasohol). be sure it’s octane rating is at least as high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol, and the other containing methanol. Do not use petrol that contains more than 10 '36 ethanol. Do not use petrol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol Never use petrol containing more than 5 96 methanol. even it it has cosolvents and corrosion inhibitors. Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete. Belore buying fuel from an unlamiliar station. try to find out it the fuel contains alcohol. If it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a petrol that contains alcohol. or one that you think contains alcohol, switch to a petrol that you know does not contain alcohol. ENGINE OIL Engine Oil Level Check Check the engine oil level each day before operating the motorcycle. The oil filler cap/dipstick (1) is at the rear of the right crankcase cover and contains a dipstick for measuring the oil level. Oil level must be maintained between the upper (2) and lower (3) level marks on the oil filler cap/dipstick. 1. Hold the motorcycle upright on firm level ground. 2. Start the engine and let it idle for 345 minutes. 3. Stop the engine. After 273 minutes. remove the oil filler cap/dipstick. wipe it clean. and reinsert the oil filler cap/ dipstick without screwing it in. Remove the oil filler cap/dipstick. The oil level should be between the upper and lower level marks on the oil filler cap/ dipstick. 26 4. If required, add the specified oil (page 56) up to the upper level mark. Do not overfill. 5. Reinstall the oil filler cap/dipstick. Check for oil leaks. Running the engine with insulficient oil can cause serious engine damage, (1) (2) 6 O (3) (1) Oillillercap/dipstick (2) Upper level mark (3) Lowerle'vel mark TYRES To safely operate your motorcycle, the tyres must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated. AWARNING Using tyres that are excessively worn or improperty inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owners manual regarding lyre inflation and maintenance. Air Pressure Properly inflated tyres provide the best combination of handling, tread life, and riding comfort, Generally, underinflated tyres wear unevenly, adversely affect handling, and are more likely to fail [tom being overheated. Underinflated tyres can also cause wheel damage in rocky terrain. Overinflated tyres make your motorcycle ride harshly, are more prone to damage from surface hazards. and wear unevenly. Make sure the valve stem caps are secure. If necessary, install a new cap. 27 Always check air pressure when your tyres are “cold." If you check air pressure when your tyres are “wann”*even if your motorcycle has only been ridden for a few milesithe readings will be higher, if you let air out of warm tyres to match the recommended cold pressures, the tyres will be underinl'lated. The recommended “cold” tyre pressures are: Front 100 kPa11.0 kgf/cm’, 15 psi) Rear 100 kPa (1.0 kgf/cm2 , 15 o i) 28 Inspection Whenever you check the tyre pressures, you should also examine the tyre treads and sidewalls [or wear. damage, and foreign objects: Look for: 0 Bumps or bulges in the side oi the tyre or the tread. Replace the tyre if you find any bumps or bulges 0 Cuts, splits or cracks in the tyre Replace the tyre if you can see fabric or cord. 0 Excessive tread Wear. Also, it you hit a pothole or hard object, pull to the side of the road as soon as you can salely and carefully inspect the tyres for damage. TreadWear Replace tyres before tread depth at the center of the tyre reaches the following (1) limit: M’ imum tread depth Front: 3.0 mm (0.12 in) .\\>\{/ Rear: 3.0 mm (0.12 in) ’/ f (1) Tyre tread depth Tube Repair and Replacement If a tube is punctured or damaged. you should replace it as soon as possible A tube that is repaired may not have the same reliability as a new one, and it may fail while you are riding. If you need to make a temporary repair by patching a tube or using an aerosol sealant, ride cautiously at reduced speed and have the tube replaced before you ride again. Any time a tube is replaced, the tyre should bescarefully inspected as described on page 2 . 30 Tyre Replacement The tyres that came on your motorcycle were designed to match the performance capabilities of your motorcycle and provide the best combination of handling, braking, durability and comfort. AWARNING Installing improper lyres 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 tyres recommended in this owner‘s manual. The recommended tyres for your motorcycle are: Front: 250* 16 APR Rear: 350*14 4FH Type: bias-ply, tube Whenever you replace a tyre, use one that is equivalent to the original and be sure the wheel is balanced after the new tyre is insmlledr Also remember to replace the inner tube whenever you replace a tyre. The old tube will probably be stretched, and it installed in a new tyre, it could fall, 31 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (1) is located below the fuel tank The ignition switch is used to prevent unauthorized use of the motorcycle. Before riding, insert the key and turn it to the ON position Alter parking the motorcycle, remove the (1) Ignition switch key. OFF \ \ \ \ \ i \ \ Key Position Function OFF The engine cannot be operated. Key can be removed 0 (ON) With the transmission in neutral, the engine can Key cannot be be started. removed 32 ENGINE Sl'OP BUITON The engine stop button (1) is next to the left handlebar grip. Push the button in and hold it in until the engine stops completely. (1) (1) Engine slop button 33 FEATURES (Not required for operation) SIDE COVER Removal: . Remove the bolt ( 1) securing the side covet 2. Pull both side cover prongs (2) out of the rubber grommets (3 ). Installation: 1 5 file the top of the side cover under the bottom edge of the seal. 2. Align the side cover prongs with the rubber grommets. Press the side cover into position. 