Honda 2006 CRF100F Owner'S Manual Download Page 64

Page: 64 / 173

(1)

(2)

(3)

(1) spark plug wrench
(2) handle
(3) tool bag

Tools

Servicing Your Honda

Saf ety 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 other than
removing the spark plug.

05/03/18 15:52:33 31KSJ620_064

Summary of Contents for 2006 CRF100F

Page 1: ...on This publication includes the latest production information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obli...

Page 2: ...oes not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a...

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: ...ing accessories 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 ot...

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: ...a detailed list of topics at the beginning of each section and an index at the back of the book Before riding take time to get acquainted with your motorcycle and how it works To protect your investme...

Page 8: ...our Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you conce...

Page 9: ...05 03 18 15 46 50 31KSJ620_009...

Page 10: ...ly Please take a few moments to read these pages This section also includes a special message for parents and location information for the safety labels on your motorcycle Important Safety Information...

Page 11: ...or smaller adults However not all youngsters are physically or emotionally ready to ride Therefore before parents allow any youngster to ride this motorcycle we urge them to carefully read the beginni...

Page 12: ...s in a safe area and slowly build your skills Personal instruction from an experienced rider can also be valuable If you need assistance ask your dealer about riding groups in your area Also be sure t...

Page 13: ...ets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either It s important to keep your motorcycle properly maintained and in safe riding condition H...

Page 14: ...ies widely from one person to another and age and size are not the only factors PHYSICAL ABILITY is an important consideration For example riders must be big enough to hold the motorcycle up get on an...

Page 15: ...ad and understand the owner s manual before riding Also be sure that your youngster has a helmet and other appropriate riding equipment and always wears it when operating the vehicle or sitting on it...

Page 16: ...t s your responsibility to see that the motorcycle is properly maintained and kept in safe operating condition SAFE AND RESPONSIBLE RIDING must be an on going commitment by you and your youngster When...

Page 17: ...ity Adding accessories or making modifications that change this motorcycle s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the motorcyc...

Page 18: ...shift position to maintain balance and stability Place weight as close to the center of the motorcycle as possible Do not attach large or heavy items such as a sleeping bag or tent to the handlebar f...

Page 19: ...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 Ho...

Page 20: ...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 21: ...rcycle 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 b...

Page 22: ...fully before you ride It describes the location function and operation of all the basic controls on your motorcycle Operation Component Locations 14 Operating Controls 17 Fuel Valve 17 Choke Lever 18...

Page 23: ...clutch lever engine stop button front brake lever throttle grip 14 Operating Controls Operation Component Locations 05 03 18 15 48 04 31KSJ620_023...

Page 24: ...rear brake pedal kickstarter 15 Operation Component Locations Operating Controls 05 03 18 15 48 07 31KSJ620_024...

Page 25: ...fuel valve choke lever ignition switch shift lever 16 Operation Component Locations Operating Controls 05 03 18 15 48 11 31KSJ620_025...

Page 26: ...the 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 th...

Page 27: ...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 28: ...ine can be started 1 ON OFF 1 ignition switch LEFT SIDE under fuel tank ON OFF 19 Operating Controls Operating Controls Ignition Switch After parking the motorcycle remove the key The ignition switch...

Page 29: ...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 30: ...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 31: ...22 Operating Controls 05 03 18 15 48 52 31KSJ620_031...

Page 32: ...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 If you re a parent be sure you also read the on...

Page 33: ...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 34: ...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 35: ...g Note to Parents If a youngster will be performing any of the following pre ride inspection procedures it s your responsibility to provide careful supervision and make sure they are performed safely...

Page 36: ...dd oil if needed page Check the level and add fuel page if needed Also make sure the fuel fill cap is securely fastened Use a wrench to make sure all accessible nuts bolts and fasteners are tight Chec...

Page 37: ...eeded Rotate the throttle to make sure it moves smoothly without sticking and snaps shut automatically when it is released in all steering positions page Squeeze the front brake lever and step on the...

Page 38: ...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 39: ...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 40: ...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 41: ...perate the kickstarter to start the engine Starting from the top of the stroke kick through to the bottom with a rapid continuous motion Do not operate the throttle Immediately after the engine starts...

Page 42: ...Open the throttle fully While pushing the engine stop button crank the engine several times with the kickstarter Release the engine stop button If the engine fails to start after repeated attempts it...

