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Honda 2004 CB250 Nighthawk, Owner'S Manual

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Honda 2004 CB250 Nighthawk Owner'S Manual Download Page 195

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61KPJ03

61CM001

31KPJ630

2004 CB250 Service Manual

Common Service Manual

2004 CB250 Owner’s Manual

Publication Item No.

Description

Price Each

Pr ices ar e subject to change without notice and without incur r ing obligation.

186

Authorized Manuals

Consumer Information

The Service Manual (Publication Item No.

) used by your authorized Honda

dealer is available from Helm, Inc.

Also available, but not necessary, to service your model is the Honda Common Service
Manual (Publication No. 61CM001 ), which explains theory of operation and basic service
information for various systems common to all Honda motorcycles, motor scooters and
ATVs.

These Honda manuals are written for the professional technician, but most mechanically-
capable owners should find them easy to use if they have the proper tools and observe proper
safety standards. Special Honda tools are necessary for some procedures.

61KPJ03

03/08/21 10:24:58 31KPJ630_195

Summary of Contents for 2004 CB250 Nighthawk

Page 1: ...ation available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold 2003 Honda Motor Co Ltd 03 08 21 09 56 48 31KPJ630_001 ...

Page 2: ...2004 Honda CB250 NIGHTHAWK OWNER S MANUAL 03 08 21 09 56 53 31KPJ630_002 ...

Page 3: ...But it s just as important to observe the break in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this 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 detailed list of topics at the beginning of each section and both an in depth tabl...

Page 4: ...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 This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California Proposition 65 Warning You may a...

Page 5: ...and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You will find important safety information in a variety of forms including on the motorcycle preceded by a s...

Page 6: ... t follow instructions A Few Words About Safety Safety Messages Safety Headings Safety Section Instructions such as Important Safety Reminders or Important Safety Precautions such as Motorcycle Safety how to use this motorcycle correctly and safely This entire manual is filled with important safety information please read it carefully 03 08 21 09 57 21 31KPJ630_006 ...

Page 7: ...w to make sure you and your motorcycle are ready to ride and important information about loading Important safety information you should know plus a look at the safety related labels on your motorcycle How to start and stop the engine shift gears and brake Also riding precautions and important information about riding with a passenger or cargo The location and function of indicators and controls o...

Page 8: ...enance schedule and instructions for specific maintenance and adjustment items How to store and transport your motorcycle and how to be an environmentally responsible rider What to do if you have a flat tire your engine won t start etc ID numbers technical specifications and other technical facts Information on warranties emission controls how to get Honda service manuals and Sequential listing of...

Page 9: ...03 08 21 09 57 47 31KPJ630_009 ...

Page 10: ...d recommendations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle Important Safety Information 2 Accessories Modifications 5 Safety Labels 7 03 08 21 09 57 52 31KPJ630_010 ...

Page 11: ...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 It s a proven fact helmets significantly reduce the number and severity of head injuries So always wear an approved motorcycle helmet and make sure your passenger does the same We also recommend that you wear eye protection sturdy boots gloves...

Page 12: ...ow this motorcycle works and handles Practice in a safe area until you build your skills and get accustomed to the motorcycle s size and weight Because many accidents involve inexperienced or untrained riders we urge all riders to take a certified course approved by the Motorcycle Safety Foundation MSF See page The most frequent motorcycle collision happens when a car turns left in front of a moto...

Page 13: ...ll accessories that would make your motorcycle unsafe page Pushing limits is another major cause of motorcycle accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and ride safely Alcohol and riding don t mix Even one drink can reduce your ability to res...

Page 14: ...the following information 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 Honda dealer for assistance and always follow these guidelines Make sure t...

Page 15: ...ll any fairing or windshield unless it was designed and tested by Honda for your motorcycle Some fairings or windshields even smaller ones can cause unstable handling of your motorcycle This is especially true if the fairing or windshield is poorly designed or improperly mounted Do not add any electrical equipment that will exceed the motorcycle s electrical system capacity page A blown fuse can c...

Page 16: ...warn you of potential hazards that could cause serious injury or they 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 03 08 21 09 58 35 31KPJ630_016 ...

Page 17: ...8 Safety Labels Motorcycle Safety 03 08 21 09 58 45 31KPJ630_017 ...

Page 18: ...age are described in this section Instructions for other components are presented in other sections of this manual where they will be most useful Component Locations 10 Indicators 13 Controls Features Fuel Valve 17 Choke Knob 17 Ignition Switch 18 Start Button 19 Engine Stop Switch 19 Headlight Dimmer Switch 20 Turn Signal Switch 20 Horn Button 21 Tripmeter Reset Knob 21 03 08 21 09 58 51 31KPJ630...

Page 19: ... stop switch headlight dimmer switch speedometer fuel fill cap clutch lever indicators ignition switch throttle grip rearview mirror choke knob rearview mirror front brake lever 10 Component Locations Instruments Controls 03 08 21 09 59 01 31KPJ630_019 ...

Page 20: ...steering lock passenger footpeg rear brake pedal footpeg oil filler cap dipstick battery tool kit compartment 11 Component Locations Instruments Controls 03 08 21 09 59 08 31KPJ630_020 ...

Page 21: ...passenger footpeg side stand shift lever footpeg air cleaner fuel valve owner s manual storage helmet holder seat release 12 Component Locations Instruments Controls 03 08 21 09 59 16 31KPJ630_021 ...

Page 22: ...ake your riding safer and more enjoyable Refer to the indicators frequently Their functions are described on the following pages 1 speedometer 2 odometer 3 gear range indicator 4 neutral indicator 5 side stand indicator 6 turn signal indicator 7 high beam indicator 8 tripmeter Odometer tripmeter read in miles 03 08 21 09 59 26 31KPJ630_022 ...

Page 23: ...ndicators come on when you turn the ignition switch ON and remain on until you select the low beam shift out of neutral or raise the side stand If one of these indicators does not come on when it should have your Honda dealer check for burned out bulbs or other problems 03 08 21 09 59 31 31KPJ630_023 ...

Page 24: ...er speed range for each gear odometer Shows the total miles ridden side stand indicator amber Lights when the side stand is put down to indicate that the side stand ignition cut off system page is activated 1 2 3 4 5 neutral indicator green Lights when the transmission is in neutral 35 03 08 21 09 59 42 31KPJ630_024 ...

Page 25: ...hes when either turn signal operates high beam indicator blue Lights when the headlight is on high beam tripmeter Shows the number of miles ridden since you last reset the meter To zero 0 the tripmeter turn the tripmeter reset knob 6 7 8 03 08 21 09 59 50 31KPJ630_025 ...

Page 26: ... to a gas station for refueling OFF for parking storing or transportation ON normal position for riding The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetors For complete information about fueling your motorcycle see page The choke knob may be used when starting the engine See page 36 73 03 08 21 10 00 03 31KPJ630_026 ...

Page 27: ...Function 18 Ignition Switch Controls Features Instruments Controls The ignition switch is used for starting and stopping the engine page The ignition key is also used to lock the steering for theft prevention page Insert the key and turn it to the right for the ON position 35 44 03 08 21 10 00 14 31KPJ630_027 ...

Page 28: ...utomatically go out but the taillight will stay on The start button is used for starting the engine Pushing the button in starts the engine See page The engine stop switch is used to stop the engine in an emergency To operate push the switch to the OFF position The switch must be in the RUN position to start the engine and it should normally remain in the RUN position even when the engine is OFF c...

Page 29: ... battery discharge The turn signal switch is used to signal a turn or a lane change To operate move the switch all the way in the proper direction and release it The appropriate turn signal lights will start blinking Remember to return the switch to the center off after completing your turn or lane change The headlight dimmer switch is used to change between the high and low beams of the headlight...

