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Honda CRF 150R 2007, Owner'S Manual

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Honda CRF 150R 2007 Owner'S Manual Download Page 180

171

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SERVICING YOUR HONDA

.39

Table of Contents

Table of Contents

Bef ore You Service Your Honda

Service Preparations

Service Procedures

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The Importance of Maintenance

.41

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Maintenance Safety

.43

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Important Safety Precautions

.43

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Maintenance Schedule

.45

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Maintenance Record

.49

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Competition Inspection

.50

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Maintenance Component Locations

.53

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Tools

.56

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Side Cover Removal

.57

Fluids & Filters

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Fuel

.59

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Engine Oil

.62

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Air Cleaner

.68

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Crankcase Breather

.72

Engine

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Throttle

.73

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Clutch System

.76

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Engine Idle Speed

.79

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Spark Plug

.80

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Spark Arrester

.82

Chassis

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Suspension

.84

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Brakes

.87

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Wheels

.95

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Tires & Tubes

.101

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Side Stand

.105

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Drive Chain

.106

Electrical

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Battery

.113

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Appearance Care

.118

05/03/30 20:20:45 31KPS630_180

Summary of Contents for CRF 150R 2007

Page 1: ...onda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold Honda Motor Co Ltd 2005 The vehicle pictured on the front cover may not match your vehicle 05 03 30 19 56 05 31KPS630_001 ...

Page 2: ...does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester Obey local laws and regulations It conforms to US EPA and California exhaust emission regulations for off road motorcycles 05 03 30 19 56 09 31KPS630_002 ...

Page 3: ...and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You will find important safety information in a variety of forms including on the motorcycle preceded by a s...

Page 4: ...n t follow instructions Safety Messages A Few Words About Safety Safety Headings Safety Section Instructions such as Important Safety Reminders or Important Safety Precautions such as Motorcycle Safety how to use this motorcycle correctly and safely This entire book is filled with important safety information please read it carefully 05 03 30 19 56 20 31KPS630_004 ...

Page 5: ...s and modifications and the location of safety labels The location function and operation of the throttle brakes clutch and other basic controls The importance of wearing a helmet and other protective gear plus how to make sure you and your motorcycle are ready to ride Why your motorcycle needs regular maintenance what you need to know before servicing your Honda a maintenance schedule and instruc...

Page 6: ...otorcycle and how to be an environmentally responsible rider What to do if you have a flat tire your engine won t start etc ID numbers technical specifications and other technical facts Information on warranties and how to get Honda service manuals Handy facts about fuel engine oil tire sizes and air pressures Sequential listing of topics in this owner s manual 05 03 30 19 56 46 31KPS630_006 ...

Page 7: ...ant to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual We also recommend that you read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back ...

Page 8: ...your Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding California Proposition 65 Warning This product contains or emits chemicals known to the Sta...

Page 9: ...05 03 30 19 57 04 31KPS630_009 ...

Page 10: ...es Modifications 7 Safety Labels 9 This section presents some of the most important information and recommendations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle 05 03 30 19 57 09 31KPS630_010 ...

Page 11: ...Your motorcycle is designed and manufactured for off road use only The tires are not made for pavement and the motorcycle does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your motorcycle across There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout...

Page 12: ...r about riding groups in your area Also be sure to read the booklet that came with your motorcycle USA only The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Pushing limits is another major cause of motorcycle acci...

Page 13: ...specially if you are stranded off road far from your base To help avoid problems inspect your motorcycle before every ride and perform all recommended maintenance Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either ...

Page 14: ...motorcycle More specific information on load limits accessories and modifications follows In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your motorcycle s handling braking and stability Adding accessories or making modifications that change this motorcycle s design and performance can also make it unsafe Also the weight of any accessories will reduce th...

Page 15: ...eeds and follow these common sense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability Place weight as close to the center of the motorcycle as possible Do not attach large or heavy items such as a sleeping bag or tent to the handlebar fork or front ...

Page 16: ... an accessory be sure to read the following information We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your dealer for assistance and always follow this...

Page 17: ... change its design or operation Such changes could seriously impair your motorcycle s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your area 05 03 30 19 57 57 31KPS630_017 ...

Page 18: ...rcycle Some labels warn you of potential hazards that could cause serious injury Others provide important safety information Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your Honda dealer for a replacement 05 03 30 19 58 06 31KPS630_018 ...

Page 19: ...10 Motorcycle Safety 05 03 30 19 58 08 31KPS630_019 ...

Page 20: ...section carefully before you ride It describes the location function and operation of all the basic controls on your motorcycle Operation Component Locations 12 Fuel Valve 15 Choke Lever 16 Ignition Switch 17 Start Button 18 Engine Stop Button 18 Front Brake Lever 18 Throttle 18 Clutch Lever 19 Shift Lever 19 Rear Brake Pedal 19 Side Stand 19 05 03 30 19 58 13 31KPS630_020 ...

Page 21: ...clutch lever engine stop button ignition switch front brake lever start button throttle grip 12 Operating Controls Operation Component Locations 05 03 30 19 58 18 31KPS630_021 ...

Page 22: ...rear brake pedal 13 Operation Component Locations Operating Controls 05 03 30 19 58 22 31KPS630_022 ...

Page 23: ...choke lever shift lever fuel valve 14 Operation Component Locations Operating Controls 05 03 30 19 58 27 31KPS630_023 ...

Page 24: ...ank to the carburetor Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON OFF RES 05 03 30 19 58 35 31KPS630_024 ...

Page 25: ...fueling to avoid running out of fuel with no reserve The choke lever is used for starting the engine page The choke increases the percentage of fuel in the fuel air mixture delivered to the engine Used to start a cold engine with air temperature below 35 C 95 F Used for normal operation for restarting a warm engine or starting a cold engine with air temperature above 35 C 95 F Used to warm a cold ...

Page 26: ...tral the engine can be started OFF ON 1 1 ignition switch FRONT OFF ON OFF ON 17 Operating Controls Operating Controls Ignition Switch The ignition switch is used to prevent unauthorized use of the motorcycle Before riding insert the key and turn it to the ON position After parking the motorcycle remove the key 05 03 30 19 58 55 31KPS630_026 ...

