Honda CRF230F 2004 Owner'S Manual Download | Manualshive

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$48.00
$48.00
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61KPS01
61CM001
31KPS610

2004 CRF230F Service Manual
Common Service Manual
2004 CRF230F Owner’s Manual

Price Each

Description

Publication Item No.

Pr ices ar e subject to change without notice and without incur r ing obligation.

160

Authorized Manuals

Consumer Information

The Service Manual (Publication Item No.

) used by your authorized Honda dealer is

available from Helm, Inc. (USA 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
(Publication No.

), 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 should find them easy to use if they have the proper tools and observe proper safety
standards. Special Honda tools are necessary for some procedures.

61CM001

61KPS01

03/03/07 16:37:44 31KPS610_169

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Summary of Contents for CRF230F 2004

Page 1: ...ation available before printing Honda 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 2003 03 03 07 16 14 53 31KPS610_001 ...

Page 2: ...2004 Honda CRF230F OWNER S MANUAL 03 03 07 16 14 56 31KPS610_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 03 03 07 16 15 08 31KPS610_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 03 03 07 16 15 33 31KPS610_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: ...03 03 07 16 15 51 31KPS610_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 03 03 07 16 15 56 31KPS610_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 03 03 07 16 16 44 31KPS610_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 03 03 07 16 16 53 31KPS610_018 ...

Page 19: ...10 Motorcycle Safety 03 03 07 16 16 56 31KPS610_019 ...

Page 20: ...this section carefully before you ride It describes the location function and operation of all the basic controls on your motorcycle 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 03 03 07 16 17 01 31KPS610_020 ...

Page 21: ...clutch lever engine stop button throttle ignition switch front brake lever start button 12 Component Locations Operating Controls 03 03 07 16 17 06 31KPS610_021 ...

Page 22: ...choke lever shift lever fuel valve side stand 13 Component Locations Operating Controls 03 03 07 16 17 10 31KPS610_022 ...

Page 23: ...rear brake pedal 14 Component Locations Operating Controls 03 03 07 16 17 14 31KPS610_023 ...

Page 24: ...e fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor cont d ON OFF RES 03 03 07 16 17 24 31KPS610_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 ON OFF 1 ignition switch FRONT ON OFF 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 03 03 07 16 17 43 31KPS610_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 03 03 07 16 18 03 31KPS610_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 03 03 07 16 18 08 31KPS610_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: ...l 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 cont d 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 63 58 104 78 03 03 07...

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: ...er 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...

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 03 03 07 16 19 45 31KPS610_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 03 03 07 16 19 50 31KPS610_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: ...fting Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rpm is too high can cause engine damage To prevent transmission damage do not coast or tow the motorcycle for long distances with the engine off 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: ...one or both wheels to slip Any wheel slip will reduce your control of your motorcycle cont d When riding in wet or raining 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 tu...

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 03 03 07 16 20 22 31KPS610_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 03 03 07 16 20 26 31KPS610_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 108 03 03 07 16 20 30 31KPS610_047 ...

Page 48: ...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 The Importance of Maintenance 41 Maintenance Safety 43 Imp...

Page 49: ...oval 56 Fluids Filters Fuel 57 Engine Oil 60 Air Cleaner 66 Crankcase Breather 70 Engine Throttle 71 Clutch System 74 Engine Idle Speed 77 Spark Plug 78 Spark Arrester 80 Chassis Suspension 82 Brakes 85 Wheels 93 Tires Tubes 99 Side Stand 103 Drive Chain 104 Electrical Battery 111 Appearance Care 116 03 03 07 16 20 42 31KPS610_049 ...

Page 50: ...r parts even if you are able to make some repairs cont d 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 ...

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 03 03 07 16 20 55 31KPS610_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 03 03 07 16 21 07 31KPS610_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: ...ervice 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 Fuel Line Throttle Operation Air Cleaner Crankcase Breather Spark Plug Valve Clearance Engine Oil Engine Oil Strainer Screen Engine Oil Centrifugal Filter Engine Idle Speed Note 1 I R I C I I I R I I I C I I I R C C I C I...