Page 30: ...set Knob Controls Features Instruments Controls The horn is used to alert other motorists To operate push the horn button The reset knob is used to reset the tripmeter to zero 0 by turning the knob in the direction shown 3 4 03 08 21 10 00 44 31KPJ630_030 ...

Page 31: ...22 Instruments Controls 03 08 21 10 00 46 31KPJ630_031 ...

Page 32: ...otorcycle and adjustments to make for your comfort convenience or safety This section also includes important information about loading Are You Ready to Ride 24 Protective Apparel 24 Rider Training 26 Is Your Motorcycle Ready to Ride 27 Pre ride Inspection 27 Load Limits Guidelines 30 Loading 30 Load Limits 31 Loading Guidelines 31 For information about adjusting the suspension on your Honda see p...

Page 33: ...t For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete protection is not possible wearing proper gear can reduce the chance of injury when you ride Following are suggestions to help you choose the proper gear You are wearing an approved motorcycle helmet...

Page 34: ...our head comfortably and securely A bright colored helmet and reflective strips can make you more noticeable in traffic Leather gloves to help protect your hands Sturdy boots with non slip soles to help protect your feet and ankles In addition to a helmet and eye protection we also recommend Additional Riding Gear An open face helmet offers some protection but a full face helmet offers more Regard...

Page 35: ...cycle works and handles Practice riding the motorcycle in a safe area to build your skills Do not ride in traffic until you get accustomed to the motorcycle s controls and feel comfortable with its size and weight We urge all riders to take a certified course approved by the Motorcycle Safety Foundation MSF New riders should start with the basic course and even experienced riders will find the adv...

Page 36: ...et on the motorcycle Before each ride it s important to inspect your motorcycle and make sure any problem you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience Look at the tires If a tire appears low use an air pressure gauge to check its pressure Also look for signs of excessive wear page or damage...

Page 37: ...ears unusual such as a leak or loose cable Make sure the headlight brake light taillight and turn signals are working properly If you are carrying a passenger or cargo also check the following Make sure you do not exceed the load limits page Check that all cargo is secure Adjust the rear suspension page according to your load 31 98 03 08 21 10 01 37 31KPJ630_037 ...

Page 38: ...ne at least once a month no matter how often you ride Remember be sure to take care of any problem you find or have your Honda dealer correct it before you ride Check these items after you get on the motorcycle Rotate the throttle to check it moves smoothly without binding Pull the brake lever and press on the brake pedal to check that they operate normally Turn the ignition on and check for norma...

Page 39: ...eep your motorcycle well maintained with good tires and brakes you can safely carry loads within the given limits and guidelines How much weight you put on your motorcycle and how you load it are important to your safety Anytime you ride with a passenger or cargo you should be aware of the following information However exceeding the weight limit or carrying an unbalanced load can seriously impair ...

Page 40: ...cargo check with your Honda dealer for advice and be sure to read the information regarding accessories on page Following are the load limits for your motorcycle Improperly loading your motorcycle can affect its stability and handling Even if your motorcycle is properly loaded you should ride at reduced speeds and never exceed 80 mph 130 km h when carrying cargo includes the weight of the rider pa...

Page 41: ... adjust the rear suspension page To prevent loose items from creating a hazard make sure that all cargo is tied down securely before you ride Place cargo weight as low and close to the center of your motorcycle as possible Balance cargo weight evenly on both sides Do not attach large or heavy items such as a sleeping bag or tent to the handlebar forks or fender 107 99 03 08 21 10 02 11 31KPJ630_04...

Page 42: ...or cargo To protect your new engine and enjoy optimum performance and service life refer to Break in Guidelines page For information about carburetor adjustment for riding at high altitude see page Safe Riding Precautions 34 Starting Stopping the Engine 35 Preparation 35 Starting Procedure 36 Flooded Engine 38 How to Stop the Engine 39 Shifting Gears 40 Braking 42 Parking 44 Riding with a Passenge...

Page 43: ...lease review the section beginning on page 1 and the section beginning on page 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 your skills and get accustomed to the motorcycle s size and weight 23 03 08 21 10 02 22 31KPJ630_043 ...

Page 44: ...efore operating the starter Your motorcycle is equipped with a side stand ignition cut off system If the side stand is down the engine cannot be started unless the transmission is in neutral If the side stand is up the engine can be started in neutral or in gear with the clutch lever pulled in After starting with the side stand down the engine will stop if the transmission is put in gear before ra...

Page 45: ...throttle closed Do not open the throttle when starting the engine with the choke on This will lean the mixture resulting in hard starting If idling is unstable open the throttle slightly If the engine is cold pull the choke knob up all the way to fully ON Immediately after the engine starts operate the choke knob to keep fast idle About a half minute after the engine starts push the choke knob dow...

Page 46: ...lightly Start the engine Low Air Temperature 10 C 50 F or below Follow steps 1 2 under Snapping the throttle or fast idling for more than about 5 minutes at normal air temperature may cause exhaust pipe discoloration Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is at fully OFF When engine rpm begins to pick up operate the choke knob to keep...

Page 47: ... clear a flooded engine Open the throttle fully Press the start button for 5 seconds If the engine still won t start refer to page Start the engine Open the throttle slightly Do not use the choke Wait 10 seconds then press the engine stop switch to RUN Follow the starting procedure Push the choke knob down all the way to fully OFF Turn the engine stop switch to OFF 1 4 2 3 5 6 7 8 143 03 08 21 10 ...

Page 48: ...hould normally remain in the RUN position even when the engine is OFF If your motorcycle is stopped with the engine stop switch OFF and the ignition switch ON the headlight and taillight will remain on resulting in battery discharge Emergency Engine Stop To stop the engine in an emergency use the engine stop switch To operate turn the switch to the OFF position 03 08 21 10 03 14 31KPJ630_048 ...

Page 49: ... release the clutch lever It is at this point the transmission of power to the rear wheel resumes Close the throttle and pull the clutch lever in completely before shifting Improper shifting may damage the engine transmission and drive train As a general rule shift while moving in a straight line Learning when to shift gears comes with experience Keep the following tips in mind Your motorcycle has...

Page 50: ...est gear that lets the engine run and accelerate smoothly This will give you good fuel economy and effective emissions control When changing gears under normal conditions use these recommended shift points From 1st to 2nd From 2nd to 3rd From 3rd to 4th From 4th to 5th 12 mph 20 km h 19 mph 30 km h 25 mph 40 km h 31 mph 50 km h From 5th to 4th From 4th to 3rd 22 mph 35 km h 16 mph 25 km h Pull the...

Page 51: ...ssion from downshifting will help slow your motorcycle 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 brake pedal 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 ste...

Page 52: ...rakelight giving a false indication to other drivers It may also overheat the brakes reducing effectiveness When descending a long steep grade use engine compression braking by downshifting with intermittent use of both brakes Continuous brake application can overheat the brakes and reduce their effectiveness Your ability to brake in a turn and to brake hard in an emergency situation are important...

Page 53: ...emember that lowering the side stand with the transmission in gear will stop the engine even if the clutch lever is pulled in That is a function of the side stand ignition cut off system Check that the side stand is down all the way The side stand indicator only indicates that the side stand ignition cut off system page is activated Use the steering lock which locks the handlebar in place Turn the...

Page 54: ... helmet secured by the holder LEFT REAR 4 4 holder 3 2 2 helmet holder 3 ignition key 45 Basic Operation Riding Parking Turn the fuel valve OFF Use the helmet holder to secure your helmet with your motorcycle Insert the ignition key and turn it clockwise to unlock the holder Hang your helmet on the holder Turn the key counterclockwise to lock the holder and then remove the key 4 5 2 3 4 03 08 21 1...

