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Honda CRF150F 2007, Owner'S Manual, Page: 87 / 191

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Honda CRF150F 2007 Owner'S Manual Download Page 87

CPR8EA-9 (NGK)
CPR9EA-9 (NGK)

Standard
For extended high
speed riding

RIGHT SIDE

(3)

(1)

(3) spark plug gap

(1) center electrode
(2) side electrode

(2)

78

Spark Plug Recommendation

Spark Plug

Servicing Your Honda

Saf ety Precautions

Using spark plugs with an improper heat range
can cause engine damage.

Refer to

on page

.

Use only the recommended type of spark plugs
in the recommended heat range.

The recommended standard 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 be recommended.

Clean any dirt from around the spark plug
base.

1.

43

06/03/20 11:06:43 31KPT640_087

Summary of Contents for CRF150F 2007

Page 1: ...tion includes the latest production information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured on the front cover may not match your vehicle 06 03 20 10 56 39 31KPT640_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 06 03 20 10 56 42 31KPT640_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 06 03 20 10 56 52 31KPT640_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 06 03 20 10 57 12 31KPT640_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: ...06 03 20 10 57 27 31KPT640_009 ...

Page 10: ...lp 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 Important Safety Information Loading Accessories Modifications Loading Accessories Modifications Safety Labels 2 5 5 7 9 06 03 20 10 57 33 31KPT640_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: ... 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 fend...

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 06 03 20 10 58 11 31KPT640_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 06 03 20 10 58 18 31KPT640_018 ...

Page 19: ...10 Motorcycle Safety 06 03 20 10 58 20 31KPT640_019 ...

Page 20: ...efully before you ride It describes the location function and operation of all the basic controls on your motorcycle Operation Component Locations Operating Controls Fuel Valve Choke Lever Ignition Switch Start Button Engine Stop Button Front Brake Lever Throttle Clutch Lever Shift Lever Rear Brake Pedal Side Stand 12 15 15 16 17 18 18 18 18 19 19 19 19 06 03 20 10 58 30 31KPT640_020 ...

Page 21: ...clutch lever engine stop button ignition switch start button front brake lever throttle grip 12 Operating Controls Operation Component Locations 06 03 20 10 58 34 31KPT640_021 ...

Page 22: ...rear brake pedal 13 Operating Controls Operation Component Locations 06 03 20 10 58 38 31KPT640_022 ...

Page 23: ...shift lever choke lever fuel valve 14 Operating Controls Operation Component Locations 06 03 20 10 58 42 31KPT640_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 06 03 20 10 58 48 31KPT640_024 ...

Page 25: ...eling 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 en...

Page 26: ...ral the engine can be started OFF ON 1 ON OFF 1 ignition switch FRONT ON OFF 17 Operating Controls Operating Controls Ignition Switch After parking the motorcycle remove the key The ignition switch is used to prevent unauthorized use of the motorcycle Before riding insert the key and turn it to the ON position 1 06 03 20 10 59 05 31KPT640_026 ...

Page 27: ...the engine See page When the start button is pushed the starter motor will crank the engine The engine stop button is used to turn the engine off during normal riding situations To operate push the button in and hold it in until the engine stops completely 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: ...press the pedal For information on braking techniques see page The clutch lever is used to disengage the clutch whenever you shift gears To operate pull the clutch lever in all the way before shifting then slowly release it after shifting The shift lever is used to select the next higher or lower gear in the transmission To operate raise the shift lever after pulling in the clutch lever to engage ...

Page 29: ...20 Operating Controls 06 03 20 10 59 20 31KPT640_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 Is Your Motorcycle Ready to Ride Protective Apparel Pre ride Inspection 22 22 24 24 06 03 20 10 59 26 31KPT640_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 Check the cable housings for wear Check the fittings for looseness Replace or tighten as needed Use a wrench to make sure all accessible nuts bolts and fasteners are tight 64 59 104 78 06 03 20 10 ...

Page 35: ...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 pages Check for smooth operation and adjust if needed pag...

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 Starting Stopping the Engine Preparation Starting Procedure Flooded Engine How to Stop th...