Page 43: ...o Stop the Engine Starting Stopping the Engine Basic Operation Riding To stop the engine shift into neutral push the engine stop button in and hold it in until the engine stops 05 03 18 15 50 23 31KSJ...

Page 44: ...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 45: ...shift down to a lower gear close the throttle pull the clutch lever in and depress the shift lever After shifting release the clutch lever and apply the throttle To continue shifting up to each highe...

Page 46: ...one or both wheels to slip Any wheel slip will reduce your control of your motorcycle cont d When riding in wet or rainy conditions or on loose surfaces the ability to maneuver and stop will be reduce...

Page 47: ...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 48: ...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 49: ...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 50: ...ore fun To help keep your motorcycle in good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find imp...

Page 51: ...ns 52 Tools 55 Side Cover Removal 56 Fluids Filters Fuel 57 Engine Oil 60 Air Cleaner 66 Engine Throttle 69 Clutch System 71 Engine Idle Speed 75 Spark Plug 76 Spark Arrester 78 Chassis Suspension 80...

Page 52: ...pects all major parts even if you are able to make some repairs A well maintained motorcycle is essential for safe economical and trouble free riding It will also help reduce air pollution Careful pre...

Page 53: ...basic maintenance can be an important part of their riding experience However if you allow a youngster to perform or assist in any maintenance task such as filling the tank with gasoline you should p...

Page 54: ...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 55: ...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 56: ...s are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you h...

Page 57: ...e marked and may require more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanical...

Page 58: ...I I R C A I In the interest of safety we recommend these items be serviced only by your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tools and service data and...

Page 59: ...Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page I L I I I I I I I I I I I I I I I I I I I I I I I I I...

Page 60: ...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 61: ...clutch lever front brake lever throttle grip 52 Servicing Your Honda Maintenance Component Locations 05 03 18 15 52 19 31KSJ620_061...

Page 62: ...adjusting nut engine oil drain bolt under engine clutch adjuster rear brake rod rear brake adjuster carburetor rear brake pedal engine oil filler cap dipstick adjusting nut drive chain 53 Maintenance...

Page 63: ...sion rear suspension air cleaner drive chain front brake cable left side cover adjusting nut drive chain front axle shaft rear axle shaft 54 Maintenance Component Locations Servicing Your Honda 05 03...

Page 64: ...afety 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 maintenan...

Page 65: ...driver to remove the slot head bolt 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 prongs wi...

Page 66: ...a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock...

Page 67: ...ther tube 3 front number plate 4 filler neck 4 3 58 Refueling Procedure Fuel Servicing Your Honda Reserve Capacity Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the...

Page 68: ...ling turn the fuel fill cap clockwise until it is secure Check that the breather tube is properly seated in the front number plate If you replace the fuel fill cap use only a genuine Honda replacement...

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

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

Page 71: ...hen the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two clas...

Page 72: ...nd remove the oil filler cap dipstick Wipe it clean Hold the motorcycle upright If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the lower level mar...

Page 73: ...ff Wait 2 3 minutes for the oil to settle Park your motorcycle on a firm level surface Remove the oil filler cap dipstick Place a drain pan under the crankcase After most of the oil is drained gently...

Page 74: ...Start the engine Let it idle 3 5 minutes then turn it off With the motorcycle held upright on level ground check the oil level If needed add oil page until it reaches the upper level mark Do not over...

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: ...if it is damaged Gently wash the air cleaner in clean non flammable high flash point solvent such as kerosene not gasoline After cleaning gently squeeze out the remaining solvent Avoid twisting or wr...

Page 77: ...e out any excess oil To keep your hands dry place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner Install the left side cover page Attach the air cleaner to its su...

Page 78: ...t to the specified 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 posit...

Page 79: ...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 80: ...Refer to on page Upper Adjustment Minor adjustments are generally made with the upper clutch cable adjuster Inspection Check freeplay Freeplay If necessary adjust to the specified range Improper free...

Page 81: ...position Hold the lower adjusting nut and loosen the lower lock nut at the lower end of the cable Turn the lower adjusting nut to obtain the specified freeplay Hold the lower adjusting nut and tighten...

Page 82: ...uster counterclockwise until a slight resistance is felt Readjust the lower cable adjuster for proper freeplay using the lower lock nut and lower adjusting nut Start the engine pull the clutch lever i...

Page 83: ...ercially available cable lubricant to prevent premature wear and corrosion If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs m...

Page 84: ...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 adjustments Warm...

Page 85: ...y Precautions Using spark plugs with 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...