Page 55: ...rage a thief Always take the ignition key with you Always use the steering lock page even if you re parking for just a minute or two A thief can easily push an unlocked motorcycle to a waiting truck In addition to the steering lock use a good quality anti theft device made specifically to lock a motorcycle to a secure object Keep your owner s manual current registration and insurance information w...

Page 56: ... page Also consider adjusting the suspension page for the extra load Be aware that carrying a passenger or heavy cargo can affect acceleration braking and handling Before riding with a passenger make sure your passenger is wearing the proper protective apparel page Tell your passenger to hold the seat strap or your waist lean with you in the turns and keep their feet on the passenger footpegs at a...

Page 57: ...48 Basic Operation Riding 03 08 21 10 04 27 31KPJ630_057 ...

Page 58: ...t least once a month and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking great For information about the exhaust emission and noise emission requirements of the U S Environmental Protection Agency EPA and the California Air Resources Board CARB see page For information about...

Page 59: ... Owner s Manual Storage 70 Seat Removal 71 Side Cover Removal 72 Fluids Filters Fuel 73 Engine Oil 76 Air Cleaner 84 Crankcase Breather 86 Throttle 87 Clutch System 89 Engine Idle Speed 93 Spark Plugs 95 Electrical Chassis Suspension 98 Brakes 101 Tires 106 Side Stand 113 Drive Chain 114 Battery 121 Appearance Care 126 03 08 21 10 04 45 31KPJ630_059 ...

Page 60: ...nce The periodic checks provide additional confidence in your motorcycle s performance more often if you ride frequently or long distances or anytime you clean your motorcycle unless you have the proper tools and service data and are mechanically qualified Type of Inspection Service Maintenance Schedule Periodic Maintenance Pre ride Inspection Refer to page interval on schedule monthly before ever...

Page 61: ...al to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun A properly maintained motorcycle will also help to reduce air pollution Remember proper maintenance is the owner s responsibility Be sure to inspect your motorcycle before each ride perform the periodic checks and follow the Maintenance Schedule in this section If your motor...

Page 62: ...hese tasks with the tools provided with your motorcycle Other tasks that are more difficult and require special tools are best performed 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 wa...

Page 63: ...intenance stand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only non flammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Be sure there is adequate v...

Page 64: ...ipped 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 If you have the tools and skills required for additional maintenance jobs you can purchase an official Honda Service Manual page 186 03 08 21 10 05 22 31KPJ630_064 ...

Page 65: ... a month even if you haven t ridden your motorcycle or as often as once a week if you ride frequently or for long distances It s a good idea to perform this maintenance any time you clean your motorcycle Check the odometer reading and perform any scheduled maintenance checks that are needed page Remember more frequent checks may be needed for riding in severe conditions 27 58 58 03 08 21 10 05 27 ...

Page 66: ...age and rear brake pedal page Check condition adjust slack and lubricate as needed page Drive Chain Fuses Nuts Bolts Make sure you have a full supply of spare fuses Check the major fasteners and tighten as needed Check the air pressure with a gauge and add air if needed page Examine the tread for wear page Look closely for nails embedded objects cuts and other types of damage page Roll your motorc...

Page 67: ...tems involve more extensive procedures and may require special training tools and equipment We recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools and equipment Procedures for such items in this schedule are provided in an official Honda Service Manual available for purchase page The service intervals in this Maintenance S...

Page 68: ...at 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 Perform the pre ride inspection page and owner maintenance page at each scheduled maintenance period Each item on the maintenance schedule requi...

Page 69: ... here Service more frequently if the motorcycle is ridden in unusually wet or dusty areas Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean A adjust L lubricate R replace Service more frequently if the motorcycle is ridden often at full throttle or in the rain California type only NOTES 1 2 3 4 03 08 21 10 06 00 31KPJ630_069 ...

Page 70: ...R I R C I 20 32 0 C C I I R I 24 38 4 I C I I R C R I R C I I NOTE 2 3 4 4 6 4 C C I I R I Refer to page 87 84 86 95 76 93 ODOMETER READING Note 1 ITEM FREQUENCY EMISSION RELATED ITEMS 61 Servicing Your Honda Maintenance Schedule Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page I...

Page 71: ...HEELS TIRES STEERING HEAD BEARINGS Refer to page 114 105 101 103 89 113 ODOMETER READING Note 1 ITEM FREQUENCY I L EVERY 500 mi 800 km NON EMISSION RELATED ITEMS 62 Maintenance Schedule Servicing Your Honda Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page In the interest of safet...

Page 72: ...ify the maintenance was performed If the motorcycle is sold these receipts should be transferred with the motorcycle to the new owner Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 600 mile 1 000 km initial maintenance is considered a normal owner operating cost and will be charged for by your dealer Use the space under Notes to record anyt...

Page 73: ... Miles km Odometer Date Notes Performed By 24 000 38 400 28 000 44 800 32 000 51 200 36 000 57 600 40 000 64 000 44 000 70 400 48 000 76 800 52 000 83 200 56 000 89 600 60 000 96 000 64 000 102 400 68 000 108 800 03 08 21 10 06 41 31KPJ630_073 ...

Page 74: ...front brake lever clutch lever fuel fill cap 65 Component Locations Servicing Your Honda 03 08 21 10 06 49 31KPJ630_074 ...

Page 75: ...t battery spark plug engine idle speed tool kit compartment oil filler cap dipstick rear spring pre load adjuster rear brake pedal main fuse fuse box 66 Component Locations Servicing Your Honda 03 08 21 10 06 57 31KPJ630_075 ...

Page 76: ... cover drive chain fuel valve air cleaner side stand rear spring pre load adjuster owner s manual storage front brake adjusting nut 67 Component Locations Servicing Your Honda 03 08 21 10 07 04 31KPJ630_076 ...

Page 77: ... Some roadside repairs minor adjustments and parts replacement can be performed with the tools contained in the kit pliers standard phillips screwdriver screwdriver handle 22 mm box end wrench extension bar spark plug wrench handle bar pin spanner tool bag 10 12 mm box end wrench 14 17 mm open end wrench 69 03 08 21 10 07 17 31KPJ630_077 ...

Page 78: ...ool kit compartment is located under the right side cover To close the compartment cover align its tabs and push it in Turn the key counterclockwise Remove the key To reach the tool kit insert the ignition key into the key slot in the compartment cover Turn the key clockwise Open the compartment cover 1 2 3 4 03 08 21 10 07 25 31KPJ630_078 ...

Page 79: ...r Honda Be careful not to flood this area when washing your motorcycle Your motorcycle provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual and other documents in the plastic storage bag in the storage compartment under the seat 2 1 03 08 21 10 07 31 31KPJ630_079 ...

Page 80: ...d pull the seat lock lever 3 downward Pull the seat 4 back and up Installation The seat must be removed to access the owner s manual and to remove the side cover Insert the prongs 5 into the fuel tank stay 6 and the stays at the rear of the frame Push down on the rear of the seat Turn the ignition key counterclockwise to lock the seat then remove the key Be sure to securely lock the seat after rei...

Page 81: ...ety Precautions Refer to on page Removal Installation Remove the seat page Remove the bolts Pull out the studs The side cover must be removed for battery and air cleaner maintenance Installation can be done in the reverse order of removal 54 1 2 3 71 2 3 1 03 08 21 10 07 53 31KPJ630_081 ...

Page 82: ...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 Your engine is designed to use any gasoline that has a pump octane number of 86 or higher Gas...

Page 83: ...mixture Avoid getting dirt dust or water in the fuel tank Refer to on page Insert the ignition key in the fuel fill cap and turn it clockwise Fuel tank capacity including reserve Reserve capacity 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 1 1 2 54 03...

