Honda CRF250F 2020 Owner'S Manual Download Page 18

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Operating Controls

When you ride off-road, you need to operate

the throttle, clutch, brakes, and other controls

without stopping to look at them. Read this

section carefully before you ride. It describes

the location, function, and operation of all the

basic controls on your motorcycle.

Operation Component Locations ..................12

Operating Controls........................................15

Ignition Switch..........................................15

Start Button ...............................................16

Engine Stop Button ...................................16

Front Brake Lever .....................................16

Throttle......................................................16

Clutch Lever..............................................17

Shift Lever ................................................17

Rear Brake Pedal.......................................17

Side Stand .................................................17

PGM-FI Malfunction Indicator Lamp

(MIL).........................................................18

Fuel Reserve Indicator ..............................18

Summary of Contents for CRF250F 2020

Page 1: ...ction and operation of the throttle brakes clutch and other basic controls Before Riding 19 The importance of wearing a helmet and other protective gear plus how to make sure you and your motorcycle are ready to ride Basic Operation Riding 25 How to start and stop the engine shift gears and brake Also riding precautions Servicing Your Honda 35 Why your motorcycle needs regular maintenance what you...

Page 2: ...Unexpected 125 What to do if you have a flat tire your engine won t start etc Technical Information 141 ID numbers technical specifications and other technical facts Consumer Information 157 Information on warranties and how to get Honda service manuals Index 164 Quick Reference Handy facts about fuel engine oil tire sizes and air pressures ...

Page 3: ...es 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 California and Environment and Climate Change Canada ECCC emission regulations for off road motorcycles ...

Page 4: ... 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 Safety Labels on the motorcycle Safety Messages preceded by a safety al...

Page 5: ...torcycle Safety Instructions how to use this motorcycle correctly and safely This entire book is filled with important safety information please read it carefully You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions ...

Page 6: ...e But it s just as important 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 detailed list of topics at the beginning of each section and an index at the ...

Page 7: ...have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information You may also want to visit our website at USA www powersports honda com Canada www hond...

Page 8: ...endations 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 Important Safety Information 2 Loading Accessories Modifications 5 Loading 5 Accessories Modifications 7 Safety Labels 9 ...

Page 9: ...lways wear an approved motorcycle helmet We also recommend that you wear eye protection sturdy boots gloves and other protective gear page 20 Never Carry a Passenger Your motorcycle is designed for one person only There are no handholds footrests or seat for a second person so never carry a passenger A passenger could interfere with your ability to move around to maintain your balance and control ...

Page 10: ... Highway Motorcyclist booklet that came with your motorcycle USA only Be Alert for Off road Hazards 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 Ride within Your Limits Pushing limits is another major cause of...

Page 11: ...ery additional drink So don t drink and ride and don t let your friends drink and ride either Keep Your Honda in Safe Condition It s important to keep your motorcycle properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your motorcycle before every ride and perform all recommen...

Page 12: ...ding 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 the maximum load the motorcycle can carry More specific information on load limits accessories and modifications follows How much weight you put on your motorcycle and how you load it are important to your safety If you decide to carry...

Page 13: ...at reduced speeds 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 f...

Page 14: ...cause 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 guideline Make sure the accessory does not reduce ground clearance and lean angle limit suspension travel or steering travel alter your riding position or interfere with operating any control...

Page 15: ... way that would 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 ...

Page 16: ...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 dealer for a replacement For USA For Canada For Canada For USA ...

Page 17: ...10 Motorcycle Safety BLANK PAGE ...

Page 18: ...ly before you ride It describes the location function and operation of all the basic controls on your motorcycle Operation Component Locations 12 Operating Controls 15 Ignition Switch 15 Start Button 16 Engine Stop Button 16 Front Brake Lever 16 Throttle 16 Clutch Lever 17 Shift Lever 17 Rear Brake Pedal 17 Side Stand 17 PGM FI Malfunction Indicator Lamp MIL 18 Fuel Reserve Indicator 18 ...

Page 19: ... Operating Controls Operation Component Locations clutch lever start button front brake lever ignition switch engine stop button throttle grip PGM FI malfunction indicator lamp MIL fuel reserve indicator ...

Page 20: ...Operating Controls 13 Operation Component Locations rear brake pedal ...

Page 21: ...14 Operating Controls Operation Component Locations shift lever ...