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: ...rmal Air Temperature 10 35 C 50 95 F Always 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 cont d Pull the choke lever up all the way to fully ON Your motorcycle can be started with the transmission in gear by pulling in the clutch lever before operating the sta...

Page 39: ...the engine until it will idle smoothly with the choke lever pushed down all the way to fully OFF Warm up the engine by opening and closing the throttle slightly With the throttle slightly open press the start button About a half minute after the engine starts push the choke lever down all the way to fully OFF If idling is unstable open the throttle slightly Immediately after the engine starts push...

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 While pushing the engine stop button press the start button for 5 seconds Follow the starting procedure page 2 3 1 4 5 30 06 03 20 11 00 45 31KPT640_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 06 03 20 11 00 49 31KPT640_041 ...

Page 42: ...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 Your motorcycle has five forward gears To start riding after the engine has been warmed and the side stand raised Close the throttle and pull the ...

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 To continue shifting up to each higher gear repeat step Remember to close the throttle and pull the clutch lever in completely before shifting 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 06 03 20 11 01 12 31KPT640_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 06 03 20 11 01 16 31KPT640_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 109 06 03 20 11 01 19 31KPT640_047 ...

Page 48: ...enance 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 Air Resources Board CARB see page For inf...

Page 49: ...val Fluids Filters Engine Chassis Electrical Fuel Engine Oil Air Cleaner Crankcase Breather Throttle Clutch System Engine Idle Speed Spark Plug Spark Arrester Suspension Brakes Wheels Tires Tubes Side Stand Drive Chain Battery Appearance Care 72 74 77 78 80 82 85 93 99 103 104 111 116 58 61 67 71 53 56 06 03 20 11 01 42 31KPT640_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 06 03 20 11 01 52 31KPT640_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 06 03 20 11 02 02 31KPT640_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: ... C I 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 72 67 71 78 61 77 Fuel Line Throttle Operation Air Cleaner Crankcase Breather Spark Plug Valve Clearance Engine Oil Engine Oil Strain...

Page 57: ...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 I I I I I I I I I I I I I I I I I I I I 104 105 87 88 91 85 74 103 82 80 93 99 Drive Chain Drive Chain Slider Brake Fluid Brake Shoes Pads Wear Brake System Clutch System Side Stand Suspension Spark Arrester Nuts Bolts Fasteners...

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 06 03 20 11 02 52 31KPT640_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: ...e or adjust 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 67 78 82 83 Competition use may cause more rapid clutch disc wear Refer to the official Honda Service Manual or see your H...

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 83 83 88 106 107 06 03 20 11 03 18 31KPT640_061 ...

Page 62: ...clutch lever front brake lever throttle grip fuel fill cap front brake fluid reservoir 53 Servicing Your Honda Maintenance Component Locations 06 03 20 11 03 23 31KPT640_062 ...

Page 63: ...rear brake pedal spark arrester spark plug engine idle speed engine oil filler cap dipstick air cleaner 54 Servicing Your Honda Maintenance Component Locations 06 03 20 11 03 26 31KPT640_063 ...

Page 64: ...engine oil drain bolt drive chain front brake caliper choke lever battery main fuse crankcase breather tube 55 Servicing Your Honda Maintenance Component Locations 06 03 20 11 03 31 31KPT640_064 ...

Page 65: ... 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 The right side cover must be removed to service the air cleaner Right Side Cover Removal Pull both side cover prongs out of the rubber grommets Remove the screw Right Side Cover Installation 1 1 2 2 3 43 1 4 2 3 06 03 20 11 03 39 31KPT640_06...

Page 66: ...d main fuse and to check the color label Left Side Cover Removal Remove the screw bolt A and bolt B Pull both side cover prongs out of the rubber grommets 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 bolts and tighten them Left Side Cover Installation 1 1 2 2 ...

Page 67: ...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 68: ...ther tube 4 3 3 steering stem nut 4 filler neck 59 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 counterclockwis...

Page 69: ...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 06 03 20 11 04 10 31KPT640_069 ...