Page 84: ...cing Your Honda Open the cap Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck After refueling align the latch in the cap with the slot in the filler neck Push the cap into the filler neck until it snaps and locks Remove the ignition key from the cap Turn the fuel valve ON if it was set on RES 2 3 6 3 5 4 03 08 21 1...

Page 85: ... Change the engine oil as specified in the maintenance schedule on page Using the proper oil page 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 in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious dama...

Page 86: ...led as energy conserving on the circular API service label suggested oil API classification JASO T 903 standard viscosity weight 77 Oil Recommendation Servicing Your Honda Engine Oil Suggested oils are equal in performance to SJ oils that are not labeled as energy conserving on the circular API service label 03 08 21 10 08 34 31KPJ630_086 ...

Page 87: ...ecommended oil Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range Do not use non detergent vegetable or castor based racing oils 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 03 08 21 10 08 44 31KPJ63...

Page 88: ...ing Your Honda Engine Oil JASO T 903 standard There are two classes MA and MB Oil conforming to the standard has the following classification on the oil container The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engines 03 08 21 10 08 50 31KPJ630_088 ...

Page 89: ...torcycle on its side stand on a firm level surface Refer to on page Start the engine and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes Remove the oil filler cap dipstick and wipe it clean Hold the motorcycle in an upright position Insert the oil filler cap dipstick until it seats but don t screw it in 2 3 4 5 6 1 1 54 03 08 21 10 09 00 31KPJ630_089 ...

Page 90: ...oil until it reaches the upper level mark Do not overfill Reinstall the oil filler cap dipstick Check for oil leaks This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained fluid page If you do not have the skills or the tools see your Honda dealer Remove the oil filler cap dipstick and check the oil level 54 7 2 3 8 9 ...

Page 91: ...n its side stand on a firm level surface 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 Place a drain pan under the crankcase drain bolt To drain the oil remove the oil filler cap dipstick crankcase drain bolt and sealing washer 1 2 3 4 1 2 1 03 08 21 10 09 20 31KPJ630_091 ...

Page 92: ... oil page approximately Pour the drained oil into a suitable container and dispose of it in an approved manner page Install the oil filler cap dipstick securely Stop the engine and wait 2 3 minutes Hold the motorcycle upright and check that the oil level is at the upper level mark on the oil filler cap dipstick page Check that there are no oil leaks If a torque wrench is not used for installation ...

Page 93: ...ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your motorcycle s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equivalent quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs...

Page 94: ...t page and the side cover page Remove the screws that secure the air cleaner housing cover Remove the cover Pull the retainer out and remove the air cleaner Disconnect the tube from the air cleaner Discard the air cleaner Install a new air cleaner Install the removed parts in reverse order of removal 1 2 3 4 5 6 7 8 2 71 1 5 3 72 4 03 08 21 10 09 55 31KPJ630_094 ...

Page 95: ... 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 Place a drain pan under the crankcase breather tube plug Remove the plug to drain the deposits in the tube Reinstall the crankcase breather tube plug 54 1 2 3 1 03 08 21 10 10 04 31KPJ630_095 ...

Page 96: ...fer to on page Inspection Check freeplay at the throttle grip flange Freeplay If necessary adjust to the specified range Adjustment Loosen the lock nut Turn the adjuster After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions 1 2 3 1 2 54 03 08 21 10 10 14 31KPJ630_096 ...

Page 97: ...o on page Check that the throttle assembly is positioned properly and the securing bolts are tight Check for smooth rotation of the throttle from fully open to fully closed in all steering positions If there is a problem see your Honda dealer 1 2 54 03 08 21 10 10 21 31KPJ630_097 ...

Page 98: ...cautions Refer to on page Your motorcycle s manually activated wet multiplate clutch is part of the primary drive system Proper freeplay adjustment allows a smooth gradual engagement when shifting gears Improper freeplay adjustment can cause premature clutch wear 54 03 08 21 10 10 30 31KPJ630_098 ...

Page 99: ...heck freeplay If necessary adjust to the specified range Upper Adjustment Attempt adjustment with the upper clutch cable adjuster first Pull back the rubber dust cover Loosen the upper lock nut Turn the upper clutch cable adjuster to obtain the specified freeplay Tighten the upper lock nut and check the freeplay again Install the dust cover 1 1 2 3 4 3 4 2 5 03 08 21 10 10 43 31KPJ630_099 ...

Page 100: ...way in to provide maximum freeplay Tighten the upper lock nut Loosen the lower lock nut Turn the lower adjusting nut to obtain the specified freeplay Tighten the lower lock nut and check the adjustment If the upper clutch cable adjuster is threaded out near its limit or the correct freeplay cannot be obtained attempt adjustment with the lower clutch cable adjuster 1 2 3 4 3 4 5 6 03 08 21 10 10 56...

Page 101: ...ly If you cannot get proper adjustment or the clutch does not work properly the cable or clutch friction discs may be worn See your Honda dealer or refer to the official Honda Service Manual page Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Check the clutch cable for kinks or signs of wear If necessary have it replaced Check that ...

Page 102: ... delivery system Adjusting the idle will not compensate for a fault elsewhere The engine must be at normal operating temperature for accurate idle speed adjustment For information about high altitude carburetor adjustment see page If the engine is cold start it and warm it up with ten minutes of stop and go riding Stop the engine The best way to assure proper carburetion is to see your Honda deale...

Page 103: ... Engine Idle Speed Servicing Your Honda Adjust idle speed with the throttle stop screw Idle speed in neutral Shift into neutral Start the engine Connect a tachometer to the engine 3 4 5 1 03 08 21 10 11 21 31KPJ630_103 ...

Page 104: ... Using spark plugs with an improper heat range can cause engine damage Safety Precautions Use only the recommended type of spark plugs in the recommended heat range Refer to on page Clean any dirt from around the spark plug bases Using the spark plug wrench provided in the tool kit remove the spark plugs cont d Disconnect the spark plug cap Take care to avoid damaging the spark plug wire when disc...

Page 105: ...or deposits are heavy replace the plug Clean a carbon or wet fouled plug with a plug cleaner if available or a wire brush Check the spark plug gap of each new plug using a wire type feeler gauge If adjustment is necessary bend the side electrode carefully The gap should be With the plug washers attached thread the spark plugs in by hand to prevent cross threading 4 5 6 1 2 03 08 21 10 11 42 31KPJ6...

Page 106: ...e a piston may be damaged If a plug is too tight the threads may be damaged Tighten each spark plug 1 8 1 4 turn after it seats if the old plug is good 1 2 turn after it seats if installing a new plug Reinstall the spark plug caps Take care to avoid pinching any cables or wires 8 7 03 08 21 10 11 49 31KPJ630_106 ...

Page 107: ...per systems hydraulically control the natural compression and rebound of the suspension springs so that traction and comfort are maintained as the wheels ride over road surfaces Lower spring pre load provides a softer ride and is usually preferred for light loads and smooth roads Higher spring pre load provides a firmer ride and is recommended for heavy loads rough road conditions and faster more ...

Page 108: ... Your Honda Safety Precautions The rear suspension can be adjusted for rider and passenger weight and riding conditions by changing the spring pre load Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only Refer to on page 54 03 08 21 10 12 07 31KPJ630_108 ...

Page 109: ...nsion Position 2 standard position Position 1 for a light load and smooth road conditions Use the pin spanner and extension bar to adjust the rear shock spring pre load Make sure that both shock absorbers are adjusted to the same position Always adjust the shock absorber position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber 5 ...

Page 110: ...play Brakes Servicing Your Honda Safety Precautions Refer to on page Mechanically activated drum braking systems on your motorcycle dissipate the heat generated by the friction of the brake shoes on the drum as the wheels are slowed 54 03 08 21 10 12 23 31KPJ630_110 ...

