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Honda CMX250, Owner'S Manual, Page: 51 / 121

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Honda CMX250 Owner'S Manual Download Page 51

50

Mainten

a

nce

Removing & Installing Body Components

Battery

❙

Removal

Make sure the ignition switch is off.

1.

Remove the right side cover. 

2

P. 51

2.

Release the rings and remove the rubber 
band.

3.

Disconnect the negative 

-

 terminal from 

the battery.

4.

Disconnect the positive 

+

 terminal from 

the battery.

5.

Remove the battery taking care not to 
drop the terminal nuts.

❙

Installation

Install the parts in the reverse order of 
removal. Always connect the positive 

+

 

terminal first. Make sure that bolts and nuts 
are tight.
For proper handling of the battery, see 
“Maintenance Fundamentals.“ 

2

P. 40

“Battery Goes Dead.“ 

2

P. 86

Negative terminal

Positive 
terminal

Battery

Rubber band

Summary of Contents for CMX250

Page 1: ...Rebel CMX250 31K17640 MOM 15509 1506 Contents Motorcycle Safety P 2 Operation Guide P 16 Maintenance P 31 Troubleshooting P 78 Information P 92 Specifications P 113 Index P 117 ...

Page 2: ...so observe the break in guidelines and always perform the pre ride inspection and other periodic checks in this manual When service is required remember that your Honda dealer knows your motorcycle best If you have the required mechanical know how and tools you can purchase an official Honda Service Manual to help you perform many maintenance and repair tasks 2 P 107 Read the warranty information ...

Page 3: ...intaining a motorcycle You must use your own good judgment You will find important safety information in a variety of forms including Safety labels on the motorcycle 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...

Page 4: ... contains important information for safe riding of your motorcycle Please read this section carefully Safety Guidelines P 3 Safety Labels P 7 Safety Precautions P 9 Riding Precautions P 10 Accessories Modifications P 13 Loading P 14 ...

Page 5: ...ies So always wear an approved motorcycle helmet and protective apparel 2 P 9 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 motorcycle 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...

Page 6: ...ou Be prepared to stop quickly or perform an evasive maneuver Make yourself more visible especially at night by wearing bright reflective clothing positioning yourself so other drivers can see you signaling before turning or changing lanes and using your horn when necessary Never ride beyond your personal abilities or faster than conditions warrant Fatigue and inattention can impair your ability t...

Page 7: ... and whether it is safe to continue 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 off and evaluate the condition of your motorcycle Inspect for fluid leaks check the tightness of critical nuts and bolts and check the handlebar control le...

Page 8: ...eath If you run the engine in confined or even partly enclosed area the air you breathe could contain a dangerous amount of carbon monoxide Never run your motorcycle inside a garage or other enclosure Carbon Monoxide Hazard 3WARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or activities that expose you to carbon monoxide ...

Page 9: ...ormation labels on your motorcycle provide important safety information and may warn you of potential hazards that could cause serious injury Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for a replacement ...

Page 10: ...Safety Labels 8 Motorcycle Safety ...

Page 11: ...ive clothing Ride defensively in response to weather and road conditions Helmet Should be safety standard certified high visibility and 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 Look for a DOT Department of Transportation certification label on any helmet you buy Gloves Fu...

Page 12: ...first 300 miles 500 km of running follow these guidelines to ensure your motorcycle s future reliability and performance Avoid full throttle starts and rapid acceleration Avoid hard braking and rapid down shifts Ride conservatively Observe the following guidelines Avoid excessively hard braking and down shifts u Sudden braking can reduce the motorcycle s stability u Where possible reduce speed bef...

Page 13: ...e 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 Exercise extra caution when braking in wet conditions If the brakes get wet apply the brakes while riding at low speed...

Page 14: ...t u Turning the handlebar to the right reduces stability and may cause the motorcycle to fall 5 Turn the ignition switch to the OFF position and remove the key 6 Lock the steering 2 P 20 7 Turn the fuel valve OFF Follow these guidelines to protect the engine Use only unleaded gasoline Use recommended octane number Using lower octane gasoline will result in decreased engine performance Do not use f...

Page 15: ...nd make your motorcycle illegal to operate on public roads and highways Before deciding to install accessories on your motorcycle be certain the modification is safe and legal Do not pull a trailer with or attach a sidecar to your motorcycle Your motorcycle was not designed for these attachments and their use can seriously impair your motorcycle s handling 3WARNING Improper accessories or modifica...

Page 16: ... an excessive load and keep within specified load limits 2 Maximum weight capacity P 113 Tie all luggage securely evenly balanced and close to the center of the motorcycle 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 ...