Page 57: ...rvice Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer 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 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 104 105 87 88 9...

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 03 03 07 16 22 05 31KPS610_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: ...park 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 ad...

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 03 03 07 16 22 35 31KPS610_061 ...

Page 62: ...rear suspension chain adjuster clutch lever front brake hose carburetor fuel tank chain guide slider engine oil drain bolt drive chain side stand chain slider crankcase breather battery fuse 53 Servicing Your Honda Component Locations 03 03 07 16 22 41 31KPS610_062 ...

Page 63: ...al spark arrester lower clutch adjusting nut oil filler cap dipstick rim lock throttle fuel fill cap air cleaner air cleaner housing cover rim lock right side cover spark plug 54 Servicing Your Honda Component Locations 03 03 07 16 22 48 31KPS610_063 ...

Page 64: ...y 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 03 03 07 16 22 54 31KPS610_064 ...

Page 65: ...emoval 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 Installation Remove the screw bolt A and bolt B Pull both side cover prongs out of the rubber grommets 1 1 2 2 3 43 1 2 4 3 5 03 03 07 16 23 04 31KPS610_065 ...

Page 66: ...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 67: ...breather tube 4 3 3 steering stem nut 4 filler neck 58 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 68: ...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 03 03 07 16 23 29 31KPS610_068 ...

Page 69: ... suggested oil 60 Oil Recommendation Engine Oil Servicing Your Honda Safety Precautions Refer to on page Using the proper oil and regularly checking adding and changing oil will help extend your engine 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 70: ...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 71: ...art may be used 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 to choose engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard has the following classification on the oil container 03 03 07 16 23 59 31KPS610_071 ...

Page 72: ...es Immediately unscrew and remove the oil filler cap dipstick Wipe it clean Hold the motorcycle upright Insert the dipstick until it seats but do not screw it in Remove the dipstick and check the oil level If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the lower level mark add the recommended oil until it reaches the upper level mark Do not ove...

Page 73: ...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 4 127...

Page 74: ...creen Check 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 Start the engine Let it idle 3 5 minutes then turn it off Tighten the oil drain bolt to the specified torque Install the O ring to the oil drai...

Page 75: ...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 76: ...ner 4 5 67 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 56 3 1 2 5 4 03 03 07 16 24 52 31KPS610_076 ...

Page 77: ... 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 03 03 07 16 ...

Page 78: ...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 79: ...ions Refer to on page Service more frequently if your motorcycle is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube Drain the deposits by pinching the plug 43 1 03 03 07 16 25 16 31KPS610_079 ...

Page 80: ...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 03 03 07 16 25 29 31KPS610_080 ...

Page 81: ...eplay 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 Tighten the lock nut on the adjuster Loosen the lower lock nut on the cable Turn t...

Page 82: ...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 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: ... tighten the lower lock nut Check the adjustment Tighten the lock nut and check the freeplay again Lower Adjustment The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out near its limit or the correct freeplay cannot be obtained Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in to provide maximum freeplay Tighten the upper lock nu...

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: ...ugs 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 pl...

Page 88: ...wrench provided with your motorcycle With the plug washer attached thread the spark plug in by hand to prevent cross threading If you have to install a new plug first check the gap Make sure the plug washer is in good condition Check the spark plug gap using a wire type feeler gauge If adjustment is necessary bend the side electrode carefully The gap should be Inspect the spark plug electrodes for...

Page 89: ...r 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 Remove the three bolts the spark arrester and the gasket from the muffler Allow the engine and muffler to cool 1 2 2 1 4 ...

Page 90: ... 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 three bolts securely 3 4 03 03 07 16 27 07 31KPS610_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 03 03 07 16 27 22 31KPS610_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 03 03 07 16 27 27 31KPS610_093 ...

Page 94: ...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 than thos...

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 1 88 03 ...

Page 97: ...t 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 t...

Page 98: ...djusting nut 4 brake arm pin 89 Rear Brake 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 Adjustment cont d 1 2 Freeplay 1 03 03 07 16 28 14 31KPS610_098 ...

Page 99: ...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 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 t...