Page 111: ... adjustments by turning the adjusting nut at the brake arm Make sure the cut out on the adjusting nut is seated on the brake arm pin after making final free play adjustment Apply the brake several times and check for free wheel rotation after the brake lever is released If proper adjustment cannot be obtained by this method see your authorized Honda dealer Check freeplay 1 1 2 2 3 03 08 21 10 12 3...

Page 112: ...Height Adjustment Place your motorcycle on its side stand Check freeplay by slowly depressing the brake pedal until the brake starts to engage Freeplay If necessary adjust to the specified range Inspection 54 1 2 1 2 1 3 1 2 The stopper bolt is provided to allow adjustment of the pedal height Loosen the lock nut and turn the stopper bolt Tighten the lock nut 03 08 21 10 12 51 31KPJ630_112 ...

Page 113: ...rm pin Apply the brake release it and then spin the wheel and check that it rotates freely Repeat this procedure several times Check the freeplay If you can t adjust the freeplay properly see your Honda dealer Check that the brake pedal assembly is positioned properly and the securing bolts are tight Adjustment Make sure the brake rod brake arm spring and fasteners are in good condition 1 2 3 4 5 ...

Page 114: ...al brake wear indicators that let you check brake wear without disassembly Application of the brake control lever or pedal causes the arrow on the brake arm to move toward a reference mark on the brake panel Apply the brake control lever or pedal and check the movement of the arrow on the brake arm Replace the brake shoes if the arrow aligns with the reference mark on the brake panel upon full app...

Page 115: ...enly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your motorcycle ride more harshly are more prone to damage from road hazards and wear unevenly Refer to on page To safely operate your motorcycle your tires must be the proper type and size in good condition with adequate tread and correctly inflated for the load you are carrying The following ...

Page 116: ...od condition may lose one to two psi per month if not checked and adjusted regularly Always check air pressure when your tires are cold after the motorcycle has been parked for at least three hours If you check air pressure when your tires are warm even if your motorcycle has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold...

Page 117: ...tire or the tread Replace any tire that has a bump or bulge Cuts slits or cracks in the tires Replace the tire if you can see fabric or cord Nails or other foreign objects embedded in the side of the tire or tread Excessive tread wear Also if you hit a pothole or hard object while riding pull to the side of the road as soon as you safely can and carefully inspect the tires for damage Tread Wear 54...

Page 118: ...mmend that you replace not repair any tire that is punctured or damaged A repaired tube will not have the same reliability as a new one and it may fail while you are riding And the tire will have lower speed and performance limits than a new one A temporary repair can sometimes be made in an emergency situation However since a temporary repair may not hold you must ride very slowly preferably with...

Page 119: ...should not exceed 50 mph 80 km h for the first 24 hours or 80 mph 130 km h at any time thereafter In addition you may not be able to safely carry as much weight Repair work should be done by a professional and the wheel should be balanced before you ride If you have a tire and tube professionally repaired at a non Honda facility we recommend that you have the work checked by your Honda dealer You ...

Page 120: ...h you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual front rear 111 Tires Servicing Your Honda The recommended tires for your motorcycle are Whenever you replace a tire remember Have the wheel balanced after the tire is installed Have the tire replaced by your Honda dealer if possible 03 08 21 10 14 07 31KPJ630_120 ...

Page 121: ...ed The old tube will probably be stretched If installed in a new tire it could fail Important Safety Reminders Do not install a radial tire on this motorcycle Mixing bias ply and radial tires can adversely affect handling and stability Do not install car tires on this motorcycle During installation the tire may separate from the rim with enough force to cause serious injury or death 03 08 21 10 14...

Page 122: ...eutral Raise the side stand Start the engine Pull the clutch lever in Shift the transmission into gear Lower the side stand all the way The engine should stop as you lower the side stand If the engine doesn t stop see your Honda dealer for service Check that the side stand assembly is working properly If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clea...

Page 123: ...areas more frequent maintenance will be necessary 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 The drive chain should be checked adjusted and lubricated as part of the pre ride inspection page Before servicing your drive chain turn the engine OFF lower the side stand and check that you...

Page 124: ...w the following vertical movement by hand Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking Inspect the drive chain for damaged rollers dry or rusted links kinked or binding links excessive wear improper adjustment damaged or missing O rings 1 2 3...

Page 125: ... and rear sprocket teeth for excessive wear or damage If necessary have your Honda dealer replace a worn sprocket Replace the drive chain page if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed 4 120 119 03 08 21 10 14 51 31KP...

Page 126: ...usted if necessary every 500 miles 800 km When operated at sustained high speeds or under conditions of frequent rapid acceleration the chain may require more frequent adjustments Refer to on page Check the chain wear label when adjusting the chain If the red zone on the label aligns with the long index mark on the chain adjuster plates after the chain has been adjusted to the proper slack the cha...

Page 127: ...the swingarm Turn both adjusting nuts an equal number of turns until the correct drive chain slack is obtained Turn the adjusting nuts clockwise to tighten the chain or counterclockwise to provide more slack Adjust the chain slack at a point midway between the drive sprocket and the rear wheel sprocket Roll the motorcycle forward Stop and place it on its side stand Recheck chain slack Chain slack ...

Page 128: ...djusting nuts lightly Then while holding the adjusting nuts with a wrench tighten the lock nuts Refer to on page Lubricate every 500 miles 800 km or sooner if chain appears dry Lubricant Check rear axle nut alignment by making sure the chain adjuster index marks align with the rear edge of the adjusting slots Both marks should correspond If the axle is misaligned turn the right or left adjusting n...

Page 129: ...ide surfaces of the chain with a dry cloth Use a high flashpoint solvent such as kerosene not gasoline 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 damaged O rings or otherwise appears unserviceable Replacement Chain You...

Page 130: ...you remove the battery or at least disconnect the battery cables negative cable first Electrical accessories use current from the battery even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your motorcycle or do not ride frequently we recommend that you charge the battery frequently see page If you plan to store your motorcycle...

Page 131: ...r to on page If you plan to store your motorcycle we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not remove the battery we recommend disconnecting the battery cables negative cable first You will get the best storage results from removing the battery and slow trickle charging it every 30 days see page Before yo...

Page 132: ...nnect the negative terminal lead from the battery first then disconnect the positive terminal lead The battery is located behind the right side cover Remove the seat page and the side cover page Remove the battery holder by removing the bolt and nut Pull the battery out of the battery box cont d 1 71 1 2 2 3 4 6 72 5 4 3 03 08 21 10 16 01 31KPJ630_132 ...

Page 133: ...ted from freezing temperatures and direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if paint is missing re paint the area Slow charge the battery see following section once every 30 days Refer to on page Be sure to read the information that came with your battery charger and follow the instructions on the battery Improper charging may damage the ...

Page 134: ...eriods without risking damage to the battery However do not intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage 1 03 08 21 10 16 14 31KPJ630_134 ...

Page 135: ...r a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your motorcycle If your motorcycle is still warm from recent operation give the engine and exhaust system time to cool off Park in a shady area Washing your motorcycle in bright sunlight may cause the finish to fade because water dr...

Page 136: ...ain parts of your motorcycle 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 After cleaning inspect for damage wear and leaks fuel oil 03 08 21 10 16 29 31KPJ630_136 ...

Page 137: ... 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 Detergent residue can corrode alloy parts Dry your motorcycle with a chamois or a soft towel Leaving water on the surface to air dry can cause dulling and water spots As you dry...

Page 138: ...al times This will help dry the brakes and restore normal braking performance If the inside of the headlight lens appears clouded immediately after washing it should clear after a few minutes of riding Refer to on page Avoid using spray cleaner products on the tires or suspension components Suggestions for using spray cleaner s follow 7 54 03 08 21 10 16 46 31KPJ630_138 ...

