Honda 2004 CRF150F Owner'S Manual Download Page 90 | Manualshive

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(1) mounting bolts

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FRONT

81

Front Suspension Inspection

Suspension

Servicing Your Honda

Saf ety Precautions

Refer to

on page

.

Loose, worn, or damaged suspension
components may adversely affect the handling
and stability of your motorcycle. If any
suspension components appear worn or
damaged, see your Honda dealer for further
inspection. Your dealer is qualified to
determine whether or not replacement parts or
repairs are needed.

Check fork operation. Pull the front brake
lever in, to lock the brake. Then pump up
and down on the fork legs several times. The
suspension should function smoothly. There
should be no oil leakage.

(cont’d)

1.

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Summary of Contents for 2004 CRF150F

Page 1: ...tion 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 o...

Page 2: ...2004 Honda CRF150F OWNER S MANUAL 03 03 07 15 59 00 31KPT610_002...

Page 3: ...nd 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...

Page 4: ...t follow instructions Safety Messages A Few Words About Safety Safety Headings Safety Section Instructions such as Important Safety Reminders or Important Safety Precautions such as Motorcycle Safety...

Page 5: ...and modifications and the location of safety labels The location function and operation of the throttle brakes clutch and other basic controls The importance of wearing a helmet and other protective...

Page 6: ...torcycle 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...

Page 7: ...nt to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual We also recommend that you read the owner s manual before you ride It s full of fac...

Page 8: ...e any questions or if you ever need a special service or repairs remember that your Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction Please report any change of a...

Page 9: ...03 03 07 15 59 51 31KPT610_009...

Page 10: ...s Modifications 7 Safety Labels 9 This section presents some of the most important information and recommendations to help you ride your motorcycle safely Please take a few moments to read these pages...

Page 11: ...our motorcycle is designed and manufactured for off road use only The tires are not made for pavement and the motorcycle does not have turn signals and other features required for use on public roads...

Page 12: ...about riding groups in your area Also be sure to read the booklet that came with your motorcycle USA only The terrain can present a variety of challenges when you ride off road Continually read the t...

Page 13: ...pecially if you are stranded off road far from your base To help avoid problems inspect your motorcycle before every ride and perform all recommended maintenance Alcohol and riding don t mix Even one...

Page 14: ...otorcycle More specific information on load limits accessories and modifications follows In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your motorcycle s h...

Page 15: ...eds and follow these common sense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift positio...

Page 16: ...an accessory be sure to read the following information We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle Because Hon...

Page 17: ...change its design or operation Such changes could seriously impair your motorcycle s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove...

Page 18: ...cycle Some labels warn you of potential hazards that could cause serious injury Others provide important safety information Read these labels carefully and don t remove them If a label comes off or be...

Page 19: ...10 Motorcycle Safety 03 03 07 16 00 54 31KPT610_019...

Page 20: ...his section carefully before you ride It describes the location function and operation of all the basic controls on your motorcycle Component Locations 12 Fuel Valve 15 Choke Lever 16 Ignition Switch...

Page 21: ...clutch lever front brake lever engine stop button throttle ignition switch 12 Component Locations Operating Controls 03 03 07 16 01 02 31KPT610_021...

Page 22: ...choke lever shift lever fuel valve side stand 13 Component Locations Operating Controls 03 03 07 16 01 07 31KPT610_022...

Page 23: ...rear brake pedal kickstarter 14 Component Locations Operating Controls 03 03 07 16 01 11 31KPT610_023...

Page 24: ...fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fu...

Page 25: ...to avoid running out of fuel with no reserve The choke lever is used for starting the engine page The choke increases the percentage of fuel in the fuel air mixture delivered to the engine Used to st...

Page 26: ...ral the engine can be started OFF ON 1 ON OFF 1 ignition switch FRONT ON OFF 17 Operating Controls Operating Controls Ignition Switch The ignition switch is used to prevent unauthorized use of the mot...

Page 27: ...m rotate the grip toward you To reduce engine rpm rotate the grip away from you The throttle will automatically return to the closed position engine idle when you remove your hand The clutch lever is...

Page 28: ...ift lever to engage the next lower gear See page The rear brake pedal is used to slow or stop your motorcycle To operate depress the pedal For information on braking techniques see page The side stand...