Page 70: ... suggested oil 61 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 71: ...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 72: ...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 06 03 20 11 04 33 31KPT640_072 ...

Page 73: ...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 74: ... bolts B If the engine is cold start it and let it idle for 3 5 minutes Turn the engine off Wait 2 3 minutes for the oil to settle Park your motorcycle on its side stand on a firm level surface Place a drain pan under the crankcase To drain the oil remove the oil filler cap dipstick oil drain bolt and sealing washer Pour the drained oil into a suitable container and dispose of it in an approved ma...

Page 75: ...Check the condition of the sealing washer on the oil drain bolt Replace the washer every other time the oil is changed Install the oil drain bolt and tighten to the specified torque Pour the recommended oil into the crankcase approximately Install the oil filler cap dipstick securely Start the engine and let it idle for 3 5 minutes Stop the engine Wait 2 3 minutes Install the engine guard 7 8 9 10...

Page 76: ...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 77: ...cleaner 4 5 68 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 4 1 2 3 3 1 2 5 4 56 06 03 20 11 05 17 31KPT640_077 ...

Page 78: ...ing 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 cont d 7 5 6 8 6 5 06...

Page 79: ...g before 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 int...

Page 80: ... Breather Servicing Your Honda Safety Precautions Refer to on page Service more frequently if your motorcycle is ridden in the rain or often at full throttle Drain the deposits by pinching the crankcase breather tube 43 1 06 03 20 11 05 39 31KPT640_080 ...

Page 81: ...adjust to the specified range Adjustment Pull the rubber dust cover back Loosen the lock nut on the throttle cable mechanism Turn the adjuster Tighten the lock nut Return the dust cover to its normal position After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions If you can t get the freeplay within the specified range contact your...

Page 82: ...that the throttle assembly is positioned properly and the securing bolts are tight Inspect the condition of the throttle cable from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced Check the cable for tension or stress in all steering positions Lubricate the cable with a commercially available cable lubricant to prevent premature rust and corrosion 1 2 1 3...

Page 83: ...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 84: ... 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 Return the dust cover to its normal position The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out...

Page 85: ...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 86: ...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 87: ...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 be recommended Clean any dirt...

Page 88: ... wire type feeler 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 tigh...

Page 89: ...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 3 ...

Page 90: ...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 06 03 20 11 07 05 31KPT640_090 ...

Page 91: ... 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 92: ... 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 06 03 20 11 07 19 31KPT640_092 ...

Page 93: ...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 06 03 20 11 07 23 31KPT640_093 ...

Page 94: ...d for this motorcycle Install a new adjuster from the lever side with the lock nut under the head of the adjuster The front brake is the hydraulic disc type As the brake pads wear the brake fluid level 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...

Page 95: ...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 96: ...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 88 1 06 ...

Page 97: ...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 98: ...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 06 03 20 11 08 00 31KPT640_098 ...

Page 99: ...ke adjusting nut Make sure the cut out on the adjusting nut is seated on the brake arm pin Apply the brake release it and then spin the wheel and check that it rotates freely Repeat this procedure several times Check the freeplay If you can t adjust the freeplay properly see your Honda dealer Adjustment 1 2 3 2 3 06 03 20 11 08 06 31KPT640_099 ...

Page 100: ...ce 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 The rear brake is equipped with an external brake wear indicator that let you check brake wear without disassembly Application of the brake control pedal causes the arrow on the brake arm to move toward a reference mark on the brake ...

Page 101: ...rvicing Your Honda Check the freeplay page Tighten the lock nut Loosen the lock nut and turn the stopper bolt Check that the rear pedal assembly is positioned properly and the securing bolts are tight Make sure the brake rod brake arm spring and fasteners are in good condition 1 2 3 1 2 89 06 03 20 11 08 21 31KPT640_101 ...

Page 102: ... 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 103: ... 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 06 03 20 11 08 30 31KPT640_103 ...

Page 104: ...e motorcycle with tie down straps 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 wheel and side collars Remove the axle holder nuts and th...

