Honda CL500A 2023 Manual Download

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Throttle

Checking the Throttle

With the engine off, check that the throttle

rotates smoothly from fully closed to fully

open in all steering positions and throttle

freeplay is correct. If the throttle does not

move smoothly or close automatically, or if

the cable is damaged, have the vehicle

inspected by your dealer.

Freeplay at the throttle grip flange:

2 - 6 mm (0.1 - 0.2 in)

20221007115421_32MLPB000_eng_BOOK Page 89 Friday, October 07 2022 11:57:00 JST

Maintenance

Freeplay

Flange

Summary of Contents for CL500A 2023

Page 1: ...e before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured in this owner s manual may not match your actual vehicle 2022 Honda Motor Co Ltd 20221007115421_32MLPB000_eng_BOOK Page 1 Friday October 07 2022 11 57 00 JST ...

Page 2: ...tions and procedures contained in this manual Pay close attention to safety messages contained in this manual and on the vehicle The following codes in this manual indicate each country The illustrations here in are based on the CL500A ED type Country Codes Code Country CL500A ED European Direct Sales Hong Kong Singapore Argentina FO Taiwan KO Korea TH Thailand U Australia New Zealand PH Philippin...

Page 3: ...r own good judgement You will find important safety information in a variety of forms including Safety labels on the vehicle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 3WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow in...

Page 4: ...ts Vehicle Safety P 2 Operation Guide P 22 Maintenance P 50 Troubleshooting P 88 Information P 99 Specifications P 112 Index P 115 20221007115421_32MLPB000_eng_BOOK Page 4 Friday October 07 2022 11 57 00 JST ...

Page 5: ...ing Precautions P 15 Accessories Modifications P 19 Loading P 20 20221007115421_32MLPB000_eng_BOOK Page 5 Friday October 07 2022 11 57 00 JST This section contains important information for safe riding of your vehicle Please read this section carefully Vehicle Safety ...

Page 6: ...ctive apparel 2 P 14 Before Riding Make sure that you are physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved helmet and protective apparel Instruct your passenger on holding onto the seat strap or your waist leaning with you in turns and keeping their feet on the footpegs even when the vehicle is stopped Take Time to Learn P...

Page 7: ...Ride within Your Limits Never ride beyond your personal abilities or faster than conditions warrant Fatigue and inattention can impair your ability to use good judgement and ride safely Don t Drink or Use Drugs and Ride Alcohol or drugs and riding don t mix Even one alcoholic drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional dri...

Page 8: ...ntinue riding Call for emergency assistance if needed Also follow applicable laws and regulations if another person or vehicle is involved in the crash If you decide to continue riding first turn the ignition switch to the Off position and evaluate the condition of your vehicle Inspect for fluid leaks check the tightness of critical nuts and bolts and check the handlebar control levers brakes and ...

Page 9: ...oxide Never run your vehicle inside a garage or other enclosure 3WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colourless odorless gas can quickly cause unconsciousness and lead to death Only run your vehicle s engine when it is located in a well ventilated area outdoors 2022100...

Page 10: ...el are as follows Read instructions contained in Owner s Manual carefully Read instructions contained in Shop Manual carefully In the interest of safety take the vehicle to be serviced only by your dealer DANGER with RED background You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING with ORANGE background You CAN be KILLED or SERIOUSLY HURT if you don t follow instruction...

Page 11: ...attery very well Handle the battery electrolyte with extreme care as it contains dilute sulfuric acid Contact with your skin or eyes can burn you or cause loss of your eyesight Read this manual carefully and understand it before handling the battery Neglect of the instructions can cause personal injury and damage to the vehicle Do not use a battery with the electrolyte at or below the lower level ...

Page 12: ...LABEL DANGER NEVER OPEN WHEN HOT Hot coolant will scald you Relief pressure valve begins to open at 1 1 kgf cm2 20221007115421_32MLPB000_eng_BOOK Page 12 Friday October 07 2022 11 57 00 JST Image Labels Vehicle Safety 9 Continued ...

Page 13: ...on guide before installing any accessory The total weight of accessories and luggage added to rider s and passenger s weight should not exceed 179 kg 395 lb which is the maximum weight capacity The luggage weight must not exceed 18 kg 40 lb under any circumstances The fitting of large fork mounted or large handlebar mounted fairing is not recommended 20221007115421_32MLPB000_eng_BOOK Page 13 Frida...

Page 14: ...f cm2 29 psi 250 kPa 2 50 kgf cm2 36 psi Driver and passenger Front Rear 200 kPa 2 00 kgf cm2 29 psi 250 kPa 2 50 kgf cm2 36 psi Keep chain adjusted and lubricated Freeplay 30 40 mm 1 2 1 6 in 20221007115421_32MLPB000_eng_BOOK Page 14 Friday October 07 2022 11 57 00 JST Image Labels Vehicle Safety 11 Continued ...

Page 15: ...R LABEL For your protection always wear helmet protective apparel FUEL LABEL Unleaded petrol only ETHANOL up to 10 by volume 20221007115421_32MLPB000_eng_BOOK Page 15 Friday October 07 2022 11 57 00 JST Image Labels Vehicle Safety 12 ...

Page 16: ... TH type MUFFLER LABEL NOTICE Don t place objects near the muffler Overheating may damage your luggage 20221007115421_32MLPB000_eng_BOOK Page 16 Friday October 07 2022 11 57 00 JST Image Labels Vehicle Safety 13 ...