Page 29: ...20 Operating Controls 03 03 07 16 01 57 31KPT610_029...

Page 30: ...y to ride To help get you prepared this section discusses how to evaluate your riding readiness and how to perform the recommended pre ride inspection of your Honda Are You Ready to Ride 22 Protective...

Page 31: ...otection is not possible wearing the proper gear can reduce the chance of injury when you ride Following are suggestions to help you choose the proper gear read this owner s manual make sure you under...

Page 32: ...n strap that can be tightened securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any...

Page 33: ...he motorcycle Use a gauge to check the air pressure Adjust if needed Also look for signs of damage or excessive wear page Make sure the spokes and rim locks are tight Also check the rims for damage pa...

Page 34: ...g and snaps shut automatically when it is released in all steering positions page Check the condition and slack Adjust and lubricate if needed Also check the chain guide slider and slipper for wear an...

Page 35: ...orcycle Ready to Ride Clutch Lever Check for smooth operation and adjust if needed page Remember be sure to take care of any problem you find or have your Honda dealer correct it before you ride 73 03...

Page 36: ...formation how to make turns ride on hills etc see the booklet that came with your Honda USA only To protect your new engine and enjoy optimum performance and service life refer to Break in Guidelines...

Page 37: ...e familiar with how this motorcycle works and handles Practice in a safe area until you build up your skills and get accustomed to your motorcycle s size and weight For your safety avoid starting or o...

Page 38: ...mperature 10 35 C 50 95 F Your motorcycle can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter Always follow the proper starting procedure d...

Page 39: ...he throttle closed operate the kickstarter Kick from the top of the stroke through to the bottom with a rapid continuous motion About a half minute after the engine starts push the choke lever down al...

Page 40: ...OFF Open the throttle fully While pushing the engine stop button crank the engine several times with the kickstarter Release the engine stop button High Air Temperature 35 C 95 F or above Do not use...

Page 41: ...ing Stopping the Engine Basic Operation Riding How to Stop the Engine To stop the engine shift into neutral push the engine stop button in and hold it in until the engine stops 03 03 07 16 03 41 31KPT...

Page 42: ...f engine rpm is too high or you release the clutch lever too quickly your motorcycle may lurch forward Release the front brake Gradually open the throttle while you slowly release the clutch lever Dep...

Page 43: ...ttle and pull the clutch lever in completely before shifting Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rpm is too high can cause engine damage...

Page 44: ...ne or both wheels to slip Any wheel slip will reduce your control of your motorcycle cont d When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduc...

Page 45: ...ing by downshifting with intermittent use of both brakes When you brake to a stop pull the clutch lever in before stopping completely to prevent stalling the engine For support put your left foot on t...

Page 46: ...ng Lower the side stand to support your motorcycle Turn the ignition switch OFF and remove the key If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park...

Page 47: ...roughly clean your motorcycle and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your motorcycle for leaks or damage Be sure to...

Page 48: ...d servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good cont d For infor...

Page 49: ...e Cover Removal 56 Fluids Filters Fuel 57 Engine Oil 60 Air Cleaner 66 Crankcase Breather 70 Engine Throttle 71 Clutch System 73 Engine Idle Speed 76 Spark Plug 77 Spark Arrester 79 Chassis Suspension...

Page 50: ...parts even if you are able to make some repairs cont d A well maintained motorcycle is essential for safe economical and trouble free riding It will also help reduce air pollution Careful pre ride in...

Page 51: ...intenance Servicing Your Honda Remember proper maintenance is the owner s responsibility Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section 03 03 0...

Page 52: ...on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance...

Page 53: ...ver park it on a firm level surface using the side stand or a maintenance stand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a n...

Page 54: ...tems are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that yo...

Page 55: ...uire more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer t...

Page 56: ...0 77 60 76 Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page In the interest...

Page 57: ...Tires Steering Head Bearings Note 1 Note 2 I L I I I I I I I I I I I I I I I I I 103 104 86 87 89 84 73 102 81 79 92 98 Should be serviced by your Honda dealer unless the owner has the proper tools a...

Page 58: ...pace under Notes to record anything you want to remind yourself about or mention to your dealer Of course if you find any problem while servicing your motorcycle be sure it is corrected as soon as pos...