Page 27: ...engine off during normal riding situations To operate push the button in and hold it in until the engine stops completely The front brake lever is used to slow or stop your motorcycle To operate pull the lever For information on braking techniques see page The throttle controls engine rpm speed To increase engine rpm rotate the grip toward you To reduce engine rpm rotate the grip away from you The...

Page 28: ...xt higher or lower gear in the transmission To operate raise the shift lever after pulling in the clutch lever to engage the next higher gear or depress the shift lever to engage the next lower gear See page The rear brake pedal is used to slow or stop your motorcycle To operate depress the pedal For information on braking techniques see page The side stand is used to support your motorcycle while...

Page 29: ...20 Operating Controls 05 03 30 19 59 15 31KPS630_029 ...

Page 30: ...dy to ride To help get you prepared this section discusses how to evaluate your riding readiness and how to perform the recommended pre ride inspection of your Honda Are You Ready to Ride 22 Protective Apparel 22 Is Your Motorcycle Ready to Ride 24 Pre ride Inspection 24 05 03 30 19 59 20 31KPS630_030 ...

Page 31: ...rotection is not possible wearing the proper gear can reduce the chance of injury when you ride Following are suggestions to help you choose the proper gear read this owner s manual make sure you understand all the safety messages know how to operate all the controls Before each ride we also suggest that you make sure you are in good physical and mental condition are free of alcohol and drugs are ...

Page 32: ...in strap that can be tightened securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy USA only Always wear a face shield or goggles to protect your eyes and help your vision In addition to a helmet and eye protection we also recommend Riding pants with knee and hip pads...

Page 33: ...the motorcycle Use a gauge to check the air pressure Adjust if needed Also look for signs of damage or excessive wear page Make sure the spokes and rim locks are tight Also check the rims for damage page Look under the motorcycle for signs of leaking fluids fuel engine oil brake fluid Before each ride it s important to inspect your motorcycle and make sure any problem you find is corrected A pre r...

Page 34: ...fuel fill cap is securely fastened Check the condition and slack Adjust and lubricate if needed Also check the chain guide slider and slipper for wear and replace if needed page Check for looseness page Use a wrench to make sure all accessible nuts bolts and fasteners are tight Check the cable housings for wear Check the fittings for looseness Replace or tighten as needed 65 60 106 80 05 03 30 20 ...

Page 35: ...s after you get on the motorcycle Check the freeplay and adjust if needed Rotate the throttle to make sure it moves smoothly without sticking and snaps shut automatically when it is released in all steering positions page Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally pages Check for proper freeplay pages Adjust freeplay if necessary page...

Page 36: ...nformation how to make turns ride on hills etc see the booklet that came with your Honda USA only To protect your new engine and enjoy optimum performance and service life refer to Break in Guidelines page For information about carburetor adjustment for riding at high altitude see page Safe Riding Precautions 28 Starting Stopping the Engine 29 Preparation 29 Starting Procedure 29 Flooded Engine 31...

Page 37: ...me familiar with how this motorcycle works and handles Practice in a safe area until you build up your skills and get accustomed to your motorcycle s size and weight For your safety avoid starting or operating the engine in an enclosed area such as a garage Your motorcycle s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Your...

Page 38: ...ways follow the proper starting procedure described below Before starting insert the key and turn the ignition switch ON Make sure that the transmission is in neutral Turn the fuel valve ON Your motorcycle can be started with the transmission in gear by pulling in the clutch lever before operating the starter cont d Normal Air Temperature 10 35 C 50 95 F Pull the choke lever up all the way to full...

Page 39: ...the engine starts push the choke lever down all the way to fully OFF If idling is unstable open the throttle slightly High Air Temperature 35 C 95 F or above Do not use the choke Start the engine following step under Low Air Temperature 10 C 50 F or below Follow steps under Warm up the engine by opening and closing the throttle slightly Continue warming up the engine until it will idle smoothly wi...

Page 40: ...peated attempts it may be flooded with excess fuel To clear a flooded engine Push the choke lever down all the way to OFF Open the throttle fully Release the engine stop button Follow the starting procedure page While pushing the engine stop button press the start button for 5 seconds 2 3 1 4 5 30 05 03 30 20 00 58 31KPS630_040 ...

Page 41: ...ting Stopping the Engine Basic Operation Riding How to Stop the Engine To stop the engine shift into neutral push the engine stop button in and hold it in until the engine stops 05 03 30 20 01 02 31KPS630_041 ...

Page 42: ...l If engine rpm is too high or you release the clutch lever too quickly your motorcycle may lurch forward Release the front brake Gradually open the throttle while you slowly release the clutch lever Depress the shift lever from neutral down to first gear To start riding after the engine has been warmed and the side stand raised Close the throttle and pull the front brake lever in Pull the clutch ...

Page 43: ...o shift down to a lower gear close the throttle pull the clutch lever in and depress the shift lever After shifting release the clutch lever and apply the throttle Remember to close the throttle and pull the clutch lever in completely before shifting To continue shifting up to each higher gear repeat step Learning when to shift gears comes with experience Upshift to a higher gear or reduce throttl...

Page 44: ...use one or both wheels to slip Any wheel slip will reduce your control of your motorcycle When riding in wet or rainy conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Rapid acceleration braking or turning may cause loss of control For your safety exercise extreme caution when braking accelerating or turning...

Page 45: ...king by downshifting with intermittent use of both brakes When you brake to a stop pull the clutch lever in before stopping completely to prevent stalling the engine For support put your left foot on the ground first then your right foot when you re through braking 05 03 30 20 01 32 31KPS630_045 ...

Page 46: ...ing Lower the side stand to support your motorcycle Turn the ignition switch OFF and remove the key If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park 05 03 30 20 01 35 31KPS630_046 ...

Page 47: ...oroughly clean your motorcycle and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your motorcycle for leaks or damage Be sure to lubricate the drive chain page to prevent rusting 110 05 03 30 20 01 40 31KPS630_047 ...

Page 48: ...n good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good cont d For information about the exhaust emission and noise emission requirements of the U S Environmental Protection Agency EPA and the California...