Page 17: ...ons Helmet Safety standard certified high visibility correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision or other approved eye protection 3WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Make sure that you and any passenger always wear an approved helmet and protective appare...

Page 18: ... Where possible reduce speed before turning otherwise you risk sliding out Exercise caution on low traction surfaces u The tyres slip more easily on such surfaces and braking distances are longer Avoid continuous braking u Repeated braking such as when descending long steep slopes can seriously overheat the brakes reducing their effectiveness Use engine braking with intermittent use of the brakes ...

Page 19: ...d sprockets to ensure correct ABS operation Engine Braking Engine braking helps slow your vehicle down when you release the throttle For further slowing action downshift to a lower gear Use engine braking with intermittent use of the brakes to reduce speed when descending long steep slopes Wet or Rainy Conditions Road surfaces are slippery when wet and wet brakes further reduce braking efficiency ...

Page 20: ...ve the key when leaving the vehicle unattended Use of an anti theft device is also recommended Parking with the Side Stand 1 Stop the engine 2 Push the side stand down 3 Slowly lean the vehicle to the left until its weight rests on the side stand 4 Turn the handlebar fully to the left u Turning the handlebar to the right reduces stability and may cause the vehicle to fall 5 Turn the ignition switc...

Page 21: ...umber Using lower octane petrol will result in decreased engine performance Do not use fuels containing a high concentration of alcohol 2 P 110 Do not use stale or contaminated petrol or an oil petrol mixture Avoid getting dirt or water in the fuel tank 20221007115421_32MLPB000_eng_BOOK Page 21 Friday October 07 2022 11 57 00 JST Riding Precautions Vehicle Safety 18 ...

Page 22: ...l accessories on your vehicle be certain the modification is safe and legal 3WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding accessories and modifications Do not pull a trailer with or attach a sidecar to your vehicle Your vehicle was not designed for these attachments and their us...

Page 23: ...mum weight capacity Maximum luggage weight 2 P 112 Tie all luggage securely evenly balanced and close to the centre of the vehicle Do not place objects near the lights or the muffler 3WARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed Follow all load limits and other loading guidelines in this manual 20221007115421_32MLPB000_eng_BOOK Page 23 Friday Oc...

Page 24: ...20221007115421_32MLPB000_eng_BOOK Page 24 Friday October 07 2022 11 57 00 JST Vehicle Safety 21 ...

Page 25: ...2 Fuse box P 97 Front brake fluid reservoir P 78 Front brake lever Throttle grip P 86 Engine oil level inspection window P 74 Rear brake fluid reservoir P 78 Rear brake pedal Seat P 72 Side cover P 73 Engine oil fill cap P 74 Steering lock P 40 Battery P 69 Tool P 49 Rear suspension spring preload adjuster P 87 ...

Page 26: ...00 JST Operation Guide 23 Clutch lever P 83 Rear suspension spring preload adjuster P 87 Side stand P 81 Shift lever P 43 Drive chain P 82 Main fuse P 98 Coolant reserve tank P 76 Ignition switch P 39 Fuel fill cap P 46 Document bag P 49 Side cover P 73 Data link connector ...

Page 27: ...October 07 2022 11 57 00 JST Operation Guide 24 SEL button SET button When the ignition switch is turned to the On position initial animation will show If any part of these displays does not come on when it should have your dealer check for problems Display Check ...

Page 28: ...gear position is shown in the gear position indicator Gear position indicator To set the clock P 32 Clock 12 hour or 24 hour display Odometer TOTAL Tripmeter TRIP A B Average fuel mileage AVG A B Current fuel mileage Reserve fuel consumption RES P 26 If the fuel gauge indicator flashes in a repeat pattern or turns off P 94 NOTICE You should refuel when the reading approaches the E 1st segment Runn...

Page 29: ...ge and reserve fuel consumption When the 1st E segment of the fuel gauge starts flashing the reserve fuel consumption information will replace the current display 20221007115421_32MLPB000_eng_BOOK Page 29 Friday October 07 2022 11 57 00 JST Operation Guide 26 Instruments Continued Odometer Tripmeter A Tripmeter B Average fuel mileage B Current fuel mileage Average fuel mileage A When the 1st E seg...

Page 30: ...as reset The average fuel mileage B will be based on tripmeter B This indicator displays the average fuel mileage B since tripmeter B was reset ED type Display range 0 0 to 299 9 L 100km km L mile gal or mile L Except ED type Display range 0 0 to 299 9 km L L 100km More than 299 9 299 9 is displayed When the tripmeter A or B is reset is displayed When is displayed except for the above mentioned ca...

Page 31: ... starts flashing When the 1st E segment of the fuel gauge starts flashing the odometer tripmeter A tripmeter B average fuel mileage A average fuel mileage B or current fuel mileage switches to the reserve fuel consumption You should refill the tank as soon as possible ED type Display range 0 0 to 99 9 L litres or 0 0 to 99 9 gal gallon Except ED type Display range 0 0 to 99 9 L litres More than 99...

Page 32: ...e the tripmeter A or average fuel mileage A is displayed When they are reset the display quickly cycles through each indication to show each item has been reset Then the display returns to the last selected indication 20221007115421_32MLPB000_eng_BOOK Page 32 Friday October 07 2022 11 57 00 JST Operation Guide 29 Continued Tripmeter A Average fuel mileage A or ...