Page 59: ...ee your Honda dealer unless you are mechanically qualified and have the proper tools Refer to the Maintenance Schedule page for regular service intervals NOTE 46 1 2 3 4 5 6 all pre ride inspection it...

Page 60: ...lace or adjust 66 77 81 82 proper operation see NOTE 1 contamination or tears gap tightness proper heat range high tension terminal security free rotation of handlebar and steering stem nut tightness...

Page 61: ...8 19 20 swingarm bearings rear suspension linkage bushings brake pads drive chain max length pin sprockets seat control cables engine mounting bolts wear and secure installation security smooth operat...

Page 62: ...axle rear suspension chain adjuster clutch lever front brake hose carburetor fuel tank chain guide slider engine oil drain bolt drive chain side stand chain slider crankcase breather 53 Servicing Your...

Page 63: ...k arrester lower clutch adjusting nut kickstarter oil filler cap dipstick rim lock throttle fuel fill cap air cleaner air cleaner housing cover rim lock right side cover spark plug 54 Servicing Your H...

Page 64: ...Precautions Refer to on page The spark plug wrench and its handle are stored in the tool bag delivered with your motorcycle You will need to provide your own tools to perform any owner maintenance ot...

Page 65: ...l Use a screwdriver to remove the screw Pull both side cover prongs out of the rubber grommets Installation Slide the top of the side cover under the bottom edge of the seat Align the side cover prong...

Page 66: ...gine 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 an...

Page 67: ...reather tube 4 3 3 steering stem nut 4 filler neck 58 Refueling Procedure Fuel Servicing Your Honda Reserve Capacity Add fuel until the level reaches the bottom of the filler neck Avoid overfilling th...

Page 68: ...After refueling turn the fuel fill cap clockwise until it is secure If you replace the fuel fill cap use only a genuine Honda replacement part Insert the breather tube in the steering stem nut 3 4 03...

Page 69: ...suggested oil 60 Engine Oil Servicing Your Honda Oil Recommendation Safety Precautions Refer to on page Using the proper oil and regularly checking adding and changing oil will help extend your engine...

Page 70: ...circular API service label Your motorcycle does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not...

Page 71: ...rt may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engi...

Page 72: ...s Immediately unscrew and remove the oil filler cap dipstick Wipe it clean Hold the motorcycle upright Insert the dipstick until it seats but do not screw it in Remove the dipstick and check the oil l...

Page 73: ...it idle for 3 5 minutes Turn the engine off Wait 2 3 minutes for the oil to settle Remove the oil filler cap dipstick Place a drain pan under the crankcase Remove the oil drain bolt O ring spring and...

Page 74: ...reen Check that the oil strainer screen sealing rubber and drain bolt O ring are in good condition Install the oil strainer screen spring and drain bolt Pour the recommended oil into the crankcase app...

Page 75: ...st mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service int...

Page 76: ...er 4 5 67 Cleaning Air Cleaner Servicing Your Honda Remove the right side cover page Remove the screws and air cleaner housing cover Remove the air cleaner Unhook the set spring take care to avoid ben...

Page 77: ...gently squeeze out the remaining solvent Avoid twisting or wringing the air cleaner This can tear the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner i...

Page 78: ...preading the oil into the air cleaner Assemble the air cleaner and holder Insert the tabs in the air cleaner holes Apply a thin coat of grease to the sealing surface of the air cleaner Clean the insid...

Page 79: ...ons Refer to on page Service more frequently if your motorcycle is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tub...

Page 80: ...fied range Adjustment Pull the rubber dust cover back Loosen the lock nut on the throttle cable mechanism Turn the adjuster Tighten the lock nut Return the dust cover to its normal position After adju...

Page 81: ...hat the throttle assembly is positioned properly and the securing bolts are tight Inspect the condition of the throttle cable from the throttle grip down to the carburetor If the cable is kinked or ch...

Page 82: ...utch assembly adjuster Refer to on page Upper Adjustment Minor adjustments are generally made with the upper clutch cable adjuster Pull the rubber dust cover back Loosen the upper lock nut Turn the up...

Page 83: ...and tighten the lower lock nut Check the adjustment Tighten the lock nut and check the freeplay again Lower Adjustment The lower clutch cable adjuster is used if the upper clutch cable adjuster is thr...

Page 84: ...can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the official Honda Service Manual pa...