3. Install the securing bolt and tighten it. Use the same procedure to remove and install the left side cover. 34 (1) Bolt (2) Prongs (3) Grommets OPERATION PRE»RIDE INSPECTION For your safety, it is very important to take a few moments before each ride to walk around your motorcycle and check its condition, If you detect any problem. be sure you take care of it, or have it corrected by your Honda dealer. AWARNING |mproper|y maintaining this motorcycle or tailing to correct a problem belore riding can cause a crash in which you can be seriously hurt or killed. Always pertorm a pre-ride inspection before every ride and correct any problems. 1. Engine oil level— add engine oil if required (page 26), Check for leaks 2, Fuel level—fill fuel tank when necessary (page 23 ). Check for leaks. 3. Front and rear brakes-check operation and if necessary, adjust {reeplay (pages 14 — 18 ). 4.1‘yres*check Condition and pressure (pages 27 7 31 ). 5. Spokes and rim locksicheck and fighten if necessary (page 72 ). 6. Drive chain—check condition and slack (page 67 ), Adjust and lubricate it necessary. 7, Chain slider' check slider wear (page 63 ). 8. Throttleicheck for smooth opening and full closing in all steering positions. Adiust freeplay il necessary (pages 64 - 65). 35 9. Clutchicheck operation, and adjust if necessary (pages 19 — 21 ). 10. Spark plug and high tension terminal 7 check [or looseness. 11, Engine stop button~check for proper function (page 33 )4 12lNuts. bolts, fasteners 7 check the front and rear wheels to see that the axle nuts are tightened securely. Check security of all other nuts. bolts. and lasteners. 36 STARTING THE ENGINE Always follow the proper starting procedure described below. This motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Your motorcycle’s exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. Do not run the engine with the garage door closed. Even with the door open. run the engine only long enough to move your motorcycle out of the garage. Preparation Before starting, insert the key and turn the ignition switch ON. Make sure that the transmission is in neutral Turn the fuel valve ON. 37 StaningProcedure To restart a warm engine, follow the procedure for “High Air Temperature.“ Normal Air Tern ralure - 0° — 95° F) 1. Pull the c o e ever up e way to Fully ON (A). (1) Choke lever (A) Fully ON (8) Fully OFF 38 2‘ With the throttle slightly open, operate the kickstarter, Kick from the top of the stroke through to the bottom with a rapid, continuous motion. the kickstarter to snap back [reely against the pedal stop can damage the engine case, 3, Warm up the engine by opening and closing the throttle slightly. 4. About a quarter minute after the engine starts, push the choke lever (1) down all the way to Fully OFF (B), 5, If idling is unstable, open the throttle slightly. H’gh Air Temgerature 35°C (95° F) or above 1. Do not use ec oke. 2. Start the engine following step 2 under “Normal Air Tempemture.” Low Air Temperature 10°C 50°F) or below 1.Follow steps 1*2 un er “Nonnal Air Temperature". 2. Warm up the engine by opening and closing the throttle slightly. 3. Continue warming up the engine until it runs smoothly and responds to the throttle, when the choke lever (1) is at Fully OFF (B). Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. 39 Flooded Engine If the engine fails to start alter repeated attempts, it may be flooded with excess fuel. To clear a flooded engine. push the choke lever down to Fully OFF (B), Open the throttle fully and crank the engine several times with the kickstaner while pushing the engine stop button. Release the engine stop button and follow the “High Air Temperature” Starting Procedure (page 39 ). RUNNING-IN Help assure your motorcycle‘s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km (15 miles). During this period, avoid lull-throttle starts and rapid acceleration. RIDING Review Motorcycle Salety (page: 1 — 10) before you ride. Make sure the side stand is fully retracted beiore riding the motorcycle 1! the stand is extended, it may interfere with control during a left turn Make sure you understand the function of the side stand mechanism. (See MAIN- TENANCE SCHEDULE on page 51 and explanation for SIDE STAND on page 79 ). LAiter the engine has been warmed up, the motorcycle is ready for riding. 2. While the engine is idling, pull in the clutch lever and depress the shift lever to shift into lst (law) gear. 3. Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start. 4, When the motorcycle attains a moderate speed, close the throttle, pull in the clutch lever and shift to 2nd gear by raising the shit lever. This sequence is repeated to progressively shift to 3rd. 4th and 5th (mp) gears. 41 5. Raise the shit lever to shift to a higher gear and depress the 5th lever to shift to a lower gear. Each stroke of the shift lever engages the next gear in sequence. The shift lever automatically returns to the horizontal position when released. 