Page 49: ...er Removal 57 Fluids Filters Fuel 59 Engine Oil 62 Air Cleaner 68 Crankcase Breather 72 Engine Throttle 73 Clutch System 76 Engine Idle Speed 79 Spark Plug 80 Spark Arrester 82 Chassis Suspension 84 Brakes 87 Wheels 95 Tires Tubes 101 Side Stand 105 Drive Chain 106 Electrical Battery 113 Appearance Care 118 05 03 30 20 01 53 31KPS630_049 ...

Page 50: ...major parts even if you are able to make some repairs A well maintained motorcycle is essential for safe economical and trouble free riding It will also help reduce air pollution Careful pre ride inspections and good maintenance are especially important because your motorcycle is designed to be ridden over rough off road terrain To help you properly care for your motorcycle this section of the man...

Page 51: ...aintenance Servicing Your Honda Remember proper maintenance is the owner s responsibility Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section 05 03 30 20 02 04 31KPS630_051 ...

Page 52: ... on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task cont d Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Be...

Page 53: ...over park it on a firm level surface using the side stand or a maintenance stand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a non flammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 05 03 30 20 02 15 31KPS630_053 ...

Page 54: ...items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for pur...

Page 55: ...quire more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer Replace every 2 years Replacement requires mechanical skill Maintenan...

Page 56: ...tools and service data and is mechanically qualified Refer to the official Honda Service Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer Note 1 I R I C I I I R I I I C I I I R C C I C I I I R I I I C I I I R C C I Fuel Line Throttle Operation Air Cleaner Crankcase Breather Spark Plug Valve Clearance Engine Oil Engine Oil Strainer Screen Engine O...

Page 57: ...cial Honda Service Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer Note 1 Note 2 I L I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Drive Chain Drive Chain Slider Brake Fluid Brake Shoes Pads Wear Brake System Clutch System Side Stand Suspension Spark Arrester Nuts Bolts Fasteners Wheels Tires Steering Head Bearings 10...

Page 58: ...space under Notes to record anything you want to remind yourself about or mention to your dealer Of course if you find any problem while servicing your motorcycle be sure it is corrected as soon as possible 600 1 000 or 6 1 200 2 000 or 12 1 800 3 000 or 18 2 400 4 000 or 24 3 000 5 000 or 30 3 600 6 000 or 36 4 200 7 000 or 42 4 800 8 000 or 48 5 400 9 000 or 54 05 03 30 20 03 17 31KPS630_058 ...

Page 59: ...See your Honda dealer unless you are mechanically qualified and have the proper tools Refer to the Maintenance Schedule page for regular service intervals NOTE 46 1 2 3 4 5 6 all pre ride inspection items engine oil fuel line valve clearance engine idle speed carburetor choke contaminants deterioration damage or leakage correct clearance correct idle speed proper operation change replace adjust ad...

Page 60: ... plug steering head bearings front suspension rear suspension 7 8 9 10 11 12 proper operation see NOTE 1 contamination or tears gap tightness proper heat range high tension terminal security free rotation of handlebar and steering stem nut tightness smooth operation oil capacity no oil leaks good boot condition smooth operation no oil leaks replace clean or replace tighten replace or secure adjust...

Page 61: ...18 19 20 swingarm bearings rear suspension linkage bushings brake pads drive chain max length pin sprockets seat control cables engine mounting bolts wear and secure installation security smooth operation kinks and correct routing tightness replace replace replace replace replace or tighten tighten lubricate or replace tighten 85 85 90 108 109 05 03 30 20 03 49 31KPS630_061 ...

Page 62: ...clutch lever front brake lever fuel fill cap throttle grip front brake fluid reservoir 53 Maintenance Component Locations Servicing Your Honda 05 03 30 20 03 55 31KPS630_062 ...

Page 63: ...rear brake pedal spark arrester air cleaner spark plug engine oil filler cap dipstick 54 Servicing Your Honda Maintenance Component Locations 05 03 30 20 03 59 31KPS630_063 ...

Page 64: ...lt engine idle speed choke lever drive chain engine oil strainer screen front brake caliper crankcase breather tube battery main fuse 55 Servicing Your Honda Maintenance Component Locations 05 03 30 20 04 04 31KPS630_064 ...

Page 65: ...Safety Precautions Refer to on page The spark plug wrench and its handle are stored in the tool bag delivered with your motorcycle You will need to provide your own tools to perform any owner maintenance other than removing the spark plug 2 1 43 3 05 03 30 20 04 10 31KPS630_065 ...

Page 66: ...ver must be removed to service the air cleaner Remove the screw Pull both side cover prongs out of the rubber grommets Right Side Cover Installation Slide the top of the side cover under the bottom edge of the seat Align the side cover prongs with the rubber grommets Press the side cover into position Install the securing screw and tighten it 1 1 2 2 3 43 2 1 3 4 05 03 30 20 04 20 31KPS630_066 ...

Page 67: ...lign the side cover prongs with the rubber grommets Press the side cover into position Install the securing screw and bolts and tighten them Left Side Cover Installation Remove the screw bolt A and bolt B Pull both side cover prongs out of the rubber grommets Left Side Cover Removal The left side cover must be removed to service the battery and main fuse and to check the color label 1 1 2 2 3 43 1...

Page 68: ...ngine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Your engine is designed to use an...

Page 69: ...breather tube 4 3 3 steering stem nut 4 filler neck 60 Refueling Procedure Fuel Servicing Your Honda Reserve Capacity Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck Fuel Tank Capacity including reserve To open the fuel fill cap pull the breather tube out of the steering stem nut Turn the fuel fill cap countercloc...

Page 70: ...a After refueling turn the fuel fill cap clockwise until it is secure If you replace the fuel fill cap use only a genuine Honda replacement part Insert the breather tube in the steering stem nut 3 4 05 03 30 20 04 55 31KPS630_070 ...

Page 71: ... suggested oil 62 Oil Recommendation Engine Oil Servicing Your Honda Safety Precautions Refer to on page Using the proper oil and regularly checking adding and changing oil will help extend your engine s life Even the best oil wears out Changing oil helps get rid of dirt and deposits held in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with insuff...