Page 85: ...tment Ten minutes of stop and go 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 adjustme...

Page 86: ...ith an improper heat range can cause engine damage Refer to on page Use only the recommended type of spark plugs in the recommended heat range The recommended standard spark plug is satisfactory for m...

Page 87: ...rench provided with your motorcycle With the plug washer attached thread the spark plug in by hand to prevent cross threading If you have to install a new plug first check the gap Make sure the plug w...

Page 88: ...rvicing prevents carbon buildup which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester prevents random spark...

Page 89: ...screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary Install the spark arrester...

Page 90: ...rcycle If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Che...

Page 91: ...on Servicing Your Honda Check the security of all handlebar and fork mounting bolts If any front suspension components appear worn or damaged see your Honda dealer for further inspection Place the mot...

Page 92: ...ock absorber attachment points and rear suspension linkage attachment points are secure Check for oil leaks in the shock absorber If any rear suspension components appear worn or damaged see your Hond...

Page 93: ...r this motorcycle Install a new adjuster from the lever side with the lock nut under the head of the adjuster The front brake is the hydraulic disc type As the brake pads wear the brake fluid level wi...

Page 94: ...ition the brake lever farther away from the handgrip turn the adjuster clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise Loosen the lock nut Pull the rubb...

Page 95: ...e level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks The recommended br...

Page 96: ...each regular maintenance interval page Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set See your Honda dealer for this service The recommended brake fluid i...

Page 97: ...adjusting nut 4 brake arm pin 88 Brakes Servicing Your Honda Rear Brake Pedal Freeplay Inspection Place your motorcycle on its side stand Check freeplay by slowly depressing the brake pedal until the...

Page 98: ...hen 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 The rear brake is equipped wi...

Page 99: ...tight Rear Make sure the brake rod brake arm spring and fasteners are in good condition Apply the brake control pedal and check the movement of the arrow on the brake arm Replace the brake shoes if th...

Page 100: ...bolt 1 2 3 3 rear brake pedal 91 Brakes Servicing Your Honda Rear Brake Pedal Height Adjustment Loosen the lock nut and turn the stopper bolt Tighten the lock nut Check the freeplay page 1 2 3 1 2 88...

Page 101: ...ly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to preve...

Page 102: ...Inspect the wheel rims and spokes for damage Tighten any loose spokes or rim locks Rotate the wheel slowly to see if it appears to wobble If it does the rim is out of round or not true If the wobble i...

Page 103: ...f the motorcycle with tie down straps Remove the front axle holder nuts and the front axle holder Unscrew and remove the axle Remove the wheel Avoid depressing the brake lever when the wheel is off th...

Page 104: ...e the front brake and pump the fork several times First tighten the upper holder nuts to the specified torque then tighten the lower axle nuts to the same torque After installing the wheel apply the b...

Page 105: ...r Press the rear brake pedal and disconnect the brake rod from the brake arm Loosen the rear axle nut while holding the axle Turn both adjusters so the rear wheel can be moved all the way forward for...

Page 106: ...are installed properly Adjust the drive chain page Torque the axle nut to Adjust the rear brake page Apply the rear brake release it then spin the wheel and check that it rotates freely Repeat this p...

Page 107: ...tailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement Make sure the valve stem caps are sec...

Page 108: ...a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are A flat tire or blo...

Page 109: ...d carefully inspect the tire as described on page Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cr...

Page 110: ...icing Your Honda The tires that came on your motorcycle were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions Use a replaceme...

Page 111: ...Precautions Refer to on page Check the side stand spring for damage and loss of tension Check the side stand assembly for freedom of movement If the side stand is stiff or squeaky clean the pivot area...

Page 112: ...motorcycle is ridden in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF lower the side stand and check that your transm...

Page 113: ...eplace 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 l...

Page 114: ...imit of adjustment Excessive slack indicates the chain is worn beyond its service limit cont d To check the chain s service limit measure the distance between a span of pins from pin center to pin cen...

Page 115: ...xle nut 3 chain adjusters 4 index marks 5 stopper pins 106 Adjustment Drive Chain Servicing Your Honda Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear spr...

Page 116: ...equally to increase or decrease chain slack After adjusting be sure the same adjuster index marks align with the stopper pins on both sides of the swingarm Torque the rear axle nut to Recheck drive c...