2 3 45 0Do not downshift when traveling at a speed that would force the engine to overrev in the next lower gear. the rear wheel may lose h'action, resulting in a possible loss 0! vehicle control 0 Do not shil’t gears without disengaging the clutch and closing the throttle. The engine and drive train could be damaged by overspeed and shock, 0 Do not tow the motorcycle or coast for long distances while the engine is oft The transmission will not be properly lubricated and damage may result. 0 Do not run the engine at high rpm with the transmission in neutral or the clutch lever pulled in. Serious engine damage may result. HIGH ALTITUDE RIDING (Except Mexico) When operating this motorcycle at high altitude the air»fuel mixture becomes overly rich. Driveability and performance may be reduced and fuel consumption increased. The carburetor can be modified to compensate for this high altitude richness, however it must be returned to standard specifications beIore extended operation at low altitudes (below 1,200 m. 4,000 feet). See your Honda dealer for this high altitude modification Sustained operation at lower altitudes with high altitude carburetor modifications may cause engine overheating and damage. LOW ALTITUDE RIDING (Mexico only) When operating this motorcycle at low altitude, the air-fuel mixture becomes overly lean. Below 1.000 m (3,3001eet), driveability and performance may be reduced. The carburetor can be modified to compensate for this low altitude leanness. However. the carburetor must be returned to standard factory specifications when higher altitude riding is desired. See your Honda dealer [or low altitude adjustments. Sustained operation at altitudes above 1,500 m (5,000 feet) with low altitude carburetor modifications may cause flooded engine. BRAKING For normal braking, gradually apply both the front and rear brakes while downshifting to suit your road speed. For maximum deceleration. close the throttle and apply the trout and rear brakes firmly. Pull in the clutch lever before courting to a complete stop to prevent stallingtheengine. Important Safety Reminders: 0 Independent operation of only the brake lever or brake pedal reduces stopping performance. ‘ Extreme application of the brake controls may cause wheel lock, reducing control of the motorcycle. ° When possible. reduce speed or brake before entering a turn; closing the throttle or braking in mid—turn may cause wheel slip. Wheel slip will reduce control of the motorcycle 0 When riding in wet or rainy conditions, or on loose surfaces. the ability to maneuver and stop will be reduced. All of our actions should be smooth under t ese conditions. Rapid acceleration, braking or turning may cause loss of control, For your safety, exercise extreme caution when braking accelerating or turning owhen descending a long. stee grade. use engine compression braking down» shifting with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness. PARKING LAiter stopping the motorcycle, shilt the transmission into neutral and tum the fuel valve OFF. Push the engine stop button in and hold it in until the engine stops completely. 2. Use the side stand to support the motorcycle while parked Park the motorcycle on (mt level ground to prevent it from falling over, If you must park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility of rolling off the side stand or overturning. 3. Turn the ignition switch OFF and remove the key. ANT lv‘l‘l-[El-T TIPS 1. Be sure the registration information [or your motorcycle is accurate and current 2. Park your motorcycle in a locked garage whenever possible. 3. Use an additional anti-theft device of good quality. 4. Put your name, address and phone number in this Ovmer’s Manual and keep it on your motorcycle at all times. Many times stolen motorcycles are identified by inlomiation in the Owner‘s Manuals which are still with them. NAME: ADDRESS: PHONE N0: MAINTENANCE THE IMPORTANCE OF MAINTENANCE A well-maintained motorcycle is essential for safe. economical, and trouble-tree riding. It will also help reduce air pollution. Carelul pre-ride inspections and good maintenance are especially important because your motorcycle is designed to be ridden over rough oft-road terrain. To help you properly care [or your motorcycle, this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding condin'ons. More frequent service is needed it you subject your motorcycle to severe use (such as competition) or ride in unusually wet or dusty areas. Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair. It your motorcycle overturns or becomes involved In a crash be sure your Honda dealer inspects all major parts, even if you are able to make some repairs AWARNING Improperty maintaining this motorcycle or tailing to correct a problem belore 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. MAINTENANCE SAFETY This section includes instructions on some important maintenance tasks. You can perform some of these tasks with the tools partied , if you have basic mechanical s 5. Other tasks that are more difficult and require special tools are best perlormed by professionals. Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service. Some of the most important safety precautions follow. However. we cannot warn you oi 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 tollow the procedures and precautions in this owner's manual. 