Page 17: ...on Front brake fluid reservoir P59 Throttle grip P74 Crankcase breather P75 Rear suspension spring preload adjuster P77 Battery P50 Main fuse P91 Spark plug P52 Throttle stop screw engine idle speed P57 Fuse box P90 Engine oil fill cap dipstick P54 ...

Page 18: ...ation Guide Clutch lever P71 Side stand P66 Shift lever P25 Fuel valve P22 Rear suspension spring preload adjuster P77 Drive chain P67 Fuel fill cap P26 Engine oil drain bolt P56 Spark plug P52 Air cleaner P58 ...

Page 19: ...ripmeter was reset Odometer Total distance ridden Gear range indicator Shows proper speed range for each gear Speedometer Turn signal indicator Neutral indicator Comes on when the transmission is in Neutral If one of these indicators does not come on when it should have your dealer check for problems ...

Page 20: ...19 Operation Guide Tripmeter reset knob The tripmeter reset knob is used to reset the tripmeter to zero 0 by turning the knob in the direction shown in the illustration ...

Page 21: ...n the RUN position u In an emergency switch to the off position to stop the engine Headlight dimmer switch High beam Low beam Horn button Start button u Headlight turns off when operating the starter motor Turn signal switch u Pressing the switch turns the turn signal off ...

Page 22: ...ion key in the lock and turn it 180 degrees clockwise u Jiggle the handlebar if the lock is difficult to engage c Remove the key Unlocking Insert the ignition key in the lock and turn it 180 degrees counterclockwise Ignition switch Switches the electrical system on off u Key can be removed when in the OFF position Turns electrical system on for starting riding OFF Turns engine off Ignition key Tur...

Page 23: ... three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON normal position for riding OFF for parking storing or transportation RES for extra fuel to get to a gas station for refueling ON OFF RES ...

Page 24: ... d Shift the transmission to Neutral indicator comes on Alternatively pull in the clutch lever to start your motorcycle with the transmission in gear so long as the side stand is raised a c d b Fully off Fully on Choke lever Start button Throttle NOTICE If the engine does not start within 5 seconds turn the ignition off and wait 10 seconds before trying to start the engine again to recover battery...

Page 25: ...b Open the throttle slightly c Start the engine Low Air Temperature 10 ºC 50 ºF or Below a Follow steps 1 6 under Normal Air Temperature b When engine rpm begins to pick up operate the choke lever to keep fast idle c Continue warming up the engine until it runs smoothly and responds to the throttle when the choke lever is at fully off If the engine does not start a Press the engine stop switch to ...

Page 26: ...nded Shift Points Shifting Up From 1st to 2nd 12 mph 20 km h From 2nd to 3rd 19 mph 30 km h From 3rd to 4th 25 mph 40 km h From 4th to 5th 31 mph 50 km h Shifting Down From 5th to 4th 22 mph 35 km h From 4th to 3rd 16 mph 25 km h NOTICE Improper shifting can damage the engine transmission and drive train Also coasting or towing the motorcycle for long distances with the engine off can damage the t...

Page 27: ...ters Reserve capacity 0 71 US gal 2 7 liters The tank should be refilled as soon as possible after switching to reserve and the fuel valve should be returned to the ON position after refueling to avoid running out of fuel with no reserve P22 Refueling and Fuel Guidelines P12 Opening the Fuel Fill Cap Open the lock cover insert the ignition key and turn it clockwise to open the cap Fuel fill cap Ig...

Page 28: ...s b Remove the ignition key and close the lock cover u The ignition key cannot be removed if the fuel fill cap is not locked c Turn the fuel valve to the ON position if it was set on RES 3WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediatel...

Page 29: ...wise to unlock Locking a Hang your helmet on the holder pin b Push in the holder pin and remove the ignition key Holder pin Helmet holder Turn Ignition key 3WARNING Riding with a helmet attached to the 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 ...

Page 30: ...tion key Turn Compartment cover Key slot Opening the Tool Kit Compartment a Insert the ignition key into the key slot on the compartment cover b Turn the ignition key clockwise c Remove the compartment cover Closing the Tool Kit Compartment a Align the tabs and push it in b Turn the ignition key counterclockwise c Remove the ignition key ...

Page 31: ...inued Operation Guide Document Bag The document bag is located on the inside of the left side cover u Be careful not to flood this area when washing your motorcycle Removing the left side cover P51 Document bag Left side cover ...

Page 32: ...h your dealer s parts department Importance of Maintenance P 32 Maintenance Schedule P 34 Maintenance Fundamentals P 37 Removing Installing Body Components P 50 Battery P 50 Side Cover P 51 Spark Plug P 52 Engine Oil P 54 Engine Idle Speed P 57 Air Cleaner P 58 Brakes P 59 Side Stand P 66 Drive Chain P 67 Clutch P 71 Throttle P 74 Crankcase Breather P 75 Other Adjustments P 76 Headlight Aim P 76 R...