Page 117: ...ved or replaced by your Honda dealer When the drive chain becomes extremely dirty it should be cleaned prior to lubrication Clean the side surfaces of the chain with a dry cloth Do not brush the rubbe...

Page 118: ...ve Chain Servicing Your Honda Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed Lubricate the drive chain 3 4 03 03 07 16 14 44 31KPT6...

Page 119: ...you re cleaning be sure to look for damage wear and gasoline or oil leaks To clean your motorcycle you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild s...

Page 120: ...stop button Rinse your motorcycle thoroughly with cool water to remove loose dirt Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially...

Page 121: ...usting Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride at a slow speed and apply the brakes several times This will help dry the bra...

Page 122: ...or an off road adventure how to transport and store your Honda and how to be an environmentally responsible motorcycle owner Preparing for a Ride 114 Transporting Your Honda 116 Storing Your Honda 118...

Page 123: ...e Bureau of Land Management USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information We recommend that you always take water food a fi...

Page 124: ...nds on the kind of terrain how long you expect to ride how far you might go from your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tool...

Page 125: ...ailer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork...

Page 126: ...ont suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that...

Page 127: ...oring it That way needed repairs won t be forgotten and it will be easier to get your motorcycle running again For more information about storage refer to the available from your Honda dealer USA only...

Page 128: ...age Storing Your Honda Tips Change the engine oil page Drain the carburetor into an approved gasoline container and dispose of it in an approved manner page If storage will last longer than one month...

Page 129: ...page then test ride your motorcycle at low speeds Cover your motorcycle with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and m...

Page 130: ...damaged and ride only in areas approved for off road vehicles Loud motorcycles can be offensive Ride as quietly as possible don t remove your spark arrester and don t modify the muffler or any other p...

Page 131: ...contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to...

Page 132: ...thing may go wrong This section gives practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines 124...

Page 133: ...decide what to do Whatever the problem the most important rules are If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on...

Page 134: ...specific problems follow If the engine wasn t making any unusual noises before it quit running and it feels normal when you operate the kickstarter you can probably rule out a major mechanical problem...

Page 135: ...he fuel system appears to be okay check the ignition system this requires a spark plug wrench If you cannot identify or correct the problem you will have to push your motorcycle back to your base or g...

Page 136: ...to assess the severity of the injuries and whether it is safe to continue riding If you cannot ride safely send someone for help Do not ride if you will risk further injury If you decide you are capa...

Page 137: ...aler check the frame and suspension after any serious crash Be sure to record your key number in the section at the rear of the manual You ll need this number to have a duplicate key made If you lose...

Page 138: ...then ride carefully back to base using the rear brake for slowing or stopping If any component of the front brake system is damaged you may be able to ride carefully back to your base using the rear...

Page 139: ...130 Taking Care of the Unexpected 03 03 07 16 17 13 31KPT610_139...

Page 140: ...d other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification 132 Specifications 134 Break in Guidelines 139 High Altitude Carburetor Ad...

Page 141: ...ne serial numbers are required when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the section at the rear of the manual The eng...

Page 142: ...nical Information Quick Reference The color code is helpful when ordering replacement parts You may record the color and code in the section at the rear of the manual The color label is attached to th...

Page 143: ...ine pump octane number of 92 or higher after draining 1 1 US qt 1 0 after disassembly 1 3 US qt 1 2 Overall length Overall width Overall height Wheelbase Dry weight Fuel tank capacity Fuel tank reserv...

Page 144: ...g 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 USA Canada or Honda 4 stroke oil Canada only or an equivalent motor...

Page 145: ...mm DPR7EA 9 NGK X22EPR U9 DENSO Intake Exhaust or or Primary reduction Gear ratio 1st 2nd 3rd 4th 5th Final reduction Final drive Valve clearance cold Spark plug standard Spark plug cold climate belo...

Page 146: ...1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm 8 1 in 207 mm axle travel 8 8 in 223 mm axle travel Drive chain freeplay New chain length Used chain service limit length Caster Trail Tire size front Tire size re...

Page 147: ...ft 74 N m 7 5 kgf m 9 lbf ft 12 N m 1 2 kgf m 80 lbf ft 108 N m 11 0 kgf m Oil drain bolt Front wheel axle Axle holder nuts Rear wheel axle Torque Specifications 138 Specifications Technical Informati...