47 SAFEI'Y PRECAUTIONS 0 Make sure the engine is oft before you begin any maintenance or repairs 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 parts. Let the engine and exhaust system cool before touching. ' Injury from moving parts. Do not run the engine unless instructed to do so. 0 Read the instructions before you begin, and make sure you have the tools and skills required. 0T0 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. 0T0 reduce the possibility of a fire or explosion, be careful when working around petrol. Use only nonflammable solvent, not petrol, to clean parts. Keep cigarettes. sparks and flames away from all fuel-related parts. Remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new genuine Honda parts or their equivalents for repair and replacement. MAINTENANCE SCHEDULE Periorrn Ihe Proride InsDeclion (stage 35 ) at each scheduled nuinkemnw period. i~ mercr AND CLEAN, ADJUST, LUBRICATE on REPLACE 1F NEcmnv c: CLEAN R: REPLACE A: ADJusr l; LUBRICATE The iollowing Mainienance Schedule specifies all rnainiennnce required to keep your molorcycle in peak ppemiing condiiinnv Mninienanee work should be pedormed in mrdmce wiih standards and specificaions oi l-lnnda by properly mined and equipped ieehnieiann Your Honda dealer nieela an oi Lheee requiremenis. . Should be serviced by your Honda dealer, unless lhe owner has proper tools and service darn und is mechanically qualified. Refer lo the omcial Honda Shop Manual n hi the interest oi aniely, we reeurnrnend these ilernsbe serviced only by your Honda dealer, Honda recommends that your Honda dealer should road test your motmycle after each periodic maintenance is camcd only NOTE: (1) Service more ireuuenliy when riddm in we! or dusly conditions. 49 WHICHEVER 4' FREQUENCY COMES W REGULER MAINT. INTERVAL FIRST 150 1000 2000 3000 40M) REFER ITEMS I mi 100 600 l 200 1800 2 400 TO NUI'E MONTH I 6 12 I8 24 PAGE 9 FUEL LINE I I 7 t0 FUEL SI‘RAINER SCREEN C C 7 . n-nzorrm OPERATION 1 I 64 AIR CLEANER Now (1) c c c c 55 SPARK PLUG I I I I 61 . VALVE CLEARANCE 1 I 1 I 1 7 ENGINE OIL R R R x R 56 0‘ ENGINE OILSI'RAINER SCREEN C C 7 t CAM CHAIN TENSION A A A A A - In ENGINE IDLE SPEED I I I I I 63 50 WHICHEVER * wnm REGULER MAINTV INTERVAL FREQUENCY COMES MM FIRST km 150 1000 2000 3000 woo REFER ITEMS I mi 100 600 I 200 1,800 2 too To NOTE MONTH l 6 12 18 24 PAGE DRIVE CHAIN NOTE (1) IL Izvtry 500 km (300 Im) or 67 every 3 mum I L DRIVE CHAIN SLIDER I I I I 68 BRAKE SHOE WEAR I I I I 76 BRAKE SYSTEM I I I I I 14 17 76 CLUTCH SYSTEM I I I I I 19 SIDE STAND I I 79 3 SUSPENSION I I 77 78 ‘ SPARK ARRESI‘ER Every mm.“ mm ml) ar 66 every 10001): mg be c t NUTS BOLTS FASTENERS I I I 7 u WHEELS/”RES I I I I I 27 72 “ STEERING HEAD BEARINGS I I I , 51 TOOL KIT The spark plug wrench (1) and its handle (2) are stored in the tool bag (3). (1) “52:5 (2) —>(://”//1 (1) Spark plug wrench (2) Handle (3) Toolbag SERIAL NUMBERS The flame and engine serial numbers are required when registering your motorcycle. They may also be required by your dealer when ordering replacement pans. Record the numbers here for your reference. FRAME NO. The frame number (1) is stamped on the left side of the steering head The engine number (2) is stamped on the left side of the engine. ENGINE N04 (1) Frame number (2) Engine number 53 COLOUR LABEL The colour label (1) is attached to the frame behind the let! side cover (page 34 ). It is helpful when ordering replacement parts. Record the colour and code here for your reference. COLOUR CODE (1) Colour label 54 AIR CLEANER Refer to the Saiety Precautions on page 48 . The air cleaner should be serviced at regular intervals (page 50 ). Service more frequently when riding in unusually wet or dusty areas. 1. Remove the left side cover (page 34 ). 2. Remove the rubber band (1) from the hook (2) and remove the air cleaner housing cover (3). Unhook the retainer (4) and remove the air cleaner (5). (1) Rubber band (2) Hook (3) Air cleaner housing cover 3. Wash the air cleaner in clean, nonflam mable or high flash point solvent and let it dry thoroughly. Never use petrol or low flash point solvents [or cleaning the air cleaner. A fire or explo— sion could result. 4. Soak the air cleaner in gear oil (SAE 80* 90) until saturated. then squeeze out the excess oil. 5. Reinstall the air cleaner. 6. Reinstall the left side cover. (4) Retainer (5) Air clmer 55 ENGINE OIL Refer to the Safety Precautions on page 48 . Oil Recommendation API 50 or higher except classification oils labeled as energy conserving on the circular API service label Viscosity SAE 10W-30 JASO T 903 MA standard Suggested Oil Honda “4-STROKE MOTORCYCLE OIL" or equivalent. 56 Your motorcycle does not need oil additives. Use the recommended oil. Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation Do not use API SH or higher oils displaying a circular API “energy conserving” service label on the container. They may alfect lubrication and clutch performance, NOT RECOMMENDED OK Do not use non—detergent. vegetable. or caster based racing oils. W Viscosity grade of engine oil should be based on average atmospheric temperature in your riding area. The following provides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures. 2040 I0 2|) 30 40 SO'C 60 BO 100 IZfl'F 57 JASO T 903 standard e standard is an index for engine oils for 4'stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification. Pnonucr MEEVING use I m COMPANY GUAMNTEEIMG nus MA PERFORMANCE (1) Code number 01 the sales company of the oil (2) on classification 58 Engine Oil Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified In the maintenance schedule (page 50 ). When ninning in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule, Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station [or reclamation, Do not throw it in the trash or pour it on the ground or down a drain. Used engine oil may cause skin cancer if repeatedly left in contact with the skin {or prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi- ble after handling used 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 [i a torque wrench is not used [or this installation. see your Honda dealer as soon as possible to verify proper assembly. Change the engine oil with the engine at normal operating temperature and the motorcycle on its side stand to assure complete and rapid draining. 59 1. Remove the oil filler Cap/dipstick from the right crankcase cover. 2. Place a drain pan under the crankcase and remove the oil drain bolt (1). 3. Operate the kickstarter several times while pressing the engine stop button to drain any oil which may be left in the engine 4. Check that the sealing msher (2) on the drain bolt is in good condition and install the bolt, Replace the sealing washer every other time the oil is changed, or each time it necessary. Oil Drain Bolt Torque: 24 N-m12.5 kgf-m ,18lbf-ft) 5. Fill the crankcase with the recommended grade oil; approximately: 0‘9 E (1.0 US at , 0,8 Imp qt) 60 6. Reinstall the oil filler cap/ dipstick. 7. Start the engine and let it idle for 2—3 minutes 8. Stop the engine and check that the oil level is at the upper level mark on the oil filler cap/dipstick with the motorcycle upright on firm, level ground. Make sure there are no oil leaks. (1) Oil dmin bolt (2) Sealing washer SPARK PLUG Refer to the Satety Precautions on page 48 . Recommended plugs Standar CR7HSA (NGK) or UZZFSR - U lDENSOl For cold climate: (Below 5°C, 41°F) CRGHSA (NGK) or UZOFSR , U (DENSO) For extended high speed riding: CR8HSA (NGK) or UZ4FSR — U (DENSO) For most riding conditions this spark plug heat range number is satisfactory However. if the motorcycle is going to be operated for extended periods at high speeds or near maximum power in hot climates. the spark plug should be changed to a colder heat range (a higher number). se a spark plug with an improper hea‘:l range Severe engine damage could res t 1 Disconnect the spark plug cap 2. Clean any dirt from around the spark plug 3. Remove the spark plug. 4 Visually inspect the spark plug electrodes for wear The center electrode should have square edges and the side electrode should not be eroded. 5. Discard the spark plug it there is apparent wear or if the insulator is cracked or chipped, 61 6. Check the spark plug gap ( 1 ) using a wiretype ieeler gauge. If adjustment is necessary. bend the side electrode (2 ) carefully. The gap should be: 0l6*0.7 mrn (0.02‘003 in) (2) (1) (1) Spark plug gap (2) Side electrode 62 7. Make sure the plug washer is in good condition 8. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. 9. Tighten the spark plug: o [f the old plug is good: 1/8 turn alter it seats. a If installing a new plug. tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 1 turn after it seats, DENSO: 3/4 tum alter it seats. l7)Then loosen the plug. c) Next, fighten the plug again: 1/8 turn after it seats. An improperly tightened spark plug can damage the engine. It a plug is too loose, a piston may be damaged. It 3 lug is too tight. the threads may be damaged). 10. Reinstall the spark plug cap. Take care to avoid pinching any cables or wires. IDLE SPEED Refer to the Satety Precautions on page 48 . Idle yea: e engine must be at normal operating temperature [or accurate idle speed adjustment. 10 minutes of stopandgo riding is sufficient. Do not attempt to compensate for faults in other systems by adjusting idle speed See your Honda dealer for regularly scheduled carburetor adjustments. (1) Throttle stop screw (2) Airscrew (A) Decrease (B) Increase 1. Warm up the engine and hold the motorcycle upright. 2. Connect a tachometer to the engine. 3. Adjust idle speed with the throttle stop screw (1), ldle speed (In neutral): 1,500 i 100 min" (rpm) Idle Mixture: I. Fdjust the fuel mixture by turning the air screw (2) clockwise until you hear the engine miss or decrease in speed, then counterclockwise until the engine again misses or decreases in speed. Set the air screw exactly between these two extreme positions. From a fully, closed position. the correct setting (between extremes of rich and lean) will be approximately: 2-1/8 .If the idle speed changes aiter adjusting fuel mixture. readjust the idle speed by turning the throttle stop screw. N THRO’ITLE OPERATION Refer to the Safety Precautions on page 48 . Cable lns ction: I Checl? ior smooth rotation 01 the throttle grip from the fully open to the fully closed position at both full steering positions. 2. Inspect the condition 01 the throttle cable (1) from the throttle grip down to the carburetor. II the cable is kinked, chafed or improperly routed. it should be replaced and/ or rerouted. 