Page 86: ...ked or chipped Check the spark plug gap using a wire type feeler gauge If adjustment is necessary bend the side electrode carefully The gap should be Make sure the plug washer is in good condition If...

Page 87: ...servicing prevents carbon buildup which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester prevents random sp...

Page 88: ...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 89: ...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 90: ...Servicing Your Honda cont d 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...

Page 91: ...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 92: ...ay by pulling in slowly on the front brake lever until the brake starts to engage If necessary adjust to the specified range Pull the rubber dust cover back Loosen the lock nut and turn the front brak...

Page 93: ...obtained using the cable adjuster Check the freeplay At the lower end of the cable loosen the lower lock nut Turn the lower adjusting nut to obtain the specified freeplay Tighten the lower lock nut L...

Page 94: ...the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times Check the freeplay If you cannot adjust the freeplay properly see your Honda dealer Inspe...

Page 95: ...in 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 front and rear brakes are equip...

Page 96: ...your Honda dealer Place your motorcycle on its side stand Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Check the front brake cable for...

Page 97: ...2 stopper bolt 1 2 88 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 85 05 03 18 1...

Page 98: ...pect the wheel rims and spokes for damage Tighten any loose spokes or rim locks Maintenance of spoke tension and wheel trueness roundness is critical to safe motorcycle operation During the first 100...

Page 99: ...noticeable see your Honda dealer for inspection Removal Raise the front wheel off the ground by placing a maintenance stand or support block under the engine Secure the rear of the motorcycle with tie...

Page 100: ...mbly Installation Reverse the removal procedure Make sure the lug on the fork leg is located in the slot in the brake panel Check front brake adjustment page If a torque wrench was not used to install...

Page 101: ...straps Unscrew the rear brake adjuster Press the rear brake pedal and disconnect the brake rod from the brake arm Loosen the adjusting nut on the chain adjuster on both sides Unscrew the rear axle nu...

Page 102: ...nstalled properly Adjust the drive chain page Adjust the rear brake page Apply the rear brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times If a t...

Page 103: ...detailed 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...

Page 104: ...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 blowout is inconven...

Page 105: ...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 cra...

Page 106: ...s Tubes Servicing 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 We...

Page 107: ...ons 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 and lub...

Page 108: ...orcycle 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 transmiss...

Page 109: ...ve chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear Replace the drive chain page if it has damaged rollers loose pins or kinks that cannot be freed Lubri...

Page 110: ...imit of adjustment Excessive slack indicates the chain is worn beyond its service limit To check the chain s service limit remove the drive chain page Then measure the distance between a span of pins...

Page 111: ...rvicing Your Honda Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your Honda dealer replace...

Page 112: ...rear wheel by hand Saturate each chain link joint so that the lubricant penetrates between the link plates pins bushings and rollers Check rear brake pedal freeplay and adjust as necessary page Freepl...

Page 113: ...r link retaining clip with pliers Do not bend or twist the clip Remove the master link Remove the drive chain Inspect the drive chain for possible wear or damage Replace the drive chain if it has dama...

Page 114: ...er link and pulling the old chain to position the new chain on the sprockets Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed Lubrica...

Page 115: ...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 116: ...eat engine stop button under fuel tank drive chain carburetor Rinse your motorcycle thoroughly with cool water to remove loose dirt Fill a bucket with cool water Mix in a mild neutral detergent such a...

Page 117: ...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 118: ...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 110 Transporting Your Honda 112 Storing Your Honda 114...

Page 119: ...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 first aid kit and...

Page 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 120...

Page 129: ...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 130: ...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 131: ...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 132: ...e 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 cap...

Page 133: ...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 134: ...If any component of the front brake system is damaged you may be able to ride carefully back to your base using the rear brake for slowing or stopping The drive chain master link brake lever or pedal...

Page 135: ...126 Taking Care of the Unexpected 05 03 18 16 01 23 31KSJ620_135...

Page 136: ...d other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification 128 Specifications 130 Break in Guidelines 135 High Altitude Carburetor Ad...

Page 137: ...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 engine number...

Page 138: ...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 139: ...ine pump octane number of 86 or higher after draining 1 0 US qt 0 9 after disassembly 1 2 US qt 1 1 Overall length Overall width Overall height Wheelbase Fuel tank capacity Fuel tank reserve Fuel reco...

Page 140: ...on the circular API service label SAE 10W 30 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 motorc...