Page 139: ...r polish and wipe with a non abrasive cloth Apply a high quality chrome aluminum polish and wipe with a non abrasive cloth Dull corroded chrome or aluminum Heavy grime Oil leaks Brake dust Use a spray cleaner degreaser If necessary rub with a sponge Rinse and dry Apply a spray cleaner polish and wipe with a non abrasive cloth Motorcycle Condition Recommended Cleaning 130 Appearance Care Servicing ...

Page 140: ...utomobiles Apply the polish or wax according to the instructions on the container If a surface on your motorcycle is chipped or scratched your Honda dealer has touch up paint to match your motorcycle s color Be sure to use your motorcycle s color code page when you buy touch up paint If the frame has a chip that exposes the metal first apply primer to prevent corrosion and then apply the touch up ...

Page 141: ...132 Servicing Your Honda 03 08 21 10 17 06 31KPJ630_141 ...

Page 142: ... helpful tips on how to store and transport your Honda and how to be an environmentally responsible motorcycle owner Storing Your Honda 134 Transporting Your Motorcycle 138 You the Environment 139 03 08 21 10 17 11 31KPJ630_142 ...

Page 143: ... get your motorcycle running again Refer to on page This procedure requires a means for draining and disposing of drained fuel page Change the engine oil page Fill the fuel tank Make sure the fuel fill cap is properly installed We suggest you perform the following procedures to keep your motorcycle in top condition These storage procedures will reduce the deterioration that can occur during storag...

Page 144: ...any convenient plastic body part so that they are positioned away from the spark plugs Remove the spark plugs from the engine and store them in a safe place Do not connect the spark plugs to the spark plug caps Pour a tablespoon 15 20 cc of clean engine oil into each cylinder and cover the spark plug holes with a piece of cloth Drain the carburetors into an approved gasoline container and dispose ...

Page 145: ...rcycle Wax all painted surfaces Apply rust inhibiting oil to the chrome pieces Lubricate the drive chain page Inflate the tires to their recommended pressures page Store your motorcycle in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation Place your motorcycle on blocks to lift both tires off the floor Cover your motorcycle with a porous material Av...

Page 146: ... months change the engine oil page If your motorcycle has been stored for more than two months ask your Honda dealer to drain and replace the fuel Charge the battery page as required Install the battery Lubricate the drive chain page Perform a pre ride inspection page then test ride your motorcycle at low speeds 1 2 3 4 5 6 54 27 81 124 119 03 08 21 10 17 51 31KPJ630_146 ...

Page 147: ...to safely lift the motorcycle and motorcycle tie down straps If your motorcycle needs to be transported it should be carried on a motorcycle trailer or a truck or trailer with a flatbed area For information about 24 hour emergency assistance see page Do not tow your motorcycle as towing can seriously damage the transmission 191 03 08 21 10 17 56 31KPJ630_147 ...

Page 148: ...the following guidelines for proper disposal It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline coolant 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...

Page 149: ...140 Tips 03 08 21 10 18 04 31KPJ630_149 ...

Page 150: ...ke to try to resume riding If the problem cannot be safely solved this section also gives instructions on the proper way to have your motorcycle transported For information about transporting your motorcycle see page General Guidelines 142 If Your Engine Quits or Won t Start 143 If You Have a Flat Tire 148 If a Fuse Blows 156 If You Crash 160 If You Lose Your Key 161 If Your Battery Is Low or Dead...

Page 151: ... do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs made as soon as possible Do not continue riding if you are hurt or your motorcycle is not in safe riding condition Additional recommendations for specific problems follow Keeping your motorcycle well maintained is the best way to reduce the possibility of h...

Page 152: ...f the problem may be a simple operational oversight If you have a problem starting the engine or experience poor engine performance the following information may help you If you can t correct the problem see your Honda dealer If your motorcycle won t start listen as you press the start button If you don t hear the starter motor turning refer to the symptom If you can hear the starter motor working...

Page 153: ...r raise the side stand blown fuse Replace with a new fuse of the same rating page battery lead loose Tighten the battery lead dead battery Charge the battery page If charging doesn t help see your Honda dealer faulty starter motor If all possible causes are negative the starter motor may be faulty See your Honda dealer 156 124 Starter motor doesn t operate 144 If Your Engine Quits or Won t Start T...

Page 154: ... and ignition coils securely If the engine still won t start see your Honda dealer weak battery loose battery cables Tighten the battery terminal bolts Charge the battery page If charging doesn t help see your Honda dealer POSSIBLE CAUSE 38 124 Starter motor works but the engine won t start Flooded Engine 145 If Your Engine Quits or Won t Start Taking Care of the Unexpected 03 08 21 10 18 52 31KPJ...

Page 155: ...m persists see your Honda dealer POSSIBLE CAUSE WHAT TO DO side stand down runs erratically misfires blubbers rich fuel mixture See your Honda dealer See your Honda dealer 93 Engine starts but stalls as you shift into gear Engine starts but runs poorly 146 If Your Engine Quits or Won t Start Taking Care of the Unexpected 03 08 21 10 19 06 31KPJ630_155 ...

Page 156: ... backfires See your Honda dealer If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer See your Honda dealer See your Honda dealer 73 Engine starts but runs poorly cont d 147 If Your Engine Quits or Won t Start Taking Care of the Unexpected 03 08 21 10 19 18 31KPJ630_156 ...

Page 157: ... or the bead has come loose from the rim there is probably not much you can do except have your motorcycle transported to a Honda dealer or other qualified service facility USA only For information about 24 hour emergency roadside assistance see page Even with a simple puncture this may be the safest and least troublesome solution For transporting instructions see page Honda does not recommend tha...

Page 158: ...r you should ride slowly not over 30 mph 50 km h and carefully preferably without a passenger or cargo until the tire and tube are replaced Stop frequently and check the air pressure If the tire is losing pressure it may be unsafe to continue riding As the tire gets low it will affect the handling of your motorcycle especially with a passenger and cargo and it may overheat and blow out We strongly...

Page 159: ... front wheel off the ground by placing a support block under the engine Remove the speedometer cable set screw and disconnect the speedometer cable Removal We recommend wheel removal be done only by your Honda dealer or another qualified mechanic Do not attempt to remove the wheel on your own Wheel removal requires mechanical skill and professional tools Remove the front brake adjusting nut and di...

Page 160: ...tallation Make sure the tang on the left front fork leg is located in the slot in the brake panel Remove the front axle shaft wheel and side collar Install the side collar and position the wheel between the fork legs Insert the front axle shaft from the right side through the left fork leg and wheel hub 1 6 1 2 3 6 03 08 21 10 19 59 31KPJ630_160 ...

Page 161: ...brake drags or the wheel does not rotate freely Install the brake cable and front brake adjusting nut Tighten the front axle nut to the specified torque If 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 braking capability Install the speedometer cable and tighten the screw securely 2 3 4 5 03 0...

Page 162: ...on a firm level surface Raise the rear wheel off the ground by placing a support block under the engine Remove the rear brake adjusting nut disconnect the brake rod from the brake arm by pushing down on the rear brake pedal Removal We recommend wheel removal be done only by your Honda dealer or another qualified mechanic Do not attempt to remove the wheel on your own Wheel removal requires mechani...

Page 163: ...om the brake panel by removing the cotter pin stopper arm nut washer and rubber grommet Remove the rear axle nut while holding the axle at the other end with a wrench Remove the rear axle shaft rear wheel and side collars from the swingarm Remove the drive chain from the rear sprocket by pushing the rear wheel forward 7 6 5 4 7 8 9 6 5 4 03 08 21 11 08 03 31KPJ630_163 ...