Page 100: ... tight Rear Make sure the brake rod brake arm spring and fasteners are in good condition 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 1 2 4 3 1 2 03 03 07 16 28 27 31KPS610_100 ...

Page 101: ...r bolt 1 2 3 3 rear brake pedal 92 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 89 03 03 07 16 28 34 31KPS610_101 ...

Page 102: ...dly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations 43 ...

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 03 03 07 16 28 47 31KPS610_103 ...

Page 104: ...of the motorcycle with tie down straps Remove the front axle holder nuts and the front axle holder Unscrew and remove the axle Remove the wheel 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 servic...

Page 105: ...te the front brake and pump the fork several times First tighten the upper holder nuts to the specified torque then tighten the lower axle nuts to the 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 ...

Page 106: ...er Press the rear brake pedal and disconnect the brake rod from the brake arm Loosen the rear axle nut while holding the axle Turn both adjusters so the rear wheel can be moved all the way forward for maximum drive chain slack Unscrew the axle nut Pull the axle out Push the wheel forward and derail the drive chain from the rear sprocket Remove the wheel Take care to prevent getting grease oil or d...

Page 107: ...s are installed properly Adjust the drive chain page Torque the axle nut to Adjust the rear brake page Apply the rear brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times If a 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: ...etailed 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 handling...

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: ...ng 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 Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Have the wheel balanced after a new tire ...

Page 112: ... Precautions 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 03 03 07 16 30 11 31KPS610_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: ...e 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 cont d 6 03 03 07 16 30 52 31KPS610_116 ...

Page 117: ...qually to increase or decrease chain slack After adjusting be sure the same adjuster index marks align with the stopper pins on both sides of the swingarm Torque the rear axle nut to Recheck drive chain slack Check rear brake pedal freeplay and adjust as necessary page Freeplay is affected when repositioning the rear wheel to adjust drive chain slack If a torque wrench is not used for this install...

Page 118: ...d 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 fitting links...

Page 119: ...ive Chain Servicing Your Honda Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed Lubricate the drive chain 3 4 03 03 07 16 31 22 31KPS610_119 ...

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: ...ttery is located in the battery compartment behind the left side cover Remove the left side cover page Remove the battery holder 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 56 1 2 3 4 03 03 07 16 31 48 31KPS610_122 ...

Page 123: ...in an area protected from freezing temperatures and 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 Be sure to read the information that came with your battery charger and follow the instructions on the battery Improper charging may damage the ...

Page 124: ...eriods without risking damage to the battery However do not 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 1 03 03 07 16 32 02 31KPS610_124 ...

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 03 03 07 16 32 29 31KPS610_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 120 Transporting Your Honda 122 Storing Your Honda 124 You the Environment 127 03 03 07 16 32 34 31KPS610_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 03 03 07 16 32 50 31KPS61...

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 03 03 07 16 33 03 31KPS610_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 03 03 07 16 33 08 31KPS6...

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 64 127...

Page 135: ...ate 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 are...

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 biodegradeable detergent when you wash your motorcyc...

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 03...

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 130 If Your Engine Quits or Won t Start 131 If You Have a Flat Tire 135 If a Fuse Blows 136 If You Crash 138 If You Lose Your Key 139 If a Component Fails 140 If Your Battery Is Low or Dead 141 120 03 03 07 16 33 45 31KPS610_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: ...dditional recommendations for specific problems follow cont d 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 I...

Page 141: ... 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 136 114 Starter motor doesn t operate 132 Taking Care of the Unexpected Taking Care of the Unexpected 03 03 07 16 34 14 31KPS610_141 ...

Page 142: ...lug caps securely If the engine still won t start see your Honda dealer Tighten the battery terminal bolts Charge the battery page 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 31 77 114 Starter motor works but the engine won t start Engine starts but runs poorly Flooded Eng...

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 57 Engine starts but runs poorly cont d 134 Taking Care of the Unexpected Taking Care of the Unexpected 03 03 07 16 34 39 31KPS610_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: ...ct them from damage caused by excess current flow short circuit or overload If something electrical on your motorcycle stops working the first thing 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 03 03 07 16 34 53 31KPS610_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 starter magnetic switch Reconnect the wire connector Install the left side cover To prevent an accidental short circuit turn the ignition switch OFF before checkin...