Page 33: ...ge B is displayed When they are reset the display quickly cycles through each indication to show each item has been reset Then the display returns to the last selected indication 20221007115421_32MLPB000_eng_BOOK Page 33 Friday October 07 2022 11 57 00 JST Operation Guide 30 Instruments Continued Tripmeter B Average fuel mileage B or ...

Page 34: ... Changing of fuel mileage meter unit 20221007115421_32MLPB000_eng_BOOK Page 34 Friday October 07 2022 11 57 00 JST Operation Guide 31 Continued Ordinary display Setting Mode Time format setting Backlight brightness adjustment Clock setting Changing of speed and mileage unit Changing of fuel mileage meter unit ED type Press and hold SEL and SET buttons Press the SET button ...

Page 35: ...ved and applied 1 Time format setting You can switch the time format between 12 hour format or 24 hour format a Turn the ignition switch to the On position b Press and hold the SEL and the SET buttons until the current time format start flashing c Press the SEL button to select 12 hr or 24 hr d Press the SET button The time format is set and then the display moves to the clock setting 202210071154...

Page 36: ...minute digits start flashing c Press the SEL button until the desired minute is displayed u Press and hold the SEL button to advance the minute quickly d Press the SET button The clock is set and then the display moves to the backlight brightness adjustment 20221007115421_32MLPB000_eng_BOOK Page 36 Friday October 07 2022 11 57 00 JST Operation Guide 33 Continued ...

Page 37: ...ge unit Except ED type The display moves to the changing of fuel mileage meter unit 4 Changing of speed and mileage unit ED type a Press the SEL button to select either km h and km or mph and mile b Press the SET button The speed and mileage unit is set and then the display moves to the changing of fuel mileage meter unit 20221007115421_32MLPB000_eng_BOOK Page 37 Friday October 07 2022 11 57 00 JS...

Page 38: ...type only Press the SEL button to select mile L or mile gal b Press the SET button The fuel mileage meter unit is set and then the display moves to the ordinary display To finalize selected settings turn the ignition switch to the Off position or press the SET button until the end of the settings is reached 20221007115421_32MLPB000_eng_BOOK Page 38 Friday October 07 2022 11 57 00 JST Operation Gui...

Page 39: ...dealer check for problems PGM FI Programmed Fuel Injection malfunction indicator lamp MIL If it comes on while riding P 90 Comes on when the ignition switch is turned to the On position Goes off when the engine starts If it comes on while engine is running P 91 Low oil pressure indicator High coolant temperature indicator Comes on briefly when the ignition switch is turned to the On position If it...

Page 40: ...tor Neutral indicator Comes on when the transmission is in Neutral ABS Anti lock Brake System indicator Comes on when the ignition switch is turned to the On position Goes off when your speed reaches approximately 10 km h 6 mph If it comes on while riding P 93 Left turn signal indicator Right turn signal indicator ...

Page 41: ...switch to the Stop position the starter motor will not operate to stop the engine Engine stop switch Headlight dimmer switch High beam Low beam Start button Turn signal switch u Pressing the switch turns the turn signal off Horn button Hazard switch Switchable when the ignition switch is in the On position Flashes the high beam headlight Passing light control switch ...

Page 42: ... 42 Friday October 07 2022 11 57 00 JST Operation Guide 39 Continued Ignition switch Switches the electrical system on off u Key can be removed when in the Off position On Turns electrical system on for starting riding Off Turns engine off ...

Page 43: ...n the steering lock c Push the ignition key down and turn it 180 degrees clockwise u Jiggle the handlebar if the lock is difficult to engage d Remove the ignition key Unlocking Insert the ignition key push it in and turn it 180 degrees counterclockwise 20221007115421_32MLPB000_eng_BOOK Page 43 Friday October 07 2022 11 57 00 JST Operation Guide 40 Switches Continued a b Turn Ignition key Push Stee...

Page 44: ... revving the engine can damage the engine and the exhaust system a Make sure the engine stop switch is in the Run position b Turn the ignition switch to the On position c Shift the transmission to Neutral N indicator comes on Alternatively pull in the clutch lever to start your vehicle with the transmission in gear so long as the side stand is raised d Press the start button with the throttle comp...

Page 45: ...button for 5 seconds b Repeat the normal starting procedure c If the engine starts open the throttle slightly if idling is unstable d If the engine does not start wait 10 seconds before trying steps a b again If Engine Will Not Start P 89 20221007115421_32MLPB000_eng_BOOK Page 45 Friday October 07 2022 11 57 00 JST Operation Guide 42 Starting the Engine Continued About 3 mm 0 1 in without freeplay...

Page 46: ...s 6 forward gears in a one down five up shift pattern If you put the vehicle in gear with the side stand down the engine will shut off 20221007115421_32MLPB000_eng_BOOK Page 46 Friday October 07 2022 11 57 00 JST Operation Guide 43 6 5 4 3 2 N 1 ...

Page 47: ...alert drivers behind you to take appropriate means to avoid a possible collision with your vehicle The emergency stop signal stops operating when You release the brakes The ABS is deactivated Your vehicle s decelerating speed becomes moderate You press the hazard switch 20221007115421_32MLPB000_eng_BOOK Page 47 Friday October 07 2022 11 57 00 JST Operation Guide 44 Hard braking Brakelight comes on...