Page 164: ... Check for free wheel rotation after the brake is released Recheck the wheel if the brake drags or the wheel does not rotate freely Installation Adjust the drive chain page and rear brake pedal free play page Connect the brake rod to the brake arm Reassemble the brake stopper arm Tighten the stopper arm nut to the specified torque Install the side collars Place the wheel into the swingarm and inst...

Page 165: ...chart on the circuit fuse box cover which fuse or fuses control that component Check those fuses first but check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation The circuit fuse boxes including spare fuses are located under the seat Recommended Fuses To prevent an accidental short circuit turn the ignition switc...

Page 166: ...wire connector Pull the fuse out If the main fuse is blown install a new main fuse To access the main fuse remove the seat page Install the seat To check or replace a circuit fuse pull the old fuse out of its retaining clips Look for a burned wire inside the fuse If the fuse is blown replace it with a spare fuse of the same rating or lower 3 4 2 5 6 7 8 9 71 5 6 4 1 2 3 For access to the circuit f...

Page 167: ...Unexpected Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Install the fuse box cover Install the seat 10 11 03 08 21 10 21 19 31KPJ630_167 ...

Page 168: ...rarily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were installed If the replacement fuse of the same rating burns out in a short time there is probably a serious electrical problem on your motorcycle Leave the blown fuse in that circuit and have your motorcycle check...

Page 169: ...ding safely carefully inspect your motorcycle for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor damage or you are unsure about possible damage ride slowly and cautiously Sometimes crash damage is hidden or not immediately apparent so you should have your motorcycle th...

Page 170: ...ace at home and carry a second duplicate in your wallet If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer you purchased your Honda from They may have it listed in their records If they don t transport your motorcycle to them or the nearest Honda dealer The dealer will probably have to remove the ignition sw...

Page 171: ...u use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your motorcycle s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer 03 08 21 10 21 40 31KPJ630_171 ...

Page 172: ...cal data plus information on government requirements and how to break in your motorcycle Vehicle Identification 164 License Plate Installation 167 Specifications 168 Break in Guidelines 175 High Altitude Carburetor Adjustment 176 Emission Control Systems 177 Oxygenated Fuels 182 03 08 21 10 21 45 31KPJ630_172 ...

Page 173: ... when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number appears on the Safety Certification Label attached to the left side of the steering head 03 08 21 10 21 54 31KPJ630_173 ...

Page 174: ... number 2 3 LEFT SIDE 165 Vehicle Identification Technical Information The frame number is stamped on the right side of the steering head The engine number is stamped on the left side of the crankcase 3 2 03 08 21 10 22 07 31KPJ630_174 ...

Page 175: ...rmation The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual The color label is attached to the frame under the seat Remove the seat page to check the label 71 03 08 21 10 22 15 31KPJ630_175 ...

Page 176: ...nstallation When you install a license plate be sure to use the washers under the heads of the plate mounting screws as shown to prevent possible vibration damage to the plate The washers are placed in a plastic bag in the document compartment 2 1 03 08 21 10 22 23 31KPJ630_176 ...

Page 177: ... 56 3 in 1 430 mm 6 3 in 160 mm 287 lbs 130 kg 289 lbs 131 kg California only overall length overall width overall height wheelbase ground clearance dry weight Dimensions Weight 168 Specifications Technical Information 03 08 21 10 22 35 31KPJ630_177 ...

Page 178: ...e label SAE 10W 40 JASO T 903 standard MA Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or an equivalent motorcycle oil SAE 80 or 90 gear oil including reserve after disassembly after draining fuel recommendation fuel tank capacity fuel tank reserve engine oil capacity engine oil recommendation drive chain lubricant Fuel Lubricants 169 Specifications Technical Information 03 08 21...

Page 179: ... 60 0 70 mm 1 500 100 rpm CR6HSA NGK 352 lbs 160 kg 2 09 2 09 in 53 0 53 0 mm intake exhaust or or or passenger capacity maximum weight capacity displacement bore stroke compression ratio spark plug standard spark plug cold climate spark plug high speed riding valve clearance cold spark plug gap idle speed Capacities Engine Specifications 170 Specifications Technical Information 03 08 21 10 23 03 ...

Page 180: ...n DID520VC5 RK520MOZ9 drive engine sprocket driven rear wheel sprocket or primary reduction gear ratio 1st 2nd 3rd 4th 5th final reduction standard sprocket sizes final drive Power Transmission 171 Specifications Technical Information 03 08 21 10 23 17 31KPJ630_180 ...

Page 181: ... 2 00 kgf cm 29 psi 200 kPa 2 00 kgf cm 12 V 7 Ah 0 16 kW caster trail tire size front tire size rear tire pressure front cold tire pressure rear cold battery generator Chassis Suspension Electrical 172 Specifications Technical Information 03 08 21 10 23 29 31KPJ630_181 ...

Page 182: ...2V 3 4W 12V 3 4W 12V 3 4W rear front headlight turn signal lights high beam indicator turn signal indicator neutral indicator instrument lights brake tail light side stand indicator Lights 173 Specifications Technical Information 03 08 21 10 23 41 31KPJ630_182 ...

Page 183: ... kgf m 43 lbf ft 59 N m 6 0 kgf m 43 lbf ft 59 N m 6 0 kgf m main other fuses oil drain bolt front wheel axle rear wheel axle nut Fuses Torque Specifications 174 Specifications Technical Information 03 08 21 10 23 51 31KPJ630_183 ...

Page 184: ...ion Help assure your motorcycle s future reliability and performance by paying extra attention to how you ride during the first 300 miles 500 km During this period avoid full throttle starts and rapid acceleration 03 08 21 10 23 55 31KPJ630_184 ...

Page 185: ...rease fuel consumption To compensate you can have the carburetors adjusted for high altitude riding See your Honda dealer However the carburetors must be returned to standard factory specifications before riding again at lower altitudes below 5 000 feet 1 500 m See your Honda dealer Sustained riding at lower altitudes with the lean high altitude setting may cause rough idling stalling or engine da...

Page 186: ...e California Air Resources Board CARB require that your motorcycle comply with applicable exhaust emissions standards during its useful life when operated and maintained according to the instructions provided The Vehicle Emission Control Information label is attached to the frame below the seat The Vacuum Hose Routing Diagram label is attached on the rear fender under the seat California only 1 2 ...

Page 187: ...n the same way but it is toxic Honda Motor Co Ltd utilizes lean carburetor settings and other systems to reduce carbon monoxide and hydrocarbons The EPA also requires that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 3 730 miles 6 000 km after the time of sale to the ultimate purchaser when operated and maintained according to the instructi...

Page 188: ...carburetor is directed into the charcoal canister and air cleaner where it is absorbed and stored while the engine is stopped When the engine is running and the purge control diaphragm valve is open fuel vapor in the charcoal canister and air cleaner is drawn into the engine through the carburetor The exhaust emission control system consists of lean carburetor settings and no adjustment should be ...

Page 189: ...here Blow by gas is returned to the combustion chamber through the air cleaner and the carburetor If you are aware of any of the following symptoms have the vehicle inspected and repaired by your authorized Honda motorcycle dealer Symptoms Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor ...

Page 190: ...trol prior to its sale or delivery to the ultimate purchaser or while it is in use or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper maintenance Re...

Page 191: ... Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume 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 use oxygenated fuels to help reduce emissions ETHANOL ethyl or grain alcohol 10 by Volume You may...

Page 192: ...spill fuel when filling the fuel tank Wipe up any spills immediately If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline 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 also contains cosolvents and corrosion inhibitors to protect the fuel system G...

Page 193: ...184 Technical Information 03 08 21 10 24 44 31KPJ630_193 ...

Page 194: ...nformation on your warranty and how to get an official Honda service manual Authorized Manuals 186 Warranty Coverage 189 Warranty Service 190 Contacting Honda 191 Your Honda Dealer 192 The Honda Rider s Club 193 Reporting Safety Defects 194 03 08 21 10 24 49 31KPJ630_194 ...