Page 33: ...ust emission and noise emission requirements of the U S Environmental Protection Agency EPA and the California Air Resources Board CARB 2 P 101 Maintenance replacement or repair of the emission control devices and systems may be performed by any motorcycle repair establishment or individual using parts that are certified to EPA standards Importance of Maintenance 3WARNING Improperly maintaining yo...

Page 34: ...nly you can decide whether or not you should perform a given task Follow these guidelines when performing maintenance Stop the engine and remove the key Place your motorcycle on a firm level surface using the side stand or a maintenance stand to provide support Allow the engine muffler brakes and other high temperature parts to cool before servicing as you can get burned Run the engine only when i...

Page 35: ...rly trained and equipped technicians Your dealer meets all of these requirements Keep an accurate record of maintenance to help ensure that your motorcycle 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 for by your dealer Retain all receipts If you sell the motor...

Page 36: ... dealer Frequency Odometer Reading 1 1 000 mi 0 6 4 8 12 16 20 24 Refer to page Items 1 000 km 1 0 6 4 12 8 19 2 25 6 32 0 38 4 Emission related Items Fuel Line Throttle Operation 74 Carburetor Choke Air Cleaner 2 49 58 Crankcase Breather 3 75 Spark Plugs 52 Valve Clearance Engine Oil Initial 600 mi 1 000 km or 1 month Regular Every 4 000 mi 6 400 km or 6 months 54 Engine Oil Strainer Screen Engin...

Page 37: ...dometer intervals whichever comes first Replacement requires mechanical skill 5 50 STATE meets California Frequency Odometer Reading 1 1 000 mi 0 6 4 8 12 16 20 24 Refer to page Items 1 000 km 1 0 6 4 12 8 19 2 25 6 32 0 38 4 Non Emission Related Items Drive Chain Every 500 mi 800 km 67 Brake Fluid 4 59 Brake Shoes Pads Wear 60 64 Brake System 37 Brake light Switch 65 Headlight Aim 76 Clutch Syste...

Page 38: ...chain Adjust slack and lubricate as needed 2 P 44 67 Check the following items if you are carrying a passenger or cargo Combined weight is within load limits 2 P 113 Cargo is secured properly Suspension spring preload is adjusted to suit load 2 P 77 Check the following items after you get on your motorcycle Throttle action moves smoothly without binding 2 P 74 Brake lever and pedal operate normall...

Page 39: ...tread for wear and damage 2 P 46 and check the rims and spokes for damage Fluid levels Check the engine oil level 2 P 54 and brake fluid level 2 P 59 Lights Check that the headlight brake light taillight turn signals and license plate light are working properly Controls Check the freeplay of the clutch lever 2 P 71 rear brake pedal 2 P 61 and throttle grip 2 P 74 Drive chain Check the slack 2 P 67...

Page 40: ... code mentioned on the color label The color label is attached to the air cleaner housing cover behind the left side cover 2 P 51 Replacing Parts 3WARNING Installing non Honda parts may make your motorcycle unsafe and cause 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 motorcycle Color label ...

Page 41: ...l 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 WARNING Battery posts terminals and related accessories contain lead and lead compounds Wash your hands after handling Batt...

Page 42: ...er maintenance free battery of the same type Charging If you use electrical accessories that drain the battery or you do not ride frequently we recommend that you charge the battery every 30 days using a charger designed specifically for your Honda which can be purchased from your dealer Read the information that came with your battery charger and follow the instructions on the battery Avoid using...

Page 43: ...pecifications 2 P 115 If a fuse fails repeatedly you likely have an electrical fault Have your motorcycle inspected by your dealer NOTICE Jump starting using an automobile battery can damage your motorcycle s electrical system and is not recommended Bump starting is also not recommended NOTICE Installing non Honda electrical accessories can overload the electrical system discharging the battery an...

Page 44: ...at the oil satisfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB For example the following label shows the MA classification 2 The SAE standard grades oils by their viscosity 3 The API classification specifies the ...

Page 45: ... 2 P 67 If the chain does not move smoothly makes strange noises has damaged rollers has loose pins has missing O rings or kinks have the chain inspected by your dealer Also inspect the front sprocket and rear wheel sprocket If either has worn or damaged teeth have the sprocket replaced by your dealer Brake Fluid NOTICE Brake fluid can damage plastic and painted surfaces Wipe up spills immediately...