Page 48: ...to avoid hard braking unless it is absolutely necessary u The emergency stop signal does not activate with the hazard switch pressed in u If the ABS stops working for a certain period during braking the emergency stop signal may not activate at all 20221007115421_32MLPB000_eng_BOOK Page 48 Friday October 07 2022 11 57 00 JST Operation Guide 45 ...

Page 49: ...k capacity 12 0 L 3 17 US gal 2 64 Imp gal TH PH type Tank capacity 12 2 L 3 22 US gal 2 68 Imp gal Refuelling and Fuel Guidelines P 18 Opening the Fuel Fill Cap Open the lock cover insert the ignition key and turn it clockwise to open the fuel fill cap 20221007115421_32MLPB000_eng_BOOK Page 49 Friday October 07 2022 11 57 00 JST Operation Guide 46 Lock cover Level plate Ignition key Fuel fill cap...

Page 50: ...annot be removed if the fuel fill cap is not locked 3WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flames away Only handle fuel outdoors Wipe up spills immediately 20221007115421_32MLPB000_eng_BOOK Page 50 Friday October 07 2022 11 57 00 JST Operation Guide 47 ...

Page 51: ...e holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed Use the helmet holder only while parked Do not ride with a helmet secured by the holder Removing the Seat P 72 20221007115421_32MLPB000_eng_BOOK Page 51 Friday October 07 2022 11 57 00 JST Operation Guide 48 Helmet holder Helmet set wire ...

Page 52: ...r P 73 Document Bag The document bag is stored behind the left side cover Store the document bag and secure it with the rubber strap as shown Removing the Left Side Cover P 73 20221007115421_32MLPB000_eng_BOOK Page 52 Friday October 07 2022 11 57 00 JST Operation Guide 49 Rubber strap Tool kit Right side cover Rubber strap Document bag Left side cover ...

Page 53: ...e Oil P 74 Coolant P 76 Brakes P 78 Side Stand P 81 Drive Chain P 82 Clutch P 83 Throttle P 86 Other Adjustments P 87 Adjusting the Rear Suspension P 87 20221007115421_32MLPB000_eng_BOOK Page 53 Friday October 07 2022 11 57 00 JST Please read Importance of Maintenance and Maintenance Fundamentals carefully before attempting any maintenance Refer to Specifications for service data Maintenance ...

Page 54: ... and schedules in this owner s manual Maintenance Safety Always read the maintenance instructions before you begin each task and make sure that you have the tools parts and skills required We cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task Follow these guidelines when performing maintenance Stop...

Page 55: ... maintenance to help ensure that your vehicle is properly maintained Make sure that whomever performs the maintenance completes this record All scheduled maintenance is considered a normal owner operating cost and will be charged to you by your dealer Retain all receipts If you sell the vehicle these receipts should be transferred with the vehicle to the new owner Honda recommends that your dealer...

Page 56: ...g System Secondary Air Supply System Evaporative Emission Control System Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary tools and are mechanically skilled Procedures are provided in an official Honda Shop Manual Inspect clean adjust lubricate or replace if necessary Replace Lubricate Clean Technical In the interest of safety have...

Page 57: ...Engine Stop Switch Clutch System 83 Side Stand 81 Suspension Nuts Bolts Fasteners Wheels Tyres 65 Steering Head Bearings Notes 1 At higher odometer reading repeat at the frequency interval established here 2 Service more frequently when riding in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Replacement requires mechanical skill 20221007115421_32M...

Page 58: ...ing System Secondary Air Supply System Evaporative Emission Control System Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary tools and are mechanically skilled Procedures are provided in an official Honda Shop Manual Inspect clean adjust lubricate or replace if necessary Replace Lubricate Clean Technical In the interest of safety ha...

Page 59: ...Horn Engine Stop Switch Clutch System 83 Side Stand 81 Suspension Nuts Bolts Fasteners Wheels Tyres 65 Steering Head Bearings Notes 1 At higher odometer reading repeat at the frequency interval established here 2 Service more frequently when riding in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Replacement requires mechanical skill 2022100711542...

Page 60: ...level Add engine oil if necessary Check for leaks 2 P 74 Coolant level Add coolant if required Check for leaks 2 P 76 Drive chain Check condition and slack adjust and lubricate if necessary 2 P 82 Brakes Check operation Front and Rear check brake fluid level and pads wear 2 P 78 2 P 79 Lights and horn Check that lights indicators and horn function properly Engine stop switch Check for proper funct...

Page 61: ...a crash in which you can be seriously hurt or killed Always use Honda Genuine Parts or equivalents that have been designed and approved for your vehicle Battery Your vehicle has a maintenance free type battery You do not have to check the battery electrolyte level or add distilled water Clean the battery terminals if they become dirty or corroded Do not remove the battery cap seals There is no nee...

Page 62: ...es repeatedly with cool water for at least 15 minutes Using water under pressure can damage your eyes Electrolyte splashes onto your skin u Remove affected clothing and wash your skin thoroughly using water Electrolyte splashes into your mouth u Rinse mouth thoroughly with water and do not swallow 3WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can ca...

Page 63: ...maintenance free battery of the same type NOTICE Installing non Honda electrical accessories can overload the electrical system discharging the battery and possibly damaging the system Fuses Fuses protect the electrical circuits on your vehicle If something electrical on your vehicle stops working check for and replace any blown fuses 2 P 97 Inspecting and Replacing Fuses Turn the ignition switch ...