Page 72: ...e circular API service label Your motorcycle does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or higher oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Do not use non detergent vegetable or castor ba...

Page 73: ...when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification 05 03 30 20 05 24 31KPS630_073 ...

Page 74: ...and remove the oil filler cap dipstick Wipe it clean Hold the motorcycle upright Insert the oil filler cap dipstick until it seats but do not screw it in Remove the oil filler cap dipstick and check the oil level Check for oil leaks Insert the oil filler cap dipstick and screw it in tightly If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the low...

Page 75: ...t it idle for 3 5 minutes Turn the engine off Wait 2 3 minutes for the oil to settle Remove the oil filler cap dipstick Place a drain pan under the crankcase Remove the oil drain bolt O ring spring and oil strainer screen Pour the drained oil into a suitable container and dispose of it in an approved manner page Park your motorcycle on its side stand on a firm level surface 1 2 3 4 5 6 1 2 3 4 129...

Page 76: ...that the oil strainer screen sealing rubber and drain bolt O ring are in good condition Install the oil strainer screen spring and drain bolt Pour the recommended oil into the crankcase approximately Install the oil filler cap dipstick securely Tighten the oil drain bolt to the specified torque Install the O ring to the oil drain bolt Start the engine and let it idle for 3 5 minutes Stop the engin...

Page 77: ...ust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your motorcycle s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quali...

Page 78: ...ner 4 5 69 Cleaning Air Cleaner Servicing Your Honda Remove the right side cover page Remove the screws and air cleaner housing cover Remove the air cleaner Unhook the set spring take care to avoid bending the set spring and set spring holder cont d 4 1 2 3 3 1 2 5 4 57 05 03 30 20 06 15 31KPS630_078 ...

Page 79: ... gently squeeze out the remaining solvent Avoid twisting or wringing the air cleaner This can tear the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil Remove the air cleaner holder from the air cleaner 7 5 6 8 6 5 05 03 30 20 ...

Page 80: ...spreading the oil into the air cleaner Assemble the air cleaner and holder Insert the tabs in the air cleaner holes Apply a thin coat of grease to the sealing surface of the air cleaner Clean the inside of the air cleaner housing Install the right side cover page Install the air cleaner housing cover and screws Install the air cleaner assembly by inserting the upper tab on the cleaner into the upp...

Page 81: ... Your Honda Crankcase Breather Safety Precautions Refer to on page Drain the deposits by pinching the plug Service more frequently if your motorcycle is ridden in the rain or often at full throttle 43 1 05 03 30 20 06 38 31KPS630_081 ...

Page 82: ...nda Safety Precautions Refer to on page Minor adjustments are generally made with the upper adjuster Upper Adjustment Check freeplay Freeplay Inspection If necessary adjust to the specified range Pull the rubber dust cover back Loosen the upper lock nut on the throttle cable mechanism Turn the upper adjuster cont d 1 2 3 1 1 2 3 43 05 03 30 20 06 50 31KPS630_082 ...

Page 83: ...d for major freeplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you can not get the proper adjustment with the upper adjuster Tighten the lock nut Return the dust cover to its normal position If you can t get the freeplay within the specified range contact your Honda dealer Loosen the lower lock nut Turn the lower adjuster Tighten the lock ...

Page 84: ...that the throttle assembly is positioned properly and the securing bolts are tight Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced Check the cables for tension or stress in all steering positions Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 2 ...

Page 85: ...r clutch assembly adjuster Refer to on page Upper Adjustment Minor adjustments are generally made with the upper clutch cable adjuster Pull the rubber dust cover back Loosen the upper lock nut Turn the upper clutch cable adjuster to obtain the specified freeplay Inspection Check freeplay Freeplay If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wea...

Page 86: ... nut Check the adjustment Tighten the lock nut and check the freeplay again Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in to provide maximum freeplay Tighten the upper lock nut and pull the dust cover back to its normal position cont d Return the dust cover to its normal position The lower clutch cable adjuster is used if the upper clutch cable adjuster is threa...

Page 87: ...u can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the official Honda Service Manual page Check that the clutch lever assembly is positioned properly and the securing bolts are tight Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and ...

Page 88: ...stment Ten minutes of stop and go riding is sufficient Do not attempt to compensate for faults in other systems by adjusting idle speed See your Honda dealer for regularly scheduled carburetor adjustments Warm up the engine shift to neutral and place the motorcycle on its stand Connect a tachometer following the tachometer manufacturer s instructions Adjust idle speed with the throttle stop screw ...

Page 89: ...th an improper heat range can cause engine damage Refer to on page Use only the recommended type of spark plugs in the recommended heat range The recommended standard spark plug is satisfactory for most riding conditions However if you plan to ride for extended periods at high speeds or near maximum power high engine rpm in hot climates or plan extended riding in cold climates a different plug may...

Page 90: ...gauge If adjustment is necessary bend the side electrode carefully The gap should be Inspect the spark plug electrodes for wear The center electrode should have square edges The side electrode should not be eroded The insulator should not be cracked or chipped If installing a new plug tighten it twice to prevent loosening If the old plug is good 1 8 turn after it seats First tighten the plug NGK t...

Page 91: ...ular servicing prevents carbon buildup which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment Allow the engine and muffler to cool Remove the bolts the spark arrester and the gasket from the muffler 1 2 43 2 1 4 ...

Page 92: ...ter screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary Install the spark arrester and the gasket in the muffler and tighten the bolts securely 3 4 05 03 30 20 08 34 31KPS630_092 ...

Page 93: ... motorcycle If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Check fork operation Pull the front brake lever in to lock the brake Then pump up and down on the fork legs several times The suspension should function smoothly There should be no oil leakage 1 43 ...

Page 94: ... Servicing Your Honda Check the security of all handlebar and fork mounting bolts If any front suspension components appear worn or damaged see your Honda dealer for further inspection Place the motorcycle on a maintenance stand Push hard against the side of the rear wheel and feel for any freeplay which indicates worn swingarm bearings cont d 1 1 2 1 05 03 30 20 08 50 31KPS630_094 ...