Page 195: ...ailable from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual Publication No 61CM001 which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them easy t...

Page 196: ...Item Description Qty Price Each Total Price 187 Consumer Information Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Inc at the address shown on the back of this or...

Page 197: ...closed payable to Helm Inc U S funds only Do not send cash MasterCard VISA Discover Account Number Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order Expiration Mo Yr Customer Signature Apartment Number Street Address No P O Box Number P O BOX 07280 DETROIT MI...

Page 198: ...if you choose to perform your own maintenance However you should have the proper tools and service information and be mechanically qualified Failures that occur due directly to improper maintenance are not covered There are responsibilities restrictions and exclusions which apply to these warranties Please read the Warranties Booklet given to you by your Honda dealer at the time of purchase Be sur...

Page 199: ...e 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 Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling ...

Page 200: ... supplied with your vehicle Please include the following information in your letter name address and telephone number product model year and frame VIN serial number date of purchase dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly If you have a difference of opinion with your dealer please remember that each dealership is indepe...

Page 201: ...r Honda dealer can inform you about competition and other riding events in your area You ll also find that your dealer is a source of information about American Honda s Rider Education Centers and the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda The pa...

Page 202: ... service facility if roadside assistance can t get you going again Reimbursement to 75 for motorcycle and scooter rider training from the Motorcycle Safety Foundation Free ATV rider training is available from the Specialty Vehicle Institute of America with the purchase of a new Honda ATV A subscription to a bi monthly insider s magazine for all members Special members only HRCA website Discounts f...

Page 203: ... Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign...

Page 204: ...195 Consumer Information 03 08 21 10 26 10 31KPJ630_204 ...

Page 205: ...mponent Locations 10 Indicators 13 Controls Features Fuel Valve 17 Choke Knob 17 Ignition Switch 18 Start Button 19 Engine Stop Switch 19 Headlight Dimmer Switch 20 Turn Signal Switch 20 Horn Button 21 Tripmeter Reset Knob 21 Are You Ready to Ride 24 Protective Apparel 24 Rider Training 26 Is Your Motorcycle Ready to Ride 27 Pre ride Inspection 27 Load Limits Guidelines 30 Loading 30 Load Limits 3...

Page 206: ...dure 36 Flooded Engine 38 How to Stop the Engine 39 Shifting Gears 40 Braking 42 Parking 44 Riding with a Passenger or Cargo 47 Component Locations 65 Tool Kit 68 Tool Kit Compartment 69 Owner s Manual Storage 70 Seat Removal 71 Side Cover Removal 72 The Importance of Maintenance 52 Maintenance Safety 53 Important Safety Precautions 54 Periodic Maintenance 56 Maintenance Schedule 58 Maintenance Re...

Page 207: ...ne Fuel 73 Engine Oil 76 Air Cleaner 84 Crankcase Breather 86 Throttle 87 Clutch System 89 Engine Idle Speed 93 Spark Plugs 95 Suspension 98 Brakes 101 Tires 106 Side Stand 113 Drive Chain 114 Battery 121 Appearance Care 126 Storing Your Honda 134 Transporting Your Motorcycle 138 You the Environment 139 03 08 21 10 26 32 31KPJ630_207 ...

Page 208: ... Blows 156 If You Crash 160 If You Lose Your Key 161 If Your Battery Is Low or Dead 162 Vehicle Identification 164 License Plate Installation 167 Specifications 168 Break in Guidelines 175 High Altitude Carburetor Adjustment 176 Emission Control Systems 177 Oxygenated Fuels 182 Authorized Manuals 186 Warranty Coverage 189 Warranty Service 190 Contacting Honda 191 Your Honda Dealer 192 The Honda Ri...

Page 209: ...el 74 carburetor altitude adjustment 176 care appearance 126 chain drive 114 choke knob 17 cleaning appearance care 126 clutch system 89 color label 166 compartment owner s manual 70 tool kit 69 accessories 5 air pressure tires 106 altitude high 176 American Honda contacting 191 apparel protective 24 appearance care 126 03 08 21 10 26 42 31KPJ630_209 ...

Page 210: ...mation 185 customer service 191 defects safety 194 drive chain 114 emission control systems 177 engine flooded 38 idle speed 93 number 165 oil 76 pinging 73 starting 35 stop switch 19 stopping 39 won t start 143 environment 139 flat tire 148 flooded engine 38 frame number 165 03 08 21 10 26 49 31KPJ630_210 ...

Page 211: ...er switch 20 helmet holder 45 high altitude carburetor adjustment 176 high beam indicator 16 Honda contacting 191 Rider s Club 193 dealer 192 Honda service manual 186 horn button 21 identification vehicle 164 idle speed engine 93 ignition cutoff system side stand 35 ignition switch 18 indicators 13 inspection pre ride 27 03 08 21 10 26 55 31KPJ630_211 ...

Page 212: ...67 limit weight 31 load limits 31 loading guidelines 31 location components indicators controls 10 maintenance 65 lock steering 44 maintenance importance 52 periodic 56 record 63 safety 53 schedule 58 manual service 186 maximum weight limit 31 modifications 6 numbers serial 164 03 08 21 10 27 02 31KPJ630_212 ...

Page 213: ...s spark 95 pre load suspension rear 99 pre ride inspection 27 problems unexpected 141 protective apparel 24 removal seat 71 side cover 72 reporting safety defects 194 rider training 2 26 Rider s Club Honda 193 riding basic operation 33 clothing 24 precautions 34 safety 2 safety precautions 34 with passenger or cargo 47 03 08 21 10 27 09 31KPJ630_213 ...

Page 214: ...g gears 40 side cover removal 72 side stand 113 side stand ignition cutoff system 35 spark knock 73 spark plugs 95 specifications 168 speedometer 15 stand side 113 start button 19 starting engine 35 troubleshooting 143 steering lock 44 stop switch engine 19 stopping engine 39 storage motorcycle 134 owner s manual 70 suspension rear suspension adjustment 99 rear suspension spring pre load 99 03 08 ...

Page 215: ...ires air pressure 106 flat 148 replacing 110 tool kit 68 training rider 2 26 transporting your motorcycle 138 tripmeter 16 tripmeter reset knob 21 trouble unexpected 141 troubleshooting starting 143 turn signal indicator 16 valve fuel 17 vehicle identification no VIN 164 03 08 21 10 27 19 31KPJ630_215 ...

Page 216: ...207 Index Index W warranty coverage 189 extended 189 service 190 washing your motorcycle 128 weight limit 31 wheels front removal 150 rear removal 153 03 08 21 10 27 23 31KPJ630_216 ...

Page 217: ...208 Memo 03 08 21 10 27 25 31KPJ630_217 ...

Page 218: ... 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 repairs are Engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal Record important information on the following page 03 08 21 10 27 32...

Page 219: ... Reference Quick Reference VIN Frame No Engine No Frame No Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 03 08 21 10 27 37 31KPJ630_219 ...

Page 220: ... Fuel Capacity Periodic Checks Pre ride Inspection Scheduled Maintenance Check the following items monthly page tires fluids lights freeplay drive chain fuses nuts bolts API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 40 JASO T 903 standard MA Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or an equivalent m...

Page 221: ...si 200 kPa 2 00 kgf cm CR6HSA NGK CR5HSA NGK CR7HSA NGK U20FSR U DENSO U16FSR U DENSO U22FSR U DENSO 20A 10A or or or Quick Reference Quick Reference Tires Tire Pressure cold Spark Plugs Fuses Front Rear Front Rear main other standard cold climate high speed riding 03 08 21 10 28 00 31KPJ630_221 ...

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