Page 64: ...oil should be changed as soon as possible Selecting the Engine Oil For recommended engine oil see Specifications 2 P 113 If you use non Honda engine oil check the label to make sure that the oil satisfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SJ or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engin...

Page 65: ...Brake fluid can damage plastic and painted surfaces Wipe up spills immediately and wash thoroughly Recommended brake fluid Honda DOT 4 Brake Fluid or equivalent Drive Chain The drive chain must be inspected and lubricated regularly Inspect the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration 2 P 82 If the chain does not move smoothly m...

Page 66: ...h if the chain is dirty After cleaning wipe dry and lubricate with the recommended lubricant Recommended lubricant Drive chain lubricant designed specifically for O ring chains If not available use SAE 80 or 90 gear oil Do not use a steam cleaner a high pressure cleaner a wire brush volatile solvent such as petrol and benzene abrasive cleaner chain cleaner or lubricant NOT designed specifically fo...

Page 67: ... 60 will provide better protection in colder climates NOTICE Using coolant not specified for aluminium engines or tap mineral water can cause corrosion FO TH PH type Use only genuine HONDA PRE MIX COOLANT without diluting with water Genuine HONDA PRE MIX COOLANT is excellent at preventing corrosion and overheating The coolant should be inspected and replaced properly by following the maintenance s...

Page 68: ...e Visually inspect your tyres and use an air pressure gauge to measure the air pressure at least once a month or any time you think the tyres look low Always check air pressure when your tyres are cold Inspecting for Damage Inspect the tyres for cuts slits or cracks that expose fabric or cords or nails or other foreign objects embedded in the side of the tyre or the tread Also inspect for any unus...

Page 69: ... depth is reached 3WARNING Riding on tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tyre inflation and maintenance Germany German law prohibits use of tyres whose tread depth is less than 1 6 mm 20221007115421_32MLPB000_eng_BOOK Page 69 Friday October 07 2022 11 57 00 JST...

Page 70: ... tyre on this vehicle Excessive heat build up can cause the tube to burst Use only tubeless tyres on this vehicle The rims are designed for tubeless tyres and during hard acceleration or braking a tube type tyre could slip on the rim and cause the tyre to rapidly deflate 3WARNING Installing improper tyres on your vehicle can adversely affect handling and stability and can cause a crash in which yo...

Page 71: ...oadside repairs minor adjustments and parts replacement with the provided tools Standard Phillips screwdriver Screwdriver handle 10 x 14 mm Open end wrench Pin spanner Fuse puller Helmet set wire 20221007115421_32MLPB000_eng_BOOK Page 71 Friday October 07 2022 11 57 00 JST Maintenance 68 ...

Page 72: ...2 2 Remove the clips 2 P 71 3 Remove the data link connector from the battery cover 4 Disconnect the negative terminal from the battery 5 Pull up the battery cover 20221007115421_32MLPB000_eng_BOOK Page 72 Friday October 07 2022 11 57 00 JST Maintenance 69 Continued Clips Negative terminal Battery cover Clips Data link connector ...

Page 73: ... the positive terminal first Make sure bolts and nuts are tight Make sure the clock information is correct after the battery is reconnected 2 P 33 For proper handling of the battery see Maintenance Fundamentals 2 P 58 Battery Goes Dead 2 P 96 20221007115421_32MLPB000_eng_BOOK Page 73 Friday October 07 2022 11 57 00 JST Removing Installing Body Components u Battery Maintenance 70 Positive terminal ...

Page 74: ...f the hole Installation 1 Push the bottom of the centre pin 2 Insert the clip into the hole 3 Press down on the centre pin to lock the clip 20221007115421_32MLPB000_eng_BOOK Page 74 Friday October 07 2022 11 57 00 JST Removing Installing Body Components u Clip Maintenance 71 Centre pin ...

Page 75: ...h forward and down on the rear of the seat until it locks in place Make sure that the seat is locked securely in position by pulling it up lightly The seat locks automatically when closed Take care not to lock your key in the compartment under the seat 20221007115421_32MLPB000_eng_BOOK Page 75 Friday October 07 2022 11 57 00 JST Removing Installing Body Components u Seat Maintenance 72 Seat lock S...

Page 76: ... the clip 2 P 71 3 Remove the prongs from the grommets 4 Remove the side cover Installation Install the parts in the reverse order of removal 20221007115421_32MLPB000_eng_BOOK Page 76 Friday October 07 2022 11 57 00 JST Removing Installing Body Components u Side Cover Maintenance 73 Prongs Grommets Side cover Clip ...

Page 77: ...r 2 to 3 minutes 3 Place your vehicle in an upright position on a firm level surface 4 Check that the oil level is between the upper level and lower level marks on the oil level inspection window 20221007115421_32MLPB000_eng_BOOK Page 77 Friday October 07 2022 11 57 00 JST Maintenance 74 Upper level Lower level Oil fill cap Oil level inspection window ...

Page 78: ...vel mark u Make sure no foreign objects enter the oil filler opening u Wipe up any spills immediately 2 Securely reinstall the oil fill cap NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine Do not mix different brands and grades of oil They may affect lubrication and clutch operation For the recommended oil and oil selection guidelines see Maintenance F...

Page 79: ...ition 3 Check that the coolant level is between the UPPER level and LOWER level marks on the reserve tank If the coolant level is dropping noticeably or the reserve tank is empty you likely have a serious leak Have your vehicle inspected by your dealer 20221007115421_32MLPB000_eng_BOOK Page 79 Friday October 07 2022 11 57 00 JST Maintenance 76 UPPER level LOWER level Reserve tank ...