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 03 03 07 16 35 30 31KPS610_150 ...

Page 151: ...142 Taking Care of the Unexpected 03 03 07 16 35 32 31KPS610_151 ...

Page 152: ...nd other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification 144 Specifications 146 Break in Guidelines 151 High Altitude Carburetor Adjustment 152 Emission Control Systems 153 Oxygenated Fuels 157 03 03 07 16 35 37 31KPS610_152 ...

Page 153: ...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 03 03 07 16 35 45 31KPS610_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 56 03 03 07 16 35 52 31KPS610_154 ...

Page 155: ...oline pump octane number of 92 or higher after draining 1 1 US qt 1 0 after disassembly 1 3 US qt 1 2 Overall length Overall width Overall height Wheelbase Dry weight Fuel tank capacity Fuel tank reserve Fuel recommendation Engine oil capacity Dimensions Weight Fuel Lubricants 146 Specifications Technical Information 03 03 07 16 36 04 31KPS610_155 ...

Page 156: ...ing on the circular API service label SAE 10W 40 JASO T 903 standard MA Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil Air cleaner oil Displacement Bore stroke Compression ratio Passenger capacity Maximum weight capacity Cargo capacity Engine oil recommendation Drive chain lubricant Fuel Lubricants Engine ...

Page 157: ... 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 148 Specifications Technical Information 03 03 07 16 36 27 31KPS610_157 ...

Page 158: ...0 kgf cm 15 psi 100 kPa 1 0 kgf cm axle travel 8 5 in 216 mm 9 1 in 230 mm axle travel Drive chain freeplay New chain length Used chain service limit length Caster Trail Tire size front Tire size rear Tire pressure front cold Tire pressure rear cold Suspension front Suspension rear Power Transmission Chassis Suspension 149 Specifications Technical Information 03 03 07 16 36 39 31KPS610_158 ...

Page 159: ... ft 74 N m 7 5 kgf m 9 lbf ft 12 N m 1 2 kgf m 80 lbf ft 108 N m 11 0 kgf m Oil drain bolt Front wheel axle Axle holder nuts Rear wheel axle Torque Specifications 150 Specifications Technical Information 03 03 07 16 36 46 31KPS610_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 03 03 07 16 36 50 31KPS610_160 ...

Page 161: ...le at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modificat...

Page 162: ...its useful life when operated and maintained according to the instructions provided California only The Vehicle Emission Control Information Label is attached to the rear fender The EPA also requires that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 1 865 miles 3 000 km after the time of sale to the ultimate purchaser when operated and main...

Page 163: ...quipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the carburetor The combustion process produces carbon monoxide CO and hydrocarbons HC Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sun...

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: ...f any of the following symptoms have the vehicle inspected and repaired by your Honda Motorcycle Dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy 1 2 3 4 5 03 03 07 16 37 16 31KPS610_165 ...

Page 166: ...imum 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 co...

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 03 03 07 16 37 31 31KP...

Page 168: ...contains information on your warranty and how to get an official Honda service manual Authorized Manuals 160 Warranty Coverage 163 Warranty Service 164 Contacting Honda 165 The Honda Rider s Club USA only 166 Your Honda Dealer 167 03 03 07 16 37 35 31KPS610_168 ...

Page 169: ...Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual Publication No 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 own...

Page 170: ...and Total 4 00 161 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 Canada See ...

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: ...ion Plan USA only For more information see your Honda dealer 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 Warranties Booklet Motorcycle Limited Warranty Noise Control Warranty USA only It i...

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: ...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 310 532 9811 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the following info...

Page 175: ...f road riding schools and adventure packages Hospitality at national events Optional insurance club pin patch etc Red Rider MX contingency and off road support at selected events Computerized trip routing color maps and special travel packages Contact your Honda dealer for more information or call 1 800 847 HRCA For a complete list of all HRCA benefits and services refer to your HRCA membership be...

Page 176: ... 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 Hond...