3. Lubricate the cable with a commercially available cable lubricant to prevent premature wear and corrosion. (1) Throttle cable Free la Ad‘ustment: lidjust lreeplay With the throttle cable adjuster (2) Measured in grip rotation, the standard throttle grip freeplay is: 2*6 mm (0.1 *02 in) 2, To adjust the freeplay. loosen the lock nut (3) and turn the adjuster, 3r Alter adjustment, check again [or smooth rotation of the throttle grip from the fully closed to the fully open position with the steering to the full right and left as well as straight ahead. If proper throttle treeplay cannot achieved, Contact your Honda dealer. (2) Throttle cable adjuster (3) lock nut (A) Decrease lreeplay (B) Increase freephy SPARKARRESTER 1. Remove the bolts (1), the spark Refer to the Safety Precautions on page 48. arrester (2), and the gasket (3) from the muffler (4 ). The exhaust system spark arrester must be 2. Use a brush to remove carbon deposits purged of accumulated carbon periodically [mm the spark arr-ester screen. Be (see Maintenance Schedule for servicing careful to avoid damaging the spark period. Page 51 ), arrester screen. The spark arrester must be free of breaks and holes, The exhaust system becomes very hot Replacejinecessary. Check the gasket. during operation and remains hot for a ReplaceJInecessary. period of time alter stopping the engine 3. Install the spark arrester and the Allow the exhaust system to cool betore gasket in the muffler and tighten the perforating this operation. bolts securely, (l) Bolts (3) Gasket (2) Spark arrester (4) Muffler 66 DRIVE CHAIN Refer to the Safety Precautions on page 48 . The service life of the drive chain is dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprockets. The drive chain should be checked and lubricated as part of the Preride Inspection (page 35 ). Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas. more frequent maintenance will be necessary. Insm’on: . urn t e engine off, plaoe the motorcycle on its side stand and shift the transmission into neutral. 2. Check slack in the lower drive chain run midway between the sprockets. Drive chain slack should be adjusted to allow the lollowing vertical movement by hand: 25-35 mm (1.0—1.4 in) w . Roll the motorcycle forward. Stop. Check the drive chain slack. Repeat this procedure several times. Drive Chain slack should remain constant. lithe chain is slack only in certain sections. some links are kinked and binding. Binding and kinking can frequently be eliminated by lubrication. Excess chain shck may allow the drive chain to damage the engine cases. (1) Drive chain 67 4. Check the chain slider (2) for wear. if the depth of groove exceeds the limit, the chain slider must be replaced See your Honda dealer. Chain slider depth limit: 6 mm (02 in) (2) Chain slider 68 5. Measure a section of the drive chain to determine whether the chain is worn beyond its service limit. Remove the drive chain and measure the distance between a span oi pins [ram pin center to pin center. If the distance exceeds the service limit, the chain is worn out and should be replaced New Chain: 1,384 mm (545 in) Service Limit: 1,412 mm (5515 in) Measure a span of : 109 pins. 6. Inspect the sprocket teeth for possible wear or damage. Damaged sprocket Worn sprocket Teeth Teeth Replace Replace Normal sprocket Teeth GOOD If the drive chain or sprockets are excessively worn or damaged, they should be replaced. Never use a new chain with worn sprockets: rapid chain wear will result. Ad‘ustment: t e rive chain requires adjustment the procedure is as tollows: 1. Place a support block under the engine to raise the rear wheel off the ground. 2. Loosen the rear axle nut (1), (1) Rear axle nut (2) Adjusting nut (3) Adjuster index mark (4) Graduated scale 69 3. Turn the adjusting nut (2) on both the right and leit chain adjusters an equal number of turns to increase or decrease chain slack. Align the chain adjuster index marks (3) with the corresponding scale graduations (4) on both sides of the swinganni I! the drive chain slack is excessive when the rear axle is moved to the furthest limit of adjustment, the drive chain is worn and must be replaced. 4. Tighten the rear axle nut to: 62 N‘m (6,3 kgf‘m , 46 "3“!) 5. Tighten the adjusting nuts. 6. Recheck drive chain slack. 7. Rear brake pedal ireeplay is affected when repositioning the rear wheel to adjust drive chain slack. Check rear brake pedal freeplay and adjust as necessary (page 17 )r 70 l! a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly, Lubrication: Use SEE 85m- 90 gear oil or a commercially prepared drive chain lubricants in preierence to motor oil or other lubricants Saturate each chain link joint so that the lubricant penetrates between the link plates. pins. bushings, and rollers. Removal and Cleaning: e e nve 0 am becomes dirty, it should be removed and cleaned prior to lubrication. 1. With the engine 0“. careiully remove the master link retaining clip (1) with a pair of pliers. Do not bend or twist the clip. Remove the master link Remove the drive chain from the motorcycle. 2. Clean the drive chain in high flash-point solvent and allow it to dry. inspect the drive chain for possible wear or damage Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Never use petrol or low flash point solvents for cleaning the drive chain. A fire or explosion could result. 3. Inspect the sprocket teeth for possible wear or damage. 4. Lubricate the drive chain (page 70 ), 5. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link The master link is the most crin'cal part affecting the SECul‘lty of the drive chain. Master links are reusable, it they remain in excellent condition, but it is recommended that a new master link retaining clip be installed whenever the drive chain Is reassembled Insmll the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. (l) Retaining clip 71 WHEEL RIMS AND SPOKES Refer to the Salety Precautions on page 48 . 1‘ Inspect the wheel rims (l) and spokes (2) {or damage 2. Tighten any loose spokes and rim locks 3.Check wheel rim runout. If runout is noticeable, see your Honda dealer for inspection. Maintenance of spoke tension and wheel trueness are critical to sale motorcycle operation During the first 150 km (100 miles). spokes will loosen more rapidly due to initial sealing 01 parts. Excessively loose spokes may result in high speed instability and possible loss of control. 72 (1) Wheel rim (2) Spoke (3) Rim lock WHEEL REMOVAL Refer to the Safety Precautions on page 48 . Front Wheel Removal 1. Raise the (rent wheel off the ground by placing a suppon block under the engine. 2. Loosen the cable guide bolt (1). 3. Disconnect the front brake cable (2) from the brake arm (3). 4. Remove the front axle nut (4) and front axle. The front wheel can now be removed. (1) Cable guide bolt (2) Front brake cable (3} Brake arm (4) Front axlenut (5) Lug (6) Slot Installation: l. Reverse the removal procedure. Make sure that the lug (5) on the fork leg is located in the slot (6) in the brake panel, Be sure to tighten the front axle nut to: 62 N4m (6.3 kgfrm , 46 Ibf-ft) 2. Check front brake adjustment. 3. After installing the wheel. apply the brake several times and then check it the wheel rotates freely. Recheck the wheel it the brake drags or it the wheel does not rotate freely. It a torque wrench was not used for installation. see your Honda dealer as soon as possible to verily proper assembly. Improper assembly may lead to loss of brakingcapacity. 73 Rear Wheel Removal 5. Unscrew the rear axle nut (5) and pull 1. Raise the rear wheel otf the ground by out the axle. Push the wheel forward and placinga support block under the engine. derail the drive chain [ram the rear 2. Remove the rear brake adjuster (l). sprocket. Tilt the motorcycle to one side 3. Press and release the rear brake pedal so that the wheel canberemovedr and disconnect the brake rod (2) from the brake arm (3). 4. Loosen the adjusting nut (4) on the chain adjuster on both sides. (2) (5) Rear axle nut (1) Brake acfiuster (3) Brakeann (2) Brake rod (4) Adjusting nut 74 Installation: 1. Reverse the removal procedure. Make sure that the lug (6) on the swingarm is located in the slot (7) in the brake panel. Be sure to tighten the rear axle nut to: 62 N-m (6‘3 kgf~m , 46 Ibt-ft) 2. Adjust the drive chain (pages 69 7 70). 3. Adjust the brake (page 17). 4. Apply the brake several times and check for free wheel rotation after the bmke Pedal is released. It a torque wrench was not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of brakingcapacity. (6) Lug (7) Slot 75 BRAKE SHOE WEAR Refer to the Safety Precautions on page 48 . The front and rear brakes are equipped wilh brake wear indicators. When the brake is applied, an arrow (1) attached to the brake arm (2) moves toward a reference mark (3) on the brake panel (4). If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced, See your Honda dealer for this service When the brake service is necessary, see your Honda dealer. Use only Honda Genuine Parts or its equivalent. 75 < FRONT BRAKE >1 (3) Reference mark (4) Brake panel (1) Arrow (2) Brake arm FRONT SUSPENSION Refer to the Safety Precautions on page 48 r Check the fork operation by locking the [rent brake and pumping the forks up and down several times. The suspension should function smoothly, with no oil leakage from the fork legs. Damaged. binding. or leaking fork should be repaired before the motorcycle is operated. Check security of all fork and handlebar mounting bolts (1). (1) (1) Mounting 1mm Operating the motorcycle with loose, worn, or damaged steering or front suspension components may adversely alfect vehicle handling and stability If any suspension components appear worn or damaged. consult your Honda dealer [or further inspection. The suspen» sian components are directly related to salety and your Honda dealer is qualified to determine whether or not replacement parts or repairs are needed. REAR SUSPENSION Refer to the Salety Precautions on page 48 . Check the rear suspension periodically by careful visual examination. Note the following items: 1. Swingarm bushings (1) should be checked by pushing hard against the side 01 the rear wheel while the motorcycle is on a support block and feeling [or looseness of the bushings. 2.Check all suspension component attachment points (2) [or security of their fasteners. 3. Check for oil leaks in the shock absorber units. If any suspension components appear worn or damaged, consult your Honda dealer [or further inspection. The suspension components are directly related to safety and your Honda dealer is qualified to deter- mine whether or not replacement parts or repairs are needed. 