Page 46: ...ning wipe dry and lubricate with the recommended lubricant Do not use a steam cleaner a high pressure cleaner a wire brush volatile solvent such as gasoline and benzene abrasive cleaner chain cleaner or lubricant NOT designed specifically for O ring chains as these can damage the rubber O ring seals Avoid getting lubricant on the brakes or tires Avoid applying excess chain lubricant to prevent spr...

Page 47: ...ally inspect your tires and use an air pressure gauge to measure the air pressure at least once a month or any time you think the tires look low Always check air pressure when your tires are cold Inspecting for Damage Inspect the tires for cuts slits or cracks that exposes fabric or cords or nails or other foreign objects embedded in the side of the tire or the tread Also inspect for any unusual b...

Page 48: ...or recommended tires air pressure and minimum tread depth see Specifications 2 P 114 Follow these guidelines whenever you replace tires Use the recommended tires or equivalents of the same size construction speed rating and load range Wear indicator location mark 3WARNING Riding on tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed...

Page 49: ...itions even when the tires are not in use In addition to your regular inspections and maintenance it is recommended that you have annual inspections performed once the tires reach 5 years old It is also recommended that all tires be removed from service after 10 years from the date of manufacture regardless of their condition or state of wear The last four digits of the TIN tire identification num...

Page 50: ...ent which cannot be cleaned with compressed air or otherwise without degrading its performance If the filter becomes dirty replace it with a new one DOT XXXX XXXX 22 09 DOT This indicates that the tire meets all requirements of the U S Department of Transportation a XXXX Factory code b XXXX Tire type code c 22 09 Date of manufacture week year Example week 22 in year 09 a b c Tire Labeling Example ...

Page 51: ...om the battery 4 Disconnect the positive terminal from the battery 5 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always connect the positive terminal first Make sure that bolts and nuts are tight For proper handling of the battery see Maintenance Fundamentals 2 P 40 Battery Goes Dead 2 P 86 Negative terminal Positive t...

Page 52: ...ide covers can be removed in the same manner Removal 1 Remove the screw 2 Remove the prongs from the grommets Installation 1 Insert the prongs into the grommets 2 Push the side cover in place 3 Tighten the screw securely Screw Prongs Screw Prongs Grommets Grommets Left Right Side cover Side cover ...

Page 53: ...ark plugs 2 Clean any dirt from around the spark plug bases 3 Remove the spark plugs using the spark plug wrench 4 Inspect the electrodes and center porcelain for deposits erosion or carbon fouling uIf the erosion or deposit is heavy replace the plug uClean a carbon or wet fouled plug with a plug cleaner otherwise use a wire brush NOTICE Using a spark plug with an improper heat range can cause eng...

Page 54: ...g is good 1 8 turn after it seats If installing a new plug tighten it twice to prevent loosening 9 Reinstall the spark plug caps Take care to avoid pinching any cables or wires The gap should be 0 024 to 0 028 in 0 60 to 0 70 mm Spark plug gap Side electrode a First tighten the plug NGK 1turn after it seats DENSO 3 4 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn...

Page 55: ...ur motorcycle in an upright position on a firm level surface 4 Remove the oil fill cap dipstick and wipe it clean 5 Insert the oil fill cap dipstick until it seats but don t screw it in Check that the oil level is between the upper level and lower level marks in the oil fill cap dipstick 6 Securely install the oil fill cap dipstick Oil fill cap dipstick Upper level Lower level ...

Page 56: ...a firm level surface when checking the oil level uDo not overfill above the upper level mark uMake sure no foreign objects enter the oil filler opening uWipe up any spills immediately 2 Securely reinstall the oil fill cap dipstick For the recommended oil and oil selection guidelines see Maintenance Fundamentals 2 P 43 NOTICE Overfilling with oil or operating with insufficient oil can cause damage ...

Page 57: ...evel surface 4 Place a drain pan under the drain bolt 5 Remove the oil fill cap dipstick drain bolt and sealing washer to drain the oil uDiscard the oil at an approved recycling center 6 Install a new sealing washer onto the drain bolt Tighten the drain bolt 7 Fill the crankcase with the recommended oil 2 P 43 114 and install the oil fill cap dipstick 8 Check the oil level 2 P 54 9 Check that ther...

Page 58: ...g the idle will not compensate for a fault elsewhere For information about high altitude carburetor adjustment see High Altitude Carburetor Adjustment 2 P 105 The engine must be at normal operating temperature for accurate idle speed adjustment 10 minutes of stop and go riding is sufficient 1 Warm up the engine place the motorcycle on its side stand 2 Connect a tachometer to the engine 3 Adjust id...

Page 59: ...e screws 3 Pull the retainer out and remove the air cleaner element 4 Disconnect the tube from the air cleaner element 5 Install the new air cleaner element uMake sure the air cleaner element is installed securely 6 Install the parts in the reverse order of removal NOTICE Using the wrong air cleaner element may cause premature engine wear or performance problems Air cleaner housing cover Screws Sc...