Page 177: ...cations 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 29 Flo...

Page 178: ...hedule 45 Maintenance Record 49 Competition inspection 50 Component Locations 53 Tools 55 Side Cover Removal 56 Fluids Filters Fuel 57 Engine Oil 60 Air Cleaner 66 Crankcase Breather 70 Engine Throttle 71 Clutch System 74 Engine Idle Speed 77 Spark Plug 78 Spark Arrester 80 Chassis Suspension 82 Brakes 85 Wheels 93 Tires Tubes 99 Side Stand 103 Drive Chain 104 Electrical Battery 111 Appearance Car...

Page 179: ...127 General Guidelines 130 If Your Engine Quits or Won t Start 131 If You Have a Flat Tire 135 If a Fuse Blows 136 If You Crash 138 If You Lose Your Key 139 If a Component Fails 140 If Your Battery Is Low or Dead 141 Vehicle Identification 144 Specifications 146 Break in Guidelines 151 High Altitude Carburetor Adjustment 152 Emission Control Systems 153 Oxygenated Fuels 157 03 03 07 16 39 03 31KPS...

Page 180: ...NTS 168 INDEX 172 QUICK REFERENCE Table of Contents Table of Contents Authorized Manuals 160 Warranty Coverage 163 Warranty Service 164 Contacting Honda 165 The Honda Rider s Club USA only 166 Your Honda Dealer 167 03 03 07 16 39 08 31KPS610_180 ...

Page 181: ...nt 152 idle speed 77 choke lever 16 cleaner air 66 cleaning appearance care 116 clutch system adjustment 74 lever 19 color label 145 competition inspection 50 battery 111 brakes fluid level 87 lever front 18 lever front adjustment 85 pad wear 88 pedal rear 19 shoe wear 90 braking 35 break in guidelines 151 button engine stop 18 start 18 03 03 07 16 39 13 31KPS610_181 ...

Page 182: ...trol systems 153 emission requirements 153 engine number 144 engine flooded 31 idle speed 77 pinging 57 starting 29 stop button 18 stopping 32 won t start 131 environment protecting 127 filter air 66 flat tire 135 flooded engine starting 31 fork 82 frame number 144 front brake lever 18 lever freeplay 85 front suspension 82 front wheel removal 95 cont d 03 03 07 16 39 20 31KPS610_182 ...

Page 183: ...ark plug 78 gasohol 157 gasoline 57 gears shifting 33 high altitude adjustment 152 Honda contacting 165 Honda service manual 160 lever clutch 19 front brake 18 shift 19 limit weight 6 loading 5 idle speed engine 77 inspection competition 50 post ride 38 pre ride 24 03 03 07 16 39 26 31KPS610_183 ...

Page 184: ...operating controls 11 oxygenated fuels 157 parking 37 pedal rear brake 19 pinging engine 57 plug spark 78 post ride inspection 38 pre ride inspection 24 reserve capacity fuel tank 58 rider training 3 166 riding basic operation 27 before 21 clothing 22 precautions 28 safety 2 rim lock 94 03 03 07 16 39 32 31KPS610_184 ...

Page 185: ...0 spark knock 57 spark plug 78 specifications 146 stand side 19 103 start button 18 starting engine 29 stop button engine 18 stopping engine 32 storage 125 suspension front 82 rear 83 throttle freeplay 71 operation 18 tires air pressure 99 flat 135 replacing 102 tools 55 towing 34 training rider 3 166 transporting 122 troubleshooting starting 131 03 03 07 16 39 36 31KPS610_185 ...

Page 186: ...177 Index Index W V valve fuel 15 vehicle identification 144 warranty coverage 163 extended 163 service 164 washing your motorcycle 117 weight limit 6 wheels 93 03 03 07 16 39 41 31KPS610_186 ...

Page 187: ...rd important notes The engine of your Honda 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 engine repairs are Engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal 03 03 07 16 39 48 31KPS610_187 ...

Page 188: ... 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 03 03 07 16 39 52 31KPS610_188 ...

Page 189: ...kes 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 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 Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or equivalent unleaded...

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