Page 141: ...0 028 in 0 60 0 70 mm or or Intake Exhaust or Valve clearance cold Spark plug standard Spark plug cold climate below 5 C 41 F Spark plug extended high speed riding Spark plug gap Idle speed Primary r...

Page 142: ...travel 5 2 in 132 mm bias play tube type 15 psi 100 kPa 1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm Drive chain freeplay New chain length Used chain service limit length Caster Trail Tire size front Tire si...

Page 143: ...18 lbf ft 24 N m 2 5 kgf m 46 lbf ft 62 N m 6 3 kgf m Oil drain bolt Wheel axles Torque Specifications 134 Specifications Technical Information 05 03 18 16 02 26 31KSJ620_143...

Page 144: ...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 145: ...he spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance c...

Page 146: ...e California Air Resources Board CARB require that your motorcycle comply with applicable exhaust emission standards during its useful life when operated and maintained according to the instructions p...

Page 147: ...s and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is to...

Page 148: ...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 149: ...or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that ma...

Page 150: ...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 151: ...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 152: ...ontains information on your warranty and how to get an official Honda service manual Authorized Manuals 144 Warranty Coverage 147 Warranty Service 148 Contacting Honda 149 The Honda Rider s Club USA o...

Page 153: ...SA only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic...

Page 154: ...otal Price Price Each 145 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 compl...

Page 155: ...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 On returns a...

Page 156: ...or more information see your Honda dealer It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to no...

Page 157: ...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 158: ...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 159: ...nsport vehicle as long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Hon...

Page 160: ...da 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 departme...

Page 161: ...mponent Locations 14 Operating Controls 17 Fuel Valve 17 Choke Lever 18 Ignition Switch 19 Engine Stop Button 20 Front Brake Lever 20 Throttle 20 Clutch Lever 20 Shift Lever 21 Rear Brake Pedal 21 Kic...

Page 162: ...Precautions 45 Maintenance Schedule 47 Maintenance Record 51 Maintenance Component Locations 52 Tools 55 Side Cover Removal 56 Fluids Filters Fuel 57 Engine Oil 60 Air Cleaner 66 Engine Throttle 69 C...

Page 163: ...a 114 You the Environment 117 General Guidelines 120 If Your Engine Quits or Won t Start 121 If You Have a Flat Tire 122 If You Crash 123 If You Lose Your Key 124 If a Component Fails 125 Vehicle Iden...

Page 164: ...TS 152 INDEX 156 QUICK REFERENCE Table of Contents Table of Contents Authorized Manuals 144 Warranty Coverage 147 Warranty Service 148 Contacting Honda 149 The Honda Rider s Club USA only 150 Your Hon...

Page 165: ...t 20 pedal rear 21 shoe wear 86 braking 37 break in guidelines 135 button engine stop 20 capacity fuel 58 carburetor high altitude adjustment 136 idle speed 75 choke lever 18 cleaner air 66 cleaning a...

Page 166: ...eed 75 pinging 57 starting 31 stop button 20 stopping 34 won t start 121 environment protecting 117 filter air 66 flat tire 122 flooded engine starting 33 fork 80 frame number 128 front brake lever 20...

Page 167: ...rake 20 shift 21 limit weight 9 loading 8 high altitude adjustment 136 Honda contacting 149 Honda service manual 144 gap spark plug 76 gasohol 141 gasoline 57 gears shifting 35 idle speed engine 75 in...

Page 168: ...ar brake 21 pinging engine 57 plug spark 76 post ride inspection 40 pre ride inspection 27 reserve capacity fuel tank 58 rider training 3 150 riding basic operation 29 before 23 clothing 24 precaution...

Page 169: ...rester 78 spark knock 57 spark plug 76 specifications 130 stand side 21 98 starting engine 31 stop button engine 20 stopping engine 34 storage 114 suspension front 80 rear 81 throttle freeplay 69 oper...

Page 170: ...161 Index Index W V valve fuel 17 vehicle identification 128 warranty coverage 147 extended 147 service 148 washing your motorcycle 107 weight limit 9 wheels 89 05 03 18 16 04 51 31KSJ620_170...

Page 171: ...ds and filters prevents premature wear and damage Frequent causes of costly engine repairs are Engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation...

Page 172: ...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 05 03 18 16 05...

Page 173: ...ance Pre ride Inspection Fuel Capacity Engine Oil rider only no passenger or cargo and any accessories Maximum Weight Capacity Tires Check the following items each time before you ride page tires spok...

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