Page 148: ...assure your motorcycle s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and...

Page 149: ...e at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased The carburetor can be modified to compen...

Page 150: ...ts useful life when operated and maintained according to the instructions provided California only The Vehicle Emission Control Information Label is attached to the rear fender The EPA also requires t...

Page 151: ...uipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the carburetor The co...

Page 152: ...trol prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any pe...

Page 153: ...any of the following symptoms have the vehicle inspected and repaired by your Honda Motorcycle Dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration A...

Page 154: ...mum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA appro...

Page 155: ...er service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates men...

Page 156: ...ontains information on your warranty and how to get an official Honda service manual Authorized Manuals 148 Warranty Coverage 151 Warranty Service 152 Contacting Honda 153 The Honda Rider s Club USA o...

Page 157: ...anada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual Publication No which explains theory of operation and...

Page 158: ...nd Total 4 00 149 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By completing th...

Page 159: ...nc U S funds only Do not send cash MasterCard VISA Discover Date Customer Signature These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery...

Page 160: ...ranties Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the time of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet Moto...

Page 161: ...esults 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...

Page 162: ...ces at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Hond...

Page 163: ...road riding schools and adventure packages Hospitality at national events Optional insurance club pin patch etc Red Rider MX contingency and off road support at selected events Computerized trip rout...

Page 164: ...only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department...

Page 165: ...cations 12 Fuel Valve 15 Choke Lever 16 Ignition Switch 17 Engine Stop Button 18 Front Brake Lever 18 Throttle 18 Clutch Lever 18 Shift Lever 19 Rear Brake Pedal 19 Kickstarter 19 Side Stand 19 Are Yo...

Page 166: ...ntenance Schedule 45 Maintenance Record 49 Competition Inspection 50 Component Locations 53 Tools 55 Side Cover Removal 56 Fluids Filters Fuel 57 Engine Oil 60 Air Cleaner 66 Crankcase Breather 70 Eng...

Page 167: ...a 118 You the Environment 121 General Guidelines 124 If Your Engine Quits or Won t Start 125 If You Have a Flat Tire 126 If You Crash 127 If You Lose Your Key 128 If a Component Fails 129 Vehicle Iden...

Page 168: ...TS 156 INDEX 160 QUICK REFERENCE Table of Contents Table of Contents Authorized Manuals 148 Warranty Coverage 151 Warranty Service 152 Contacting Honda 153 The Honda Rider s Club USA only 154 Your Hon...

Page 169: ...ar 89 braking 35 break in guidelines 139 button engine stop 18 capacity fuel 58 carburetor high altitude adjustment 140 idle speed 76 choke lever 16 cleaner air 66 cleaning appearance care 110 clutch...

Page 170: ...peed 76 pinging 57 starting 29 stop button 18 stopping 32 won t start 125 environment protecting 121 filter air 66 flat tire 126 flooded engine starting 31 fork 81 frame number 132 front brake lever 1...

Page 171: ...oline 57 gears shifting 33 high altitude adjustment 140 Honda contacting 153 Honda service manual 148 idle speed engine 76 inspection competition 50 post ride 38 pre ride 24 kickstarter 19 lever clutc...

Page 172: ...rking 37 pedal rear brake 19 pinging engine 57 plug spark 77 post ride inspection 38 pre ride inspection 24 reserve capacity fuel tank 58 rider training 3 155 riding basic operation 27 before 21 cloth...

Page 173: ...starting 125 schedule maintenance 45 service customer 153 manuals 148 warranty 152 shifting gears 33 shoe brake 89 side cover removal 56 side stand 19 102 spark arrester 79 spark knock 57 spark plug...

Page 174: ...165 Index Index W V valve fuel 15 vehicle identification 132 warranty coverage 151 extended 151 service 152 washing your motorcycle 110 weight limit 6 wheels 92 03 03 07 16 21 22 31KPT610_174...

Page 175: ...d important notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage...

Page 176: ...Quick Reference Record important information here Frame No Engine No Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 03 03 07 16 21...

Page 177: ...spokes rims leaks engine oil fuel drive chain cables nuts bolts spark plug and cap throttle brakes and clutch lever rider only no passenger or cargo and any accessories API Service Classification SG o...

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