78 (1) Swingarm bushings (2) Attachment points SIDE STAND Reier to the Saiety Precautions on page 48 . Check the side stand spring (1) [or damage and loss of tension. and the side stand assembly for freedom of movement. If the side stand is squeaky or stiff. clean the pivot area and lubricate the pivot bolt with clean engine oil. (1) (1) Side stand spring 79 CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect [or damage. wear and oil leakage. Avoid cleaning products that are not specifically designed {or motorcycle or automobile surtacesr They may contain harsh detergents or chemical solvents that could damage the metal, paint» and plastic on your motorcycle, II your motorcycle is still warm from recent operation. give the engine and exhaust system time to cool oif. We recommend avoiding the use of high pressure water spray (typical in coin- operated car washes). High pressure water (or air) can damage certain parts of the motorcycle. High pressure washer spray can damage Certain pans of your motorcycle. If you use a high pressure washer, avoid spraying the following areas: Wheel Hubs Muffler Outlet Under Seat Engine Stop Button Under Fuel Tank Drive Chain Carburetor Ignition Switch Washing the motorcycle 1 Rinse the motorcycle thoroughly with cool water to remove loose dirt. 2 Clean the motorcycle with a sponge or soft cloth using cool water. Avoid directing water to muffler outlets and electrical parts. 3. Clean the plastic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing it frequently with fresh water, Take care to keep brake fluid or chemical solvents off the motorcycle. They will damage the plastic and painted surfaces, 4.A[ter cleaning, rinse the motorcycle thoroughly with plenty 01 Clean watert Strong detergent residue can corrode alloy parts 5 Dry the motorcycle, smrt the engine. and let' it run for several minutes. 6.Test the brakes before riding the motorcycle. Several applications may be necessary to restore normal braking performance. 7. Lubricate the drive chain immediately after washing and drying the motorcycle. Braking efficiency may be temporarily impaired immediately after washing the motorcycle. Anticipate longer stopping distance to avoid a possible accident. 81 Finishing Touches After washing your motorcycle. consider using a commercially-available spray cleaner/ polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax according to the instructions on the container. STORAGE GUIDE Extended storage. such as [or winter, requires that you take certain steps to reduce the eflects of deterioration from non-use of the motorcycle, In addition, necessary repairs should be made BEFORE storing the motorcycle; otherwise these repairs may be forgotten by the time the motorcycle is removed [rum storage STORAGE 1‘ Change the engine oil and clean the filter screen. 2. Drain the fuel tank and carburetor into an approved petrol container. Reinstall the fuel fill cap on the tank. To assure proper performance aiter storage lasting more than one month, it is important to drain the carburetor. AWARNING Petrol is highly flammable and explosive. You can be bumed or seriously injured when handling tuel. 0 Stop the engine and keep heat, sparks, and flame away. o Refuel only outdoors o wipe up spills immediately. 83 3. To prevent rusting in the cylinder, pertorrn the lollowing: ' Remove the spark plug cap from the spark plug, Using tape or string, secure the cap to any convenient plastic body part so that it is positioned away [mm the spark plug. - Remove the spark plug from the engine and store it in a safe place‘ Do not connect the spark plug to the spark plug cap 0 Pour a tablespoon (15 20 cm“) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth. 0 Crank the engine several times to distribute the oil. O Reinstall the spark plug and spark plug cap, 4. Wash and dry the motorcycle. Wax all painted surfaces. Coat chrome with rustinhibiting oil. 5. Lubricate the drive chain (page 70 ). 6.1nflate the tyres to their recommended pressures. Place the motorcycle on blocks to raise both tyres off the ground, 7. Cover the motorcycle (don't use plastic or other coated materials) and store in an unheated area, free of dampness with a minimum of daily temperature variation. Do not store the motorcycle in direct sunlight. REMOVAL FROM STORAGE 1. Uncover and clean the motorcycle. Change the engine oil if more than 4 months have passed since the snarl of storage, 2. Perform all Pre-n'de Inspection checks (page 35 ). 3. Test ride the motorcycle at low speeds in a safe riding area away from traffic SPECIFICATIONS DIMENSIONS Overall length Overall width Ovemll height Wheelbase CAPACITIIE Engine oil Fuel tank Fuel reserve Passenger capacity Maximum weight capacity After draining After disassembly 86 1,749 mm (68.9 in) 727 mm (23.6 in) 995 mm (39.2 in) 1.209 mm (47.6 in) “10 USqIAlBImpqt) fl(12USqI,10|mpqt) M1 32 US gal, 110plmp gal) 0 M0. 18 US gal O 15 Imp gal) O erator only; no passenger 100k 9 (220 lbs) ENGINE Bore and stroke Compression ratio Displacemem Spark plug Standard For cold climate (Below 5°C. 41°F) For extended high speed riding Spark plug gap Valve clearance (Cold) Idle speed 47.5 X 45 mm (1.87 X 1.77 in) 9.7:1 79.7 cm3 (4.86 cu-in) CR7HSA (NGK) or UzzFSR— U (DENSO) CRGHSA (NGK) or UZOFSR — U (DENSOJ CRSHSA (NGK) or U24FSR—U (DENSO) 0.670] mm (0.02—0.03 in) Intake 0.05 mm (0,002 in) Exhaust 0.05 mm (0.002 in) 1,500 3: 100 min“ (rpm) CHASSIS AND SUSPENSION Caster Trail Tyre size, from Tyre size. rear Tyre type POWER TRANSMISSION Primary reduction Gear ratio. 151 2nd 3rd 4th 5th Final reduction 28°02’ 74 mm (29 in) 2.50— 16 4PH 3,60— 14 4PR bias—ply, tube