Page 60: ... horizontal and that the fluid level is above the LOWER level mark If the brake fluid level in the reservoir is below the LOWER level mark or the brake lever freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you most likely have a leak Have your motorcycle inspected by your dealer Front brake fluid reservoir LOWER level mark ...

Page 61: ... the brake pad wear indicators The pads need to be replaced if a brake pad is worn to the indicator Inspect the brake pads from below the brake caliper If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time Wear indicator Wear indicator Disc Brake pads ...

Page 62: ...ck nut and turn the stopper bolt 3 Tighten the lock nut and check the freeplay Inspecting the Rear Brake Pedal Freeplay 1 Place your motorcycle on its side stand on a firm level surface 2 Measure the distance of the rear brake pedal before the starts to take hold Make sure the brake rod brake arm spring and fastener are in good condition Lock nut Brake pedal Stopper bolt Freeplay at the tip of the...

Page 63: ... arm pin when adjusting the freeplay If proper adjustment cannot be obtained by this method see your dealer 1 Adjust by turning the rear brake adjusting nut a half turn at a time 2 Apply the brake several times and check for free wheel rotation after the brake pedal is released Adjusting nut Brake arm pin Increase Freeplay Adjusting nut Brake arm pin Decrease Freeplay ...

Page 64: ...ere is a gap between the rear brake adjusting nut and brake arm pin After adjustment confirm the freeplay of the brake pedal Make sure the brake rod brake arm spring and fastener are in good condition Brake arm pin Gap Brake arm Adjusting nut Push NOTICE Do not turn the adjuster beyond its natural limits ...

Page 65: ...lied an arrow attached to the brake arm moves toward a reference mark on the brake panel If the arrow aligns with the reference mark on full application of the brake the brake shoes must be replaced See your dealer for this service When the brake service is necessary see your dealer Use only Honda Genuine Parts or its equivalent Brake panel Arrow Brake arm Reference mark ...

Page 66: ...rake Light Switch Check the operation of the brake light switch Hold the brake light switch and 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 Brake light switch Adjusting nut A B ...

Page 67: ... grease 2 Check the spring for damage or loss of tension 3 Sit on the motorcycle put the transmission in 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 motorcycle inspected by your dealer Side stand spring ...

Page 68: ...spected by your dealer 1 Shift the transmission to Neutral Stop the engine 2 Place your motorcycle on the side stand on a level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets uDo not ride your motorcycle if the slack exceeds 1 15 16 in 50 mm 4 Roll the motorcycle forward and check that the chain moves smoothly 5 Inspect the sprockets 2 P 44 Drive chain ...

Page 69: ...ecial tools Have the drive chain slack adjusted by your dealer 1 Place the transmission in Neutral Stop the engine 2 Place your motorcycle on the side stand on a level surface 3 Loosen the rear axle nut 4 Loosen the lock nuts on both sides of the swingarm Rear edge of adjusting slot Adjusting nut Lock nut Chain adjuster index marks Lock nut Adjusting nut Rear axle nut ...

Page 70: ...marks align with the rear edge of the adjusting slots Both marks should correspond If the axle is misaligned turn the right or left adjusting nuts until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut 8 Tighten the drive chain adjusting nuts lightly then hold the adjusting nuts and tighten the lock nuts 9 Recheck drive chain slack 10 Rear brake pedal freeplay is affected ...

Page 71: ...sted to the proper slack the chain is excessively worn and must be replaced If necessary have the drive chain replaced by your dealer Checking the Drive Chain Slider Check the condition of the drive chain slider The drive chain slider will need to be replaced if the chain slider is worn to the wear limit line If necessary have the drive chain slider replaced by your dealer Chain RK 520MOZ9 or DID ...

Page 72: ... 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 Freeplay at the clutch lever 3 8 to 13 16 in 10 to 20 mm Freeplay Clutch lever NOTICE Improper freeplay adjustment can cause premature clutch wear ...

Page 73: ...per lock nut 3 Turn the upper clutch cable adjuster until the freeplay is 3 8 to 13 16 in 10 to 20 mm 4 Tighten the upper lock nut and check the freeplay again 5 Install the rubber dust cover 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 adjusting nut Upper lock nut Upper clutch cable ...

Page 74: ...eeplay is 3 8 to 13 16 in 10 to 20 mm 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your motorcycle should move smoothly and accelerate gradually If proper adjustment cannot be obtained or t...