Page 95: ...hock absorber attachment points and rear suspension linkage attachment points are secure Check for oil leaks in the shock absorber If any rear suspension components appear worn or damaged see your Honda dealer for further inspection 2 3 3 2 05 03 30 20 08 56 31KPS630_095 ...

Page 96: ...s the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop If the front brake lever freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page there is probably air in the brake system See your Honda dealer to have the air bled from the system Never use adjusters other tha...

Page 97: ...sition the brake lever farther away from the handgrip turn the adjuster clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise Loosen the lock nut Pull the rubber dust cover back Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay If brake lever freeplay is not within this range see your Honda dealer 1 2 3 ...

Page 98: ...he level is at or below the LOWER level mark check the brake pads for wear page Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container or an equivalent Other Inspections Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings 1 90 05 ...

Page 99: ...at each regular maintenance interval page Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set See your Honda dealer for this service The recommended brake fluid is Honda DOT 4 Brake Fluid or any brake fluid of equal equality and performance Use fresh brake fluid from a sealed container Brake fluid should be added and replaced by your Honda dealer Check that ...

Page 100: ...ke Pedal Freeplay Brakes Servicing Your Honda Inspection Place your motorcycle on its side stand Check freeplay by slowly depressing the brake pedal until the brake starts to engage If necessary adjust to the specified range 1 2 Freeplay 1 05 03 30 20 09 39 31KPS630_100 ...

Page 101: ...ithout disassembly Application of the brake control pedal causes the arrow on the brake arm to move toward a reference mark on the brake panel Check the freeplay If you can t adjust the freeplay properly see your Honda dealer Apply the brake release it and then spin the wheel and check that it rotates freely Repeat this procedure several times Turn the rear brake adjusting nut Make sure the cut ou...

Page 102: ...are tight Apply the brake control pedal and check the movement of the arrow on the brake arm Replace the brake shoes if the arrow aligns with the reference mark on the brake panel upon full application of the brake If replacement is necessary see your Honda dealer Make sure the brake rod brake arm spring and fasteners are in good condition 1 2 4 3 1 2 05 03 30 20 09 58 31KPS630_102 ...

Page 103: ...r bolt 1 2 RIGHT SIDE 94 Rear Brake Pedal Height Adjustment Brakes Servicing Your Honda Loosen the lock nut and turn the stopper bolt Tighten the lock nut Check the freeplay page 1 2 3 1 2 91 05 03 30 20 10 05 31KPS630_103 ...

Page 104: ... spoke tension and wheel trueness roundness is critical to safe motorcycle operation During the first 100 miles 150 km spokes will loosen more rapidly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control Neglecting this maintenance may also cause rim or spoke damage It s also important that the rim locks are secu...

Page 105: ... Inspect the wheel rims and spokes for damage Tighten any loose spokes or rim locks Rotate the wheel slowly to see if it appears to wobble If it does the rim is out of round or not true If the wobble is noticeable see your Honda dealer for inspection 1 1 2 2 3 3 05 03 30 20 10 19 31KPS630_105 ...

Page 106: ...rcycle with tie down straps Remove the front axle holder nuts and the front axle holder Avoid depressing the brake lever when the wheel is off the motorcycle This will force the caliper pistons out of the cylinders The result will be loss of brake fluid If this occurs the brake system will require service See your Honda dealer for this service Unscrew and remove the front axle shaft Remove the whe...

Page 107: ...he same torque After installing the wheel apply the brake several times and then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely Check front brake adjustment page If a torque wrench was not used to install the wheel see your Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity...

Page 108: ...rake rod from the brake arm by pushing down on the rear brake pedal Take care to prevent getting grease oil or dirt on the brake shoe surfaces This can cause poor brake performance or rapid brake shoe wear after reassembly Unscrew the rear axle nut Pull the rear axle shaft out Push the wheel forward and derail the drive chain from the rear sprocket Remove the wheel and side collar Turn both chain ...

Page 109: ...djusters are installed properly Adjust the drive chain page Tighten the rear axle nut to the specified torque If a torque wrench was not used to install the wheel see your Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity Apply the rear brake release it then spin the wheel and check that it rotates freely Repeat this procedure several...

Page 110: ...e detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement Make sure the valve stem caps are secure If necessary install a new cap Properly inflated tires provide the best combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handl...

Page 111: ...n for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are A flat tire or blowout is inconvenient and may even cause an accident Take time to inspect your tires and wheels before you ride For more information about handling flat tires see page If you decide to adjust tire...

Page 112: ...d carefully inspect the tire as described on page Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Check the position of both valve stems A tilted valve s...

Page 113: ...es Servicing Your Honda The tires that came on your motorcycle were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions We recommend that tires be replaced by your Honda dealer Have the wheel balanced after a new tire is installed Replace the tube any time you replace a tire The old tube will probably be stretched and if insta...

Page 114: ...ions Refer to on page Check the side stand spring for damage and loss of tension Check the side stand assembly for freedom of movement If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clean engine oil 1 2 1 43 05 03 30 20 11 44 31KPS630_114 ...

Page 115: ...the motorcycle is ridden in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF lower the side stand and check that your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule Check slack in the lower drive chain run midway between...

Page 116: ...ace the drive chain page if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed Check the chain slider chain guide slider chain roller and lower slider for wear If the chain slider and lower slider are worn to the bottom of the cu...

Page 117: ...est limit of adjustment Excessive slack indicates the chain is worn beyond its service limit To check the chain s service limit measure the distance between a span of pins from pin center to pin center If the distance exceeds the service limit the drive chain is worn out and should be replaced This motorcycle has a staked master link drive chain which requires a special tool for cutting and stakin...

Page 118: ...D REPLACE 109 Drive Chain Servicing Your Honda Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your Honda dealer replace a worn sprocket 6 05 03 30 20 12 24 31KPS630_118 ...

Page 119: ...se or decrease chain slack If a torque wrench is not used for this installation see your Honda dealer as soon as possible to verify proper assembly Check rear brake pedal freeplay and adjust as necessary page Freeplay is affected when repositioning the rear wheel to adjust drive chain slack Recheck drive chain slack Torque the rear axle nut to After adjusting be sure the same adjuster index marks ...