Page 105: ...Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity Reverse the removal procedure Install the side collars into the wheel Insert the front axle shaft through the wheel hub and left fork leg Tighten the front axle shaft to the specified torque Install the axle holder with the UP mark upward and first tighten the upper axle holder nuts un...

Page 106: ... brake 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 chai...

Page 107: ...justers are installed properly 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 times Adjust the rear brake page Tighten the rear axle nut to the specified to...

Page 108: ...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 109: ...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 110: ...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 111: ... Tubes Servicing Your Honda The tires that came on your motorcycle were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions We 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 i...

Page 112: ...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 43 1 06 03 20 11 09 36 31KPT640_112 ...

Page 113: ...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 114: ...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 115: ...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 116: ... 2 rear axle nut 3 chain adjusters 4 index marks 5 stopper pins 107 Adjustment 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 06 03 20 11 10 06 31KPT640_116 ...

Page 117: ...just 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 align with the stopper pins on both sides of the swingarm If a torque wrench is not used for this installation see your Honda dealer as soon as possible to verify proper assembly 3 4 5 6...

Page 118: ... 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 06 03 20 11 10 21 31KPT640_118 ...

Page 119: ... removed or replaced by your Honda dealer When the drive chain becomes extremely dirty it should be cleaned prior to lubrication Clean the side surfaces of the chain with a dry cloth Do not brush the 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 fittin...

Page 120: ...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 121: ...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 122: ...battery compartment behind the left side cover Remove the battery holder Remove the left side cover page Make sure the ignition switch is OFF Removal 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 1 2 3 4 5 1 57 2 3 4 06 03 20 11 10 49 31KPT640_122 ...

Page 123: ...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 Install the left side cover Install the batter...

Page 124: ...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 125: ...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 126: ... 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 127: ...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 06 03 20 11 11 28 31KPT640_127 ...

Page 128: ...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 Transporting Your Honda Storing Your Honda You the Environment 120 122 124 127 06 03 20 11 11 33 31KPT640_128 ...

Page 129: ...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 130: ...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 06 03 20 11 11 46 31KPT64...

Page 131: ...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 132: ...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 06 03 20 11 11 57 31KPT640_132 ...

Page 133: ...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 06 03 20 11 12 02 31KPT6...

Page 134: ...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 4 127 65...

Page 135: ... 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 Wash and dry your motorcycle Remove the battery and charge it fully Store it in an area protected from freezing temperatures and direct sunlight Slow charge the battery page once a month Perform a pre ride inspection page then ...

Page 136: ... 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 biodegradable detergent when you wash your motorcycl...

Page 137: ...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 06...

Page 138: ...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 If Your Engine Quits or Won t Start If You Have a Flat Tire If a Fuse Blows If You Crash If You Lose Your Key If a Component Fails If Your Battery Is Low or Dead 120 130 131 135 136 138 139 140 141 06 03 20 11 12 37 31KPT640_138 ...

Page 139: ... 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 140: ...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 141: ...hift 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 136 115 Starter motor doesn t operate 132 Taking Care of the Unexpected Taking Care of the Unexpected 06 03 20 11 13 00 31KPT640_141 ...

Page 142: ...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 31 115 77 Starter motor works but the engine won t start Engine starts but runs poorly Flooded Engi...

Page 143: ... 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 58 Engine starts but runs poorly cont d 134 Taking Care of the Unexpected Taking Care of the Unexpected 06 03 20 11 13 22 31KPT640_143 ...

Page 144: ...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 145: ...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 06 03 20 11 13 34 31KPT640_145 ...

Page 146: ...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 147: ...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 148: ... 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 149: ...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 150: ...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 06 03 20 11 14 06 31KPT640_150 ...

Page 151: ...142 Taking Care of the Unexpected 06 03 20 11 14 08 31KPT640_151 ...

Page 152: ...nd other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification Specifications Break in Guidelines High Altitude Carburetor Adjustment Emission Control Systems Oxygenated Fuels 144 146 151 152 153 157 06 03 20 11 14 14 31KPT640_152 ...