Page 75: ...se automatically or if the cable is damaged have the motorcycle inspected by your dealer Adjusting the Throttle Cable Freeplay 1 Slide the cable boot 2 Loosen the lock nut 3 Turn the adjuster until the freeplay is 1 16 to 1 4 in 2 to 6 mm 4 Tighten the lock nut return the cable boot and inspect the throttle action again Freeplay at the throttle grip flange 1 16 to 1 4 in 2 to 6 mm Freeplay Flange ...

Page 76: ...ankcase Breather Cleaning the Crankcase Breather 1 Remove the crankcase breather tube plug from the tube 2 Drain deposits into a suitable container 3 Install the crankcase breather tube plug Crankcase breather tube plug ...

Page 77: ...Adjusting the Headlight Aim You can adjust vertical aim of the headlight for proper alignment Turn the screw in or out as necessary using a Phillips screwdriver provided in the tool kit Obey local laws and regulations Lower Rise Screw ...

Page 78: ...oad by the adjuster to suit the load or the road surface Use the pin spanner and extension bar to turn the adjuster Position 1 is for a decrease spring preload soft or turn the position 3 to 5 increase spring preload hard The standard position is 2 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber NOTICE Do not attempt to disassemble service or improperly dispose of...

Page 79: ...Troubleshooting Engine Will Not Start P 79 Tire Puncture P 80 Electrical Trouble P 86 Battery Goes Dead P 86 Burned out Light Bulb P 86 Blown Fuse P 90 ...

Page 80: ...uence 2 P 23 Check that there is gasoline in the fuel tank If the problem continues have your motorcycle inspected by your dealer Starter Motor Does Not Operate Check the following items Check for a blown fuse 2 P 90 Check for a loose battery connection or battery terminal corrosion 2 P 40 50 Check the condition of the battery 2 P 86 If the problem continues have your motorcycle inspected by your ...

Page 81: ...ou are riding If you need to make a temporary repair by patching a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before you ride again Anytime a tube is replaced the tire should be carefully inspected as described Removing Wheels Follow these procedures if you need to remove a wheel in order to repair a puncture 3WARNING Riding your motorcycle with a ...

Page 82: ...aintenance stand or a hoist 3 Remove the speedometer cable set screw and disconnect the speedometer cable 4 Loosen the axle pinch bolt 5 Remove the front axle shaft front wheel side collar and speedometer gearbox uAvoid getting grease oil or dirt on the disc or pad surfaces uDo not pull the brake lever while the front wheel is removed Speedometer cable set screw Speedometer cable Front axle shaft ...

Page 83: ... After installing the wheel apply the brake lever several times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely 7 Install the speedometer cable and tighten the speedometer cable set screw securely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper assembly may lea...

Page 84: ...Remove the rear brake adjusting nut disconnect the brake rod from the brake arm by pushing down on the rear brake pedal 3 Disconnect the brake stopper arm from the brake panel by removing the cotter pin stopper arm nut washer and rubber grommet Rear brake adjusting nut Brake rod Rear axle nut Drive chain lock nut Brake arm Stopper arm nut Drive chain adjusting nut Cotter pin Brake stopper arm ...

Page 85: ...e collars into the rear wheel 2 Place the rear wheel between the swingarm and install the drive chain over the rear wheel sprocket 3 Insert the rear axle shaft from the left side through the left swingarm wheel hub and brake panel 4 Temporarily tighten the rear axle nut 5 Reassemble the brake stopper arm and tighten the stopper arm nut 6 Connect the brake rod to the brake arm 7 Adjust the drive ch...

Page 86: ...reely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity A used cotter pin may not effectively secure a fastener Always replace a used cotter pin with a new one ...

Page 87: ...ot recover after recharging contact your dealer Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ignition switch to the OFF position Allow the bulb to cool before replacing it Do not use bulbs other than those specified Check the replacement bulb for correct operation before riding For the light bulb wattage see Specifications 2 P 115 NOTICE Jump startin...

Page 88: ...ght 3 Disconnect the connector 4 Remove the dust cover 5 Unlock the pin and remove the bulb 6 Install a new bulb in the reverse order of removal uInstall the dust cover with its TOP mark facing up Do not touch the glass surface with your fingers If you touch the bulb with your bare hands clean it with a cloth moistened with isopropyl rubbing alcohol Screws Connector Headlight Bulb TOP mark Dust co...

Page 89: ...ly press the bulb and turn it counterclockwise 4 Install a new bulb in the reverse order of removal Front Rear Turn Signal Bulb 1 Remove the screws 2 Remove the turn signal lens 3 Slightly press the bulb and turn it counterclockwise 4 Install a new bulb in the reverse order of removal Brake tail light lens Bulb Screws Screws Bulb Turn signal lens ...