Page 120: ... oil Commercial chain lubricants may contain solvents which could damage the rubber O rings Lubricate every 300 miles 500 km or sooner if chain appears dry The O rings in this chain can be damaged by steam cleaning high pressure washers and certain solvents 05 03 30 20 12 45 31KPS630_120 ...

Page 121: ...the side surfaces of the chain with a dry cloth Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rings Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceable Replacement chain Inspect the sprocket teeth for wear or damage We recommend replacing the s...

Page 122: ...you remove the battery or at least disconnect the battery cables negative cable first If you plan to store your motorcycle see page If your battery seems weak and or is leaking electrolyte causing slow starting or other electrical problems see your Honda dealer Electrical accessories use current from the battery even when the ignition is OFF Limited operation also allows the battery to discharge I...

Page 123: ...r to on page Before you remove the battery be sure to read all the information that follows as well as the information on the battery label You will get the best storage results from removing the battery and slow trickle charging it every 30 days see page If you do not remove the battery we recommend disconnecting the battery cables negative cable first If you plan to store your motorcycle we reco...

Page 124: ...battery compartment behind the left side cover cont d Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Pull the battery out of the battery compartment Remove the battery holder Remove the left side cover page Make sure the ignition switch is OFF Removal 1 2 3 2 3 4 4 5 58 1 05 03 30 20 13 23 31KPS630_124 ...

Page 125: ...nd direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if paint is missing re paint the area Slow charge the battery see following section once every 30 days Installation Reinstall in the reverse order of removal Be sure to connect the positive terminal first then the negative terminal Check all bolts and other fasteners are secure 6 7 8 9 1 2 05 03...

Page 126: ...t intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage Refer to on page Be sure to read the information that came with your battery charger and follow the instructions on the battery Improper charging may damage...

Page 127: ...e you re cleaning be sure to look for damage wear and gasoline or oil leaks To clean your motorcycle you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your motorcycle If your motorcycle is sti...

Page 128: ... stop button Rinse your motorcycle thoroughly with cool water to remove loose dirt Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles Wash your motorcycle with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime After washin...

Page 129: ...rusting Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance 6 7 8 05 03 30 20 14 06 31KPS630_129 ...

Page 130: ...for an off road adventure how to transport and store your Honda and how to be an environmentally responsible motorcycle owner Preparing for a Ride 122 Transporting Your Honda 124 Storing Your Honda 126 You the Environment 129 05 03 30 20 14 11 31KPS630_130 ...

Page 131: ...he Bureau of Land Management USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trailer include a tool kit tire repair supplies and tools tubes and tires wire duct tape and rope extra ga...

Page 132: ...ends on the kind of terrain how long you expect to ride how far you might go from your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure you can carry them safely and know how to use them Also be sure to follow the loading guidelines and weight limit page 6 05 03 30 20 14 27 31KPS63...

Page 133: ...railer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Use a loading ramp Make sure the fuel valve is off Secure the motorcycle in an upright position using motorcycle tie down straps Avoid using rope which can loosen and allow the motorcycle to fall ove...

Page 134: ...ront suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that you do not transport your motorcycle on its side This can damage the motorcycle and leaking gasoline could be a hazard 05 03 30 20 14 39 31KPS630_134 ...

Page 135: ...toring it That way needed repairs won t be forgotten and it will be easier to get your motorcycle running again For more information about storage refer to the available from your Honda dealer USA only We suggest you perform the following procedures to keep your motorcycle in top condition These storage procedures will reduce the deterioration that can occur during storage 05 03 30 20 14 44 31KPS6...

Page 136: ...rage Storing Your Honda Tips Change the engine oil page Drain the carburetor into an approved gasoline container and dispose of it in an approved manner page If storage will last longer than one month carburetor draining is important to assure proper performance after storage Check that the fuel valve is OFF Fill the fuel tank Make sure the fuel fill cap is properly installed cont d 1 2 3 4 66 129...

Page 137: ...te Store your motorcycle in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation Inflate the tires to their recommended pressures page Lubricate the drive chain Wash and dry your motorcycle Perform a pre ride inspection page then test ride your motorcycle at low speeds Lubricate the drive chain Remove the battery and charge it fully Store it in an area...

Page 138: ... damaged and ride only in areas approved for off road vehicles Loud motorcycles can be offensive Ride as quietly as possible don t remove your spark arrester and don t modify the muffler or any other part of your air intake and exhaust systems Such modifications not only increase noise they also reduce engine performance and may be illegal Use a biodegradeable detergent when you wash your motorcyc...

Page 139: ...d contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and get instructions on how to dispose of non recyclable wastes 05...

Page 140: ...ction gives practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines 132 If Your Engine Quits or Won t Start 133 If You Have a Flat Tire 137 If a Fuse Blows 138 If You Crash 140 If You Lose Your Key 141 If a Component Fails 142 If Your Battery Is Low or Dead 143 122 05 03 30 20 15 21 31KPS630_140 ...

Page 141: ... decide what to do Whatever the problem the most important rules are If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and continue riding Or you may be able to make a temporary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help When a problem is more s...

Page 142: ...on Additional recommendations for specific problems follow Proper operation and maintenance can prevent starting and engine performance problems In many cases the cause of the problem may be a simple operational oversight If you have a problem starting the engine or experience poor engine performance the following information may help you If you can t correct the problem see your Honda dealer If y...

Page 143: ... into neutral Replace with a new fuse of the same rating page Tighten the battery lead Charge the battery page If charging doesn t help see your Honda dealer If all possible causes are negative the starter motor may be faulty See your Honda dealer 117 138 Starter motor doesn t operate 134 Taking Care of the Unexpected Taking Care of the Unexpected 05 03 30 20 15 49 31KPS630_143 ...

Page 144: ...age If charging doesn t help see your Honda dealer Check engine idle adjustment page If the problem persists see your Honda dealer See your Honda dealer See your Honda dealer Install the spark plug cap securely If the engine still won t start see your Honda dealer loose or unconnected spark plug cap 31 117 79 Starter motor works but the engine won t start Engine starts but runs poorly Flooded Engi...