Page 80: ...lant level u Do not overfill above the UPPER level mark u Make sure no foreign objects enter the reserve tank opening 2 Securely reinstall the reserve tank cap 3WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out potentially scalding you Always let the engine and radiator cool down before removing the radiator cap 20221007115421_32MLPB000_eng_BOOK Page 80 F...

Page 81: ...uid level in either reservoir is below the LWR level mark or LOWER level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you most likely have a leak Have your vehicle inspected by your dealer 20221007115421_32MLPB000_eng_BOOK Page 81 Friday October 07 2022 11 57 00 JST Maintenance 78 Front brake fluid reservoir UPPER level...

Page 82: ...brake caliper 2 Rear Inspect the brake pads from the rear right of the vehicle If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time 20221007115421_32MLPB000_eng_BOOK Page 82 Friday October 07 2022 11 57 00 JST Brakes u Inspecting the Brake Pads Maintenance 79 Front Rear Brake pads Disc Wear indicators Brake pads Wear indicators Disc ...

Page 83: ...turn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction B if the switch operates too soon 20221007115421_32MLPB000_eng_BOOK Page 83 Friday October 07 2022 11 57 00 JST Brakes u Adjusting the Brakelight Switch Maintenance 80 Brakelight switch Adjusting nut A B ...

Page 84: ...sion 3 Sit on the vehicle shift the transmission to Neutral and raise the side stand 4 Start the engine pull the clutch lever in and shift the transmission into gear 5 Lower the side stand all the way The engine should stop as you lower the side stand If the engine doesn t stop have your vehicle inspected by your dealer 20221007115421_32MLPB000_eng_BOOK Page 84 Friday October 07 2022 11 57 00 JST ...

Page 85: ...icle on its side stand on a firm level surface 3 Move the lower part of the drive chain up and down to check chain slack midway between the sprockets Drive chain slack 30 40 mm 1 2 1 6 in u Do not ride your vehicle if the slack exceeds 50 mm 2 0 in 4 Roll the vehicle forward and check that the chain moves smoothly 5 Inspect the sprockets 2 P 62 6 Clean and lubricate the drive chain 2 P 63 20221007...

Page 86: ...for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion NOTICE Improper freeplay adjustment can cause premature clutch wear 20221007115421_32MLPB000_eng_BOOK Page 86 Friday October 07 2022 11 57 00 JST Maintenance 83 Freeplay Clutch lever ...

Page 87: ...3 Tighten the upper lock nut and check the freeplay again Lower 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 adjusting nut 20221007115421_32MLPB000_eng_BOOK Page 87 Friday October 07 2022 11 57 00 JST Clutch u Adjusting the Clutch Lever Freeplay Maintenance 84 Upper clutch cabl...

Page 88: ...ay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the vehicle does not creep Gradually release the clutch lever and open the throttle Your vehicle should move smoothly and accelerate gradually If proper adjustment cannot be obtained or the clutch does not work correctly see your dealer 20221007115421_32MLPB000_eng_BOOK Page 88 Friday October...

Page 89: ...g positions and throttle freeplay is correct If the throttle does not move smoothly or close automatically or if the cable is damaged have the vehicle inspected by your dealer Freeplay at the throttle grip flange 2 6 mm 0 1 0 2 in 20221007115421_32MLPB000_eng_BOOK Page 89 Friday October 07 2022 11 57 00 JST Maintenance 86 Freeplay Flange ...

Page 90: ...n spring preload soft or turn the position from 3 to 5 to increase spring preload hard The standard position is 2 NOTICE Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber NOTICE Do not turn the adjuster beyond its limits Adjust both left and right shock absorbers to the same spring preload 20221007115421_32MLPB000_eng_BOOK Page 90 Friday October 07 2022 11 57 00 JST...

Page 91: ...rammed Fuel Injection Malfunction Indicator Lamp MIL P 92 ABS Anti lock Brake System Indicator P 93 Other Warning Indications P 94 Fuel Gauge Failure Indication P 94 Tyre Puncture P 95 Electrical Trouble P 96 Battery Goes Dead P 96 Burned out Light Bulb P 96 Blown Fuse P 97 20221007115421_32MLPB000_eng_BOOK Page 91 Friday October 07 2022 11 57 00 JST Troubleshooting ...

Page 92: ... soon as possible Starter Motor Does Not Operate Check the following items Check the correct engine starting sequence 2 P 41 Make sure engine stop switch is in the Run position 2 P 38 Check for a blown fuse 2 P 97 Check for a loose battery connection 2 P 69 or battery terminal corrosion 2 P 58 Check the condition of the battery 2 P 96 If the problem continues have your vehicle inspected by your de...

Page 93: ... that the radiator fan is operating and then turn the ignition switch to the Off position If the fan is not operating Suspect a fault Do not start the engine Transport your vehicle to your dealer If the fan is operating Allow the engine to cool with the ignition switch in the Off position 3 After the engine has cooled inspect the radiator hose and check if there is a leak 2 P 76 If there is a leak...

Page 94: ...ue riding if the low oil pressure indicator goes off Rapid acceleration may momentarily cause the low oil pressure indicator to come on especially if the oil is at or near the low level If the low oil pressure indicator stays on when the oil level is at the proper level stop the engine and contact your dealer If the engine oil level goes down rapidly your vehicle may have a leak or another serious...