Page 90: ... 89 Troubleshooting License Plate Light Bulb 1 Remove the nuts 2 Remove the license light cover lens 3 Slightly press the bulb and turn it counterclockwise 4 Install a new bulb in the reverse order of removal Nuts Bulb License light cover lens ...

Page 91: ...se Box Fuses 1 Remove the right side cover 2 P 51 2 Remove the fuse box cover 3 Slide the fuses out its clips one by one to check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating 4 Reinstall the fuse box cover 5 Reinstall the right side cover Spare fuse Fuse box cover Slide Push in Pull up Clips ...

Page 92: ...t and check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating uSpare main fuse is provided in the starter magnetic switch 4 Reinstall parts in the reverse order of removal Main fuse Wire connector Spare main fuse Starter magnetic switch NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your motorcycle inspected by your dealer ...

Page 93: ...cycle P 97 Transporting Your Motorcycle P 98 You the Environment P 99 Vehicle Identification Number P 100 Emission Control Systems P 101 High Altitude Carburetor Adjustment P 105 Oxygenated Fuels P 106 Authorized Manuals P 107 Warranty Coverage and Service P 109 Honda Contacts P 110 Reporting Safety Defects P 112 ...

Page 94: ...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 assembly will probably have to be removed by your dealer to determine the key number A metal key holder may cause damage to the area surrounding the ignition switch Ignition key Steering lock key ...

Page 95: ...en riding will cause the engine to suddenly turn off making riding unsafe If you stop the engine using the engine stop switch turn the ignition switch off Failing to do so will drain the battery The odometer returns to 0 when the read out exceeds 99 999 9 The tripmeter returns to 0 when the read out exceeds 999 9 The owner s manual registration and insurance information can be stored in the plasti...

Page 96: ...onents with extra care to avoid scratching them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water and dry with a soft clean cloth 4 After the motorcycle dries lubricate any moving parts u Make sure that no lubricant spills onto the brakes or tires Brake discs pads drum or shoes contaminated with oil will suffer gre...

Page 97: ... side cover 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 Any condensation inside the headlight should dissipate after a few minutes of running the engine Do not use wax or polishing compounds on matte painted surface u Use a soft cloth or sponge plenty o...

Page 98: ...ing a full body motorcycle cover If you won t be riding for an extended period follow these guidelines Wash your motorcycle and wax all painted surfaces except matte painted surfaces Coat chrome pieces with rust inhibiting oil Lubricate the drive chain 2 P 44 Place your motorcycle on a maintenance stand and position a block so that both tires are off the ground After rain remove the body cover and...

Page 99: ...nter Storage Guide available from your dealer Transporting Your Motorcycle If your motorcycle needs to be transported it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform and motorcycle tie down straps Never try to tow your motorcycle with a wheel or wheels on the ground NOTICE Towing your motorcycle can cause serious damage to the ...

Page 100: ...r Put oil and other toxic wastes in approved containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center 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 gasoline and cleaning solvents cont...

Page 101: ... register your motorcycle They may also be required when ordering replacement parts The VIN is stamped on the right side of the steering head and also appears on the Safety Certification Label attached to the left side of the steering head The engine number is stamped on the left side of the crankcase You should record these numbers and keep them in a safe place VIN VIN ...

Page 102: ...l Systems Your motorcycle engine emits combustion byproducts including carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC Gasoline evaporation also emits hydrocarbons Controlling the production of NOx CO and HC is important for the environment Engine number ...

Page 103: ...d and maintained according to the instructions provided Compliance with the terms of the Distributor s Warranties for Honda Motorcycle Emission Control Systems is necessary in order to maintain a valid emissions system warranty The Vehicle Emission Control Information label is attached to the right side of the swingarm The EPA requires that motorcycles built after January 1 1983 comply with applic...

Page 104: ... riding The engine is equipped 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 intake manifold The fuel tank fuel hoses and fuel vapor charge hoses use fuel permeation control technologies to prevent fuel vapor emissions Tampering with these components to reduce or defeat...

Page 105: ...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 person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part o...

Page 106: ...hen operated at high altitudes Above 6 500 feet 2 000 m a rich mixture can cause driveability problems reduce engine performance and increase fuel consumption To compensate you can have the carburetors adjusted for high altitude riding See your dealer However the carburetors must be returned to standard factory specifications before riding again at lower altitudes below 5 000 feet 1 500 m See your...

Page 107: ... up to 5 by volume that contain cosolvents and corrosion inhibitors to protect the fuel system Never use a blend containing more than 5 If you accidentally fill your fuel tank with an oxygenated fuel containing higher percentages you may experience performance problems To resolve the problem have your dealer drain the fuel tank and replace with the correct fuel Fuel system or performance problems ...