Page 145: ... switched OFF See your Honda dealer If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer See your Honda dealer See your Honda dealer 59 Engine starts but runs poorly cont d 136 Taking Care of the Unexpected Taking Care of the Unexpected 05 03 30 20 16 17 31KPS630_145 ...

Page 146: ...tube patch kit to repair the puncture This requires removing the tire If the leak is more serious or a temporary repair doesn t hold the tube must be replaced The tire will also need to be replaced if it is damaged page Replacing a tube or tire involves removing and re installing the wheel pages If you are unable to repair a flat tire on the trail you will need to push the motorcycle back to your ...

Page 147: ...ng you should check for is a blown fuse Check the fuse before looking elsewhere for another possible cause of the problem Replace the blown fuse and check component operation All of the electrical circuits on your motorcycle have a fuse to protect them from damage caused by excess current flow short circuit or overload 05 03 30 20 16 31 31KPS630_147 ...

Page 148: ...in fuse remove the left side cover page Remove the starter magnetic switch from the battery box Disconnect the wire connector of the starter magnetic switch Pull the fuse out If the main fuse is blown install a new main fuse Install the left side cover To prevent an accidental short circuit turn the ignition switch OFF before checking or replacing the fuse Reconnect the wire connector Install the ...

Page 149: ...ly inspect your motorcycle for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor damage or you are unsure about possible damage but decide to try riding the motorcycle back to your base ride slowly and cautiously Sometimes crash damage is hidden or not immediately apparen...

Page 150: ... lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer you purchased your Honda from They may have it listed in their records If they don t transport your motorcycle to them or the nearest Honda dealer The dealer will probably have to remove the ignition switch assembly to find the key number so they can make a key fo...

Page 151: ...e then ride carefully back to base using the rear brake for slowing or stopping If any component of the front brake system is damaged you may be able to ride carefully back to your base using the rear brake for slowing or stopping The drive chain brake lever or pedal control cables and other components can be damaged as you ride in dense brush or over rocky terrain Making a trailside repair depend...

Page 152: ...specially if you use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your motorcycle s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer 05 03 30 20 17 07 31KPS630_152 ...

Page 153: ...144 Taking Care of the Unexpected 05 03 30 20 17 10 31KPS630_153 ...

Page 154: ...nd other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification 146 Specifications 148 Break in Guidelines 153 High Altitude Carburetor Adjustment 154 Emission Control Systems 155 Oxygenated Fuels 159 05 03 30 20 17 15 31KPS630_154 ...

Page 155: ...ine serial numbers are required when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the section at the rear of the manual The engine number is stamped on the left side of the engine The frame number is stamped on the right side of the steering head 1 2 05 03 30 20 17 24 31KPS630_155 ...

Page 156: ...hnical Information Quick Reference The color code is helpful when ordering replacement parts You may record the color and code in the section at the rear of the manual The color label is attached to the frame behind the left side cover page 1 58 05 03 30 20 17 30 31KPS630_156 ...

Page 157: ...1 US qt 1 0 after disassembly 1 3 US qt 1 2 premium unleaded gasoline pump octane number of 91 or higher Overall length Overall width Overall height Wheelbase Fuel tank capacity Fuel tank reserve Fuel recommendation Engine oil capacity Dimensions Fuel Lubricants 148 Specifications Technical Information 05 03 30 20 17 42 31KPS630_157 ...

Page 158: ...Honda 4 stroke oil Canada only or an equivalent motorcycle oil Air cleaner oil API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 40 JASO T 903 standard MA Displacement Bore stroke Compression ratio Passenger capacity Maximum weight capacity Cargo capacity Engine oil recommendation Drive chain lubricant Fuel Lubricants Engine ...

Page 159: ... 035 in 0 80 0 90 mm 1 400 100 rpm Intake Exhaust or or Primary reduction Gear ratio 1st 2nd 3rd 4th 5th 6th Final reduction Final drive Valve clearance cold Spark plug standard Spark plug cold climate below 5 C 41 F Spark plug gap Idle speed Power Transmission Engine Specifications 150 Specifications Technical Information 05 03 30 20 18 07 31KPS630_159 ...

Page 160: ...le travel 8 5 in 216 mm 15 psi 100 kPa 1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm bias ply tube Drive chain freeplay New chain length Used chain service limit length Caster Trail Tire size front Tire size rear Tire type Tire pressure front cold Tire pressure rear cold Suspension front Suspension rear Power Transmission Chassis Suspension 151 Specifications Technical Information 05 05 06 12 15 43 31KPS63...

Page 161: ... 11 0 kgf m 12 V 4 Ah 0 06 kW 5 000 rpm 7 5 A 54 lbf ft 73 5 N m 7 5 kgf m Oil drain bolt Front wheel axle Axle holder nuts Rear wheel axle main battery generator Torque Specifications Fuse Electrical 152 Specifications Technical Information 05 05 13 10 38 45 31KPS630_161 ...

Page 162: ... assure your motorcycle s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration 05 03 30 20 18 34 31KPS630_162 ...

Page 163: ...the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 6 500 feet 2 000 meters have your servicing dealer perform this carburetor modification...

Page 164: ...es 3 000 km after the time of sale to the ultimate purchaser when operated and maintained according to the instructions provided USA only The U S Environmental Protection Agency EPA and the California Air Resources Board CARB require that your motorcycle comply with applicable exhaust emission standards during its useful life when operated and maintained according to the instructions provided The ...

Page 165: ... Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons The exhaust emission control system is composed of appropriate carburetor settings No adjustments should be made except for an idle speed adjustment with the throttle stop screw or carburetor adjustment for high altitude operation The exhaust emission control system is separate from the crankcase e...

Page 166: ...ntrol prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper maintenance...

Page 167: ...g or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engine s emission performance unless your motorcycle will be used exclusively in competition If you modify your engine for use in sanctioned competition events you must deface or destro...

Page 168: ...minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline...

Page 169: ...her service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately 05 03 30 20 19 20 31KP...