Page 95: ...immediately get your vehicle inspected at a dealer NOTICE If you drive with the malfunction indicator lamp on the emissions control system and the engine could be damaged What to do when the indicator lamp blinks Park the vehicle in a safe place with no flammable items and wait at least 10 minutes with the engine stopped until it cools NOTICE If the malfunction indicator lamp blinks again when res...

Page 96: ...s above 10 km h 6 mph If the ABS indicator stays on your brakes will continue to work as a conventional system but without the anti locking function The ABS indicator may flash if you turn the rear wheel while the rear wheel is lifted off the ground In this case turn the ignition switch to the Off position and then to the On position again The ABS indicator will go off after your speed reaches 30 ...

Page 97: ...n If the fuel system has an error the fuel gauge indicators will be displayed as shown in the illustrations If this occurs see your dealer as soon as possible 20221007115421_32MLPB000_eng_BOOK Page 97 Friday October 07 2022 11 57 00 JST Troubleshooting 94 ...

Page 98: ...ollow the instructions provided with the emergency tyre repair kit Riding your vehicle with a temporary tyre repair is very risky Do not exceed 50 km h 30 mph Have the tyre replaced by your dealer as soon as possible 3WARNING Riding your vehicle with a temporary tyre repair can be risky If the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary...

Page 99: ...cause permanent damage If the battery does not recover after recharging contact your dealer NOTICE Jump starting using an automobile battery can damage your vehicle s electrical system and is not recommended Burned out Light Bulb All light bulbs on the vehicle are LEDs If there is an LED which is not turned on see your dealer for servicing 20221007115421_32MLPB000_eng_BOOK Page 99 Friday October 0...

Page 100: ... check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating u The fuse puller is stored in the tool kit 2 P 49 u Spare fuses are provided behind the fuse box cover 4 Reinstall parts in the reverse order of removal 20221007115421_32MLPB000_eng_BOOK Page 100 Friday October 07 2022 11 57 00 JST Electrical Trouble u Blown Fuse Troubleshooting 97 Continued Fuse box cover Sp...

Page 101: ...fuse with a spare fuse of the same rating u Spare main fuse is provided in the starter magnetic switch 4 Reinstall parts in the reverse order of removal NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your vehicle inspected by your dealer 20221007115421_32MLPB000_eng_BOOK Page 101 Friday October 07 2022 11 57 00 JST Electrical Trouble u Blown Fuse Troubleshooting 98 Ma...

Page 102: ...01 Caring for Your Vehicle P 103 Storing Your Vehicle P 106 Transporting Your Vehicle P 107 You the Environment P 108 Serial Numbers P 109 Fuels Containing Alcohol P 110 Catalytic Converter P 111 20221007115421_32MLPB000_eng_BOOK Page 102 Friday October 07 2022 11 57 00 JST Information ...

Page 103: ... contractors only for the purpose of the technical diagnosis research and development of the vehicle Keys Ignition Key Steering Lock Key Be sure to record the key number provided with the key number plate Store the spare key and key number in a safe location To make a duplicate take the spare key or the key number to your dealer If you lose all ignition keys and the key number the ignition switch ...

Page 104: ...he engine using the engine stop switch turn the ignition switch to the Off position Failing to do so will drain the battery Odometer The display remains at 999 999 when the odometer exceeds 999 999 Tripmeter Each tripmeter resets to 0 0 when the trip mileage exceeds 9 999 9 Document Bag The owner s manual registration and insurance information can be stored in the plastic document bag behind the l...

Page 105: ...st slipper clutch system helps to prevent the rear tyre from locking up when the deceleration of your vehicle produces a strong engine braking effect It also makes the clutch lever operation feel lighter Use only MA classification engine oil for your vehicle Using engine oil other than MA classification oil could result in damage to the assist slipper clutch system 20221007115421_32MLPB000_eng_BOO...

Page 106: ...ecting water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your vehicle with plenty of clean water and dry with a soft clean cloth 4 After the vehicle dries lubricate any moving parts u Make sure that no lubricant spills onto the brakes or tyres Brake discs pads drum or shoes contaminated with oil will suffer greatly reduced braking effectiveness and can lead to a crash 5 Lu...

Page 107: ...the under seat compartment can damage your documents and other belongings Do not direct water at the air cleaner u Water in the air cleaner can prevent the engine from starting Do not direct water near the headlight u The headlight s inside lens may fog temporarily after washing or while riding in the rain This does not impact the headlight function However if you see a large amount of water or ic...

Page 108: ...emove stubborn stains use diluted detergent and rinse thoroughly with plenty of water Avoid getting petrol brake fluid or detergents on the instruments panels or headlight Exhaust Pipe and Muffler If the exhaust pipe and muffler are painted do not use a commercially available abrasive kitchen cleaning compound Use a neutral detergent to clean the painted surface on the exhaust pipe and muffler If ...

Page 109: ...and and position a block so that both tyres are off the ground After rain remove the body cover and allow the vehicle to dry Remove the battery 2 P 69 to prevent discharge Fully charge the battery and then place it in a shaded well ventilated area u If you leave the battery in place disconnect the negative terminal to prevent discharge After removing your vehicle from storage inspect all maintenan...