Page 153: ...ne serial numbers are required when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the section at the rear of the manual The engine number is stamped on the left side of the engine The VIN is stamped on the right side of the steering head 2 1 06 03 20 11 14 21 31KPT640_153 ...

Page 154: ...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 57 06 03 20 11 14 26 31KPT640_154 ...

Page 155: ...er disassembly 1 1 US qt 1 0 after draining 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 146 Specifications Technical Information 06 03 20 11 14 36 31KPT640_155 ...

Page 156: ...onda 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 30 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 S...

Page 157: ...0 90 mm CPR9EA 9 NGK Intake Exhaust Primary reduction Gear ratio 1st 2nd 3rd 4th 5th Final reduction Final drive Valve clearance cold Spark plug standard Spark plug For extend high speed riding Spark plug gap Idle speed Power Transmission Engine Specifications 148 Specifications Technical Information 06 03 20 11 14 54 31KPT640_157 ...

Page 158: ...tube 70 100 19 NHS 42M 90 100 16 NHS 51M 15 psi 100 kPa 1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm Drive chain freeplay New chain length Used chain service limit length Caster Trail Tire size front Tire size rear Tire type Tire pressure front cold Tire pressure rear cold Suspension front Suspension rear Power Transmission Chassis Suspension 149 Specifications Technical Information 06 03 20 11 15 04 31KP...

Page 159: ...f ft 73 5 N m 7 5 kgf m 9 lbf ft 12 N m 1 2 kgf m 22 lbf ft 30 N m 3 1 kgf m Battery Generator Main Oil drain bolt Front axle shaft Axle holder nuts Rear axle nut Torque Specifications Electrical Fuse 150 Specifications Technical Information 06 03 20 11 15 12 31KPT640_159 ...

Page 160: ... 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 06 03 20 11 15 15 31KPT640_160 ...

Page 161: ...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 162: ...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 163: ... 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 164: ...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 165: ...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 166: ...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 167: ...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 06 03 20 11 15 50 31KP...

Page 168: ...contains information on your warranty and how to get an official Honda service manual Authorized Manual Warranty Coverage Warranty Service Contacting Honda The Honda Rider s Club USA only Your Honda Dealer 160 163 164 165 166 168 06 03 20 11 15 56 31KPT640_168 ...

Page 169: ... 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 170: ...l Item Description Qty 161 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 171: ...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 172: ...For more information see your Honda dealer Motorcycle Limited Warranty Exhaust Emission Warranty USA only Noise Control Warranty USA only There are responsibilities restrictions and exclusions which apply to these warranties Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the time of purchase Be sure to keep your Honda owner s card USA only with your Warran...

Page 173: ...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 174: ...ny differences 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 4C 7B telephone 866 784 1870 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the foll...

Page 175: ...letion of a Motorcycle Safety Foundation training course Separate complimentary training from the Specialty Vehicle Institute of America for purchasers of new ATVs 24 hour toll free roadside assistance for your new Honda includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow One full year of magazine six issues Racing contingency programs an...

Page 176: ...you purchased an off road motorcycle ATV or PWC your benefits do not include roadside assistance or trip interruption protection Contact your Honda dealer for more information or call 1 800 847 4722 or log on to www hrca honda com 06 03 20 11 16 54 31KPT640_176 ...

Page 177: ...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 178: ...169 Consumer Information 06 03 20 11 17 02 31KPT640_178 ...

Page 179: ...e Inspection Parking Braking Shifting Gears How to Stop the Engine Flooded Engine Starting Procedure Preparation Starting Stopping the Engine Safe Riding Precautions Pre ride Inspection Is Your Motorcycle Ready to Ride Protective Apparel Are You Ready to Ride Rear Brake Pedal Side Stand Shift Lever Clutch Lever Throttle Front Brake Lever Engine Stop Button Start Button Ignition Switch Choke Lever ...