Page 170: ...contains information on your warranty and how to get an official Honda service manual Authorized Manuals 162 Warranty Coverage 165 Warranty Service 166 Contacting Honda 167 The Honda Rider s Club USA only 168 Your Honda Dealer 169 05 03 30 20 19 24 31KPS630_170 ...

Page 171: ... only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners shoul...

Page 172: ...harge Grand Total 5 00 163 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Inc at the address shown on the back of this order form USA only Can...

Page 173: ...Inc U S funds only Do not send cash MasterCard VISA Discover Date Customer Signature These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order Check here if your billing address is different from the shipping address shown above Expiration Mo Yr Account Number P O BOX 072...

Page 174: ...For more information see your Honda dealer It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle There are responsibilities restrictions and exclusions which apply to these warranties Please read the Honda Motorcycle Warranties Book...

Page 175: ...results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the repair it is best to talk to the service manager of your Honda dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling of...

Page 176: ...nces at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 866 784 1870 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the following info...

Page 177: ...ansport vehicle as long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Specialty Vehicle Institute of America ...

Page 178: ...ada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda The sales department offers the H...

Page 179: ...nt Locations 12 Fuel Valve 15 Choke Lever 16 Ignition Switch 17 Start button 18 Engine Stop Button 18 Front Brake Lever 18 Throttle 18 Clutch Lever 19 Shift Lever 19 Rear Brake Pedal 19 Side Stand 19 Are You Ready to Ride 22 Protective Apparel 22 Is Your Motorcycle Ready to Ride 24 Pre ride Inspection 24 Safe Riding Precautions 28 Starting Stopping the Engine 29 Preparation 29 Starting Procedure 2...

Page 180: ... 45 Maintenance Record 49 Competition Inspection 50 Maintenance Component Locations 53 Tools 56 Side Cover Removal 57 Fluids Filters Fuel 59 Engine Oil 62 Air Cleaner 68 Crankcase Breather 72 Engine Throttle 73 Clutch System 76 Engine Idle Speed 79 Spark Plug 80 Spark Arrester 82 Chassis Suspension 84 Brakes 87 Wheels 95 Tires Tubes 101 Side Stand 105 Drive Chain 106 Electrical Battery 113 Appeara...

Page 181: ...129 General Guidelines 132 If Your Engine Quits or Won t Start 133 If You Have a Flat Tire 137 If a Fuse Blows 138 If You Crash 140 If You Lose Your Key 141 If a Component Fails 142 If Your Battery Is Low or Dead 143 Vehicle Identification 146 Specifications 148 Break in Guidelines 153 High Altitude Carburetor Adjustment 154 Emission Control Systems 155 Oxygenated Fuels 159 05 03 30 20 20 50 31KPS...

Page 182: ...NTS 170 INDEX 174 QUICK REFERENCE Table of Contents Table of Contents Authorized Manuals 162 Warranty Coverage 165 Warranty Service 166 Contacting Honda 167 The Honda Rider s Club USA only 168 Your Honda Dealer 169 05 03 30 20 20 54 31KPS630_182 ...

Page 183: ...lever front adjustment 87 pad wear 90 pedal rear 19 shoe wear 92 braking 35 break in guidelines 153 button engine stop 18 start 18 capacity fuel 60 carburetor high altitude adjustment 154 idle speed 79 choke lever 16 cleaner air 68 cleaning appearance care 118 clutch system adjustment 76 lever 19 color label 147 competition inspection 50 05 03 30 20 21 00 31KPS630_183 ...

Page 184: ...ion control systems 155 emission requirements 155 engine number 146 engine flooded 31 idle speed 79 pinging 59 starting 29 stop button 18 stopping 32 won t start 133 environment protecting 129 filter air 68 flat tire 137 flooded engine starting 31 fork 84 frame number 146 front brake lever 18 lever freeplay 87 front suspension 84 front wheel removal 97 05 03 30 20 21 08 31KPS630_184 ...

Page 185: ...recommendation 59 oxygenated 159 tank capacity 60 valve 15 gap spark plug 80 gasohol 159 gasoline 59 gears shifting 33 high altitude adjustment 154 Honda contacting 167 Honda service manual 162 idle speed engine 79 inspection competition 50 post ride 38 pre ride 24 05 03 30 20 21 16 31KPS630_185 ...

Page 186: ...pinging engine 59 plug spark 80 post ride inspection 38 pre ride inspection 24 reserve capacity fuel tank 60 rider training 3 169 riding basic operation 27 before 21 clothing 22 precautions 28 safety 2 rim lock 96 maintenance component locations 53 record 49 safety 43 schedule 45 manual service 162 modifications 8 05 03 30 20 21 22 31KPS630_186 ...

Page 187: ...2 spark knock 59 spark plug 80 specifications 148 stand side 19 105 start button 18 starting engine 29 stop button engine 18 stopping engine 32 storage 127 suspension front 84 rear 85 throttle freeplay 73 operation 18 tires air pressure 101 flat 137 replacing 104 tools 56 towing 34 training rider 3 169 transporting 124 troubleshooting starting 133 05 03 30 20 21 28 31KPS630_187 ...

Page 188: ...179 Index Index W V valve fuel 15 vehicle identification 146 warranty coverage 165 extended 165 service 166 washing your motorcycle 119 weight limit 6 wheels 95 05 03 30 20 21 33 31KPS630_188 ...

Page 189: ...ing because of improper installation poor seal Record important information on the following page Frequent causes of costly chassis repair are Chain A loosely adjusted chain or a chain stretched because of lack of lubrication may come off and damage an engine case or wheel hub Spokes Loose spoke may break and damage the wheel hub or rim Your Honda engine can be the most expensive component to repa...

Page 190: ... Quick Reference Record important information here Frame No Engine No Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 05 03 30 20 21 48 31KPS630_190 ...

Page 191: ...s rims leaks engine oil fuel drive chain cables nuts bolts spark plug and cap throttle brakes and clutch lever rider only no passenger or cargo and any accessories Tires Maximum Weight Capacity Engine Oil Fuel Capacity Tire Pressure cold premium unleaded gasoline pump octane number of 91 or higher tank reserve Spark Plug Fuse API Service Classification SG or higher except oils labeled as energy co...

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