Page 108: ...e Winter Storage Guide in conjunction with the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician However if you possess the proper tools observe the safety standards and are mechanically capable you should find them easy to use Special Honda tools are necessary for some...

Page 109: ...Authorized Manuals 108 Information Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST ...

Page 110: ...r workmanship of your Honda Your warranty coverage does not apply to the normal wear and deterioration associated with use of the motorcycle Your warranty coverage is not voided if you perform your own maintenance However failures that occur due directly to improper maintenance are not covered by these warranties You can extend almost all of your warranty coverage through the Honda Protection Plan...

Page 111: ...your problem with the appropriate member of the dealership s management team If you are still not satisfied contact the owner of the dealership or their designated representative Honda Contacts If you wish to contact Honda directly to comment on your experiences with your motorcycle or with your dealer please send your comments to the following address Please include the following information in y...

Page 112: ...d Honda Genuine Accessories that provide the same quality that went into your motorcycle The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage Your Honda dealer can also supply information about riding events and information about safety training available in your local area and the Honda Rider s Club of America The Honda Rider s Club of America HRCA ...

Page 113: ...may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or American Honda Motor Co Inc To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Admini...

Page 114: ...13 mm Curb weight 331 lb 150 kg Maximum weight capacity 1 345 lb 156 kg Passenger capacity Rider and 1 passenger Minimum turning radius 8 53 ft 2 60 m Displacement 14 27 cu in 234 cm3 Bore x stroke 2 09 2 09 in 53 0 x 53 0 mm Compression ratio 9 2 1 Fuel Unleaded gasoline Recommended 86 PON or higher Fuel tank capacity 2 64 US gal 10 0 liters Fuel reserve capacity 0 71 US gal 2 7 liters Battery YT...

Page 115: ...4 to 0 028 in 0 60 to 0 70 mm Idle speed In neutral 1 400 100 rpm Recommended engine oil API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil or an equivalent motorcycle oil Engine oil capacity After draining 1 6 US qt 1 5 liters After disassembly 1 9 US...

Page 116: ... 12V 23W x 2 Rear turn signal lights 12V 23W x 2 License plate light 12V 8W Main fuse 20A Other fuses 10A Engine oil drain bolt 18 lbf ft 25 N m 2 5 kgf m Rear axle nut 65 lbf ft 88 N m 9 0 kgf m Front axle shaft 45 lbf ft 61 N m 6 2 kgf m Front axle pinch bolt 19 lbf ft 26 N m 2 7 kgf m Rear brake stopper arm nut 16 lbf ft 22 N m 2 2 kgf m ...

Page 117: ...116 Information Record VIN Engine No Color Label Code Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Manager ...

Page 118: ...ont Rear Turn Signal 88 Headlight 87 License Plate Light 89 C Caring for Your Motorcycle 95 Clutch System 71 Color Label 39 Crankcase Breather 46 75 D Document Bag 30 94 Drive Chain 44 67 E Electrical Trouble 86 Emission Control Systems 101 Engine Idle Speed 57 Number 100 Oil 43 54 Starting 23 Stop Switch 20 94 Stopping 94 Environment 99 Equipment Document Bag 30 94 Owner s Manual 30 94 Tool Kit 2...

Page 119: ...t Holder 28 High Altitude Carburetor Adjustment 105 High Beam Indicator 18 Honda Contacts 110 Horn Button 20 I Ignition Cut off System Side Stand 66 Ignition Key 93 Ignition Switch 21 94 Information Record 116 Instruments and Indicators 18 L Labels 7 Load Limits 14 Loading Guidelines 14 M Maintenance Fundamentals 37 Importance 32 Safety 33 Schedule 34 Maximum Weight Limit 14 113 Modifications 13 ...

Page 120: ...7 Recommended Fuel 26 Oil 43 114 Refueling 26 Removal Battery 50 Side Cover 51 Repair Kit 80 Reporting Safety Defects 112 Riding Precautions 10 S Safety Labels 7 Safety Precautions 9 Shifting Gears 25 Side Cover 51 Side Stand 66 Side Stand Ignition Cut off System 66 Spark Plug 52 Specifications 113 Speedometer 18 Start Button 20 Starting the Engine 23 Steering Lock 21 Stopping the Engine 94 ...

Page 121: ...ressure 46 Puncture 80 Replacing 46 80 Transporting Your Motorcycle 98 Tripmeter 18 19 94 Troubleshooting 78 Turn Signal Indicator 18 Turn Signal Switch 20 V Vehicle Identification Number 100 W Warranty Coverage and Service 109 Washing Your Motorcycle 95 Weight Limit 14 113 Wheels Front Removal 81 Rear Removal 83 ...

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