Page 180: ...fety Precautions Maintenance Schedule Maintenance Record Competition Inspection Maintenance Component Locations Side Cover Removal Fuel Engine Oil Air Cleaner Crankcase Breather Throttle Clutch System Engine Idle Speed Spark Plug Spark Arrester Suspension Brakes Wheels Tires Tubes Side Stand Drive Chain Battery Appearance Care 41 43 43 45 49 50 53 56 72 74 77 78 80 82 85 93 99 103 104 111 116 58 6...

Page 181: ...elines If Your Engine Quits or Won t Start If You Have a Flat Tire If a Fuse Blows If You Crash If You Lose Your Key If a Component Fails If Your Battery Is Low or Dead Vehicle Identification Specifications Break in Guidelines High Altitude Carburetor Adjustment Oxygenated Fuels Emission Control Systems 120 122 124 127 130 131 135 136 138 139 140 141 144 146 151 152 153 157 06 03 20 11 17 53 31KPT...

Page 182: ...EFERENCE CONSUMER INFORMATION 159 Table of Contents Table of Contents Authorized Manual Warranty Coverage Warranty Service Contacting Honda The Honda Rider s Club USA only Your Honda Dealer 160 163 164 165 166 168 06 03 20 11 18 00 31KPT640_182 ...

Page 183: ...ustment 85 pad wear 88 pedal rear 19 shoe wear 91 braking 35 break in guidelines 151 button engine stop 18 start 18 capacity fuel 59 carburetor high altitude adjustment 152 idle speed 77 choke lever 16 29 cleaner air 67 cleaning appearance care 116 clutch system adjustment 74 lever 19 color label 145 competition inspection 50 consumer information 159 06 03 20 11 18 05 31KPT640_183 ...

Page 184: ...control systems 153 emission requirements 153 engine number 144 engine flooded 31 idle speed 77 pinging 58 starting 29 stop button 18 stopping 32 won t start 131 environment protecting 127 filter air 67 flat tire 135 flooded engine starting 31 fork 82 front brake lever 18 lever freeplay 85 front suspension 82 front wheel removal 95 06 03 20 11 18 11 31KPT640_184 ...

Page 185: ...recommendation 58 oxygenated 157 tank capacity 59 valve 15 gap spark plug 79 gasohol 157 gasoline 58 gears shifting 33 high altitude adjustment 152 Honda contacting 165 Honda service manual 160 idle speed engine 77 inspection competition 50 post ride 38 pre ride 24 06 03 20 11 18 17 31KPT640_185 ...

Page 186: ...ting controls 11 operation component locations 12 oxygenated fuels 157 parking 37 pedal rear brake 19 pinging engine 58 plug spark 78 post ride inspection 38 pre ride inspection 24 reserve capacity fuel tank 59 rider training 3 168 riding basic operation 27 before 21 clothing 22 precautions 28 safety 2 rim lock 94 06 03 20 11 18 22 31KPT640_186 ...

Page 187: ...ter 80 spark knock 58 spark plug 78 specifications 146 stand side 19 103 start button 18 starting engine 29 stop button engine 18 stopping engine 32 storage 124 suspension front 82 rear 83 throttle freeplay 72 operation 18 tires air pressure 99 flat 135 replacing 102 towing 34 training rider 3 168 transporting 122 troubleshooting starting 131 06 03 20 11 18 27 31KPT640_187 ...

Page 188: ...179 Index Index W V warranty coverage 163 extended 163 service 164 washing your motorcycle 117 weight limit 6 wheels 93 valve fuel 15 vehicle identification no VIN 144 06 03 20 11 18 31 31KPT640_188 ...

Page 189: ...ing because of improper installation poor seal Your Honda engine can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage 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 hu...

Page 190: ...ce Quick Reference Record important information here VIN Engine No Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 06 03 20 11 18 42 31KPT640_190 ...

Page 191: ... nuts bolts spark plug cap throttle brakes and clutch lever rider only no passenger or cargo and any accessories Tires Engine Oil Fuel Capacity premium unleaded gasoline pump octane number of 91 or higher tank reserve Maximum Weight Capacity Spark Plug Tire Pressure cold about every 600 miles 1 000 km or 6 months Fuse API Service Classification SG or higher except oils labeled as energy conserving...

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