Page 22: ...d turn it to the ON position After parking the motorcycle remove the key Ignition Switch Key Position Function Key Removal OFF The engine cannot be operated The key can be removed ON With the transmission in neutral or in gear with the clutch lever pulled in the engine can be started The key cannot be removed 1 ignition switch OFF ON 1 ON OFF FRONT ...

Page 23: ...erate 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 31 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 throttle will automatically return to the cl...

Page 24: ...te 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 Shifting Gears page 29 The rear brake pedal is used to slow or stop your motorcycle To operate depress the pedal For information on braking techniques see page 31 The side stand is used to support your motorcycle while parked page 33 To operate use ...

Page 25: ...ve your dealer check for problems If it comes on at any other time reduce speed and take the motorcycle to your dealer as soon as possible When this indicator comes on while riding fuel reserved in the tank is about 0 34 US gal 1 3 The indicator should also light for a few seconds and then go off when the ignition switch is turned on If the indicator does not come on when it should have your deale...

Page 26: ...nda are both ready 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 20 Protective Apparel 20 Is Your Motorcycle Ready to Ride 22 Pre ride Inspection 22 ...

Page 27: ...re free of alcohol and drugs are wearing an approved motorcycle helmet with chin strap tightened securely eye protection and other protective clothing For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved jersey shirt or jacket whenever you ride Although complete protection is not possible wearing the prop...

Page 28: ...rtation sticker on any helmet you buy USA only Always wear a face shield or goggles to protect your eyes and help your vision Additional Riding Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect your feet ankles and lower legs Off road motorcycle gloves to help protect your hands Riding pants with knee and hip pads a riding jersey wit...

Page 29: ...cle Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems Pre ride Inspection Tires Use a gauge to check the air pressure Adjust if needed Also look for signs of damage or excessive wear page 94 Spokes Rims Make sure the spoke...

Page 30: ...fastened Drive Chain Check the condition and slack Adjust and lubricate if needed Also check the chain slider guide slider and roller for wear and replace if needed page 98 Cables Check the cable housings for wear Check the fittings for looseness Replace or tighten as needed Nuts Bolts Use a wrench to make sure all accessible nuts bolts and fasteners are tight Spark Plug Cap Check for looseness pa...

Page 31: ...e throttle to make sure it moves smoothly without sticking and snaps shut automatically when it is released in all steering positions page 71 Brakes Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally pages 82 86 Check for proper adjustment page 82 Clutch Lever Check for smooth operation and adjust if needed page 72 Indicators Turn the ignitio...

Page 32: ...e turns ride on hills etc see the Tips Practice Guide for the Off Highway Motorcyclist 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 149 Safe Riding Precautions 26 Starting Stopping the Engine 27 Preparation 27 Starting Procedure 27 Flooded Engine 28 Bank Angle Sensor Ignition Cut off System 28...

Page 33: ...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 motorcycle is not equipped with lights Do not ride at night Safe Riding Precautions Running the engine of your vehicle while in an enclosed or even partially enclose...

Page 34: ...ey and turn the ignition switch to ON and confirm the following The transmission is in neutral The PGM FI malfunction indicator lamp MIL is off This motorcycle has a fuel injected engine Follow the procedure indicated below Any Air Temperature 1 With the throttle completely closed press the start button 2 If you cannot start the engine open the throttle slightly about 0 1 in 3 mm without freeplay ...

Page 35: ...he normal engine starting procedure page 27 Your motorcycle s banking lean angle sensor system is designed to automatically stop the engine and fuel pump if the motorcycle is overturned Before restarting the engine you must turn the ignition switch to the OFF position and then back to ON The engine will not restart until you perform this procedure To stop the engine shift into neutral and turn the...

Page 36: ...tral down to first gear 4 Release the front brake Gradually open the throttle while you slowly release the clutch lever If engine rpm speed is too low when you release the clutch lever the engine will stall If engine rpm is too high or you release the clutch lever too quickly your motorcycle may lurch forward 5 When you attain a moderate speed close the throttle pull the clutch lever in and raise ...

Page 37: ...efore shifting Improper shifting may damage the engine transmission and drive train Learning when to shift gears comes with experience Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Downshift to a lower gear before you feel the engine laboring lugging at low rpm Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rp...

Page 38: ...heels to lock and slide reducing control