Page 110: ...ding ramp or lifting platform and motorcycle tie down straps Never try to tow your vehicle with a wheel or wheels on the ground NOTICE Towing your vehicle with a wheel or wheels on the ground can cause serious damage to the transmission 20221007115421_32MLPB000_eng_BOOK Page 110 Friday October 07 2022 11 57 00 JST Transporting Your Vehicle Information 107 ...

Page 111: ...ved containers and take them to a recycling centre Call your local or state office of public works or environmental services to find a recycling centre in your area and to get instructions on how to dispose of non recyclable wastes Do not place used engine oil in the trash or pour it down a drain or on the ground Used oil petrol coolant and cleaning solvents contain poisons that can hurt refuse wo...

Page 112: ...ired in order to register your vehicle They may also be required when ordering replacement parts You should record these numbers and keep them in a safe place 20221007115421_32MLPB000_eng_BOOK Page 112 Friday October 07 2022 11 57 00 JST Serial Numbers Information 109 Frame number Engine number ...

Page 113: ...erating symptoms or performance problems try a different brand of petrol Except TH type The following fuel blends can be used in your vehicle Ethanol ethyl alcohol up to 10 by volume u Petrol containing ethanol may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may Damage the painting of the fuel tank Damage the rubber tubes of the fuel line Cause corrosion of...

Page 114: ...pollution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your vehicle s catalytic converter Always use unleaded petrol Leaded petrol will damage the catalytic converter Keep the engine in good running condition Have your vehicle serviced if your engine is misfiring backfiring stalling or otherwise not runn...

Page 115: ...m weight capacity 1 Except KO type 179 kg 395 lb KO type 159 kg 351 lb Maximum luggage weight 2 ED type 18 kg 40 lb Passenger capacity Rider and 1 passenger Minimum turning radius Except KO type 2 70 m 8 9 ft KO type 2 6 m 8 5 ft Displacement Except TH type 471 cm3 28 7 cu in TH type 471 03 cm3 28 733 cu in Bore x stroke Except TH PH type 67 0 x 66 8 mm 2 64 x 2 63 in TH PH type 67 000 x 66 800 mm...

Page 116: ...ed tyre Front DUNLOP MIXTOUR Rear DUNLOP MIXTOUR G Tyre category of use 1 Normal Permitted Special Not Permitted Snow Not Permitted Moped Not Permitted Tyre air pressure Front 200 kPa 2 00 kgf cm2 29 psi Rear 250 kPa 2 50 kgf cm2 36 psi Minimum tread depth Front 1 5 mm 0 06 in Rear 2 0 mm 0 08 in Spark plug standard CPR8EA 9 NGK Spark plug gap 0 80 0 90 mm 0 031 0 035 in Idle speed 1 200 100 rpm R...

Page 117: ...OLANT Recommended drive chain lubricant Drive chain lubricant designed specifically for O ring chains If not available use SAE 80 or 90 gear oil Drive chain slack 30 40 mm 1 2 1 6 in Standard drive chain DID520VF2 or RK520MOZX No of links 112 Standard sprocket size Drive sprocket 15T Driven sprocket Except FO type 41T FO type 40T Bulbs Headlight LED Brakelight Taillight LED Front turn signal Posit...

Page 118: ...ustment 84 Freeplay 83 Colour Label 58 Coolant 76 Crash 5 Current Fuel Mileage 28 D Digital Clock Adjustment 33 Display Setting 31 Drive Chain 62 82 E Electrical Trouble 96 Engine Oil 61 74 Overheats 90 Starting 41 Stop Switch 38 101 Stopping 39 101 Will Not Start 89 Environment 108 Equipment Owner s Manual 49 Tool 49 F Flooded Engine 42 Frame Number 109 20221007115421_32MLPB000_eng_BOOK Page 118 ...

Page 119: ...orn Button 38 I Ignition Cut off System Banking Sensor 102 Side Stand 81 Ignition Key 100 Ignition Switch 39 101 Image Labels 7 Indicators 36 Instruments 24 Instruments Controls Other Features 101 L Labels 7 Load Limits 20 Loading Guidelines 20 Low Oil Pressure Indicator 36 91 M Maintenance Fundamentals 57 Importance 51 Safety 51 Schedule 52 Maximum Weight Limit 20 112 Modifications 19 20221007115...

Page 120: ...t 64 Engine Oil 61 Fuel 46 Refuelling 46 Removal Battery 69 Clip 71 Seat 72 Side Cover 73 Repair Kit 95 Riding Precautions 15 S Safety Guidelines 3 Safety Precautions 14 Seat 72 Serial Numbers 109 Shifting Gears 43 Side Cover 73 Side Stand 81 Side Stand Ignition Cut off System 81 Specifications 112 Speedometer 25 Start Button 38 Starting the Engine 41 Steering Lock 40 Stopping Engine 39 101 202210...

Page 121: ... Vehicle 107 Tripmeter 26 27 101 Troubleshooting 88 Turn Signal Indicator 37 Turn Signal Switch 38 Tyres Air Pressure 65 Puncture 95 Replacing 65 95 W Warning Indicators On or Flashing 91 Washing Your Vehicle 103 Weight Limit 20 20221007115421_32MLPB000_eng_BOOK Page 121 Friday October 07 2022 11 57 00 JST Index 118 ...

Page 122: ...20221007115421_32MLPB000_eng_BOOK Page 122 Friday October 07 2022 11 57 00 JST Thailand only HELMET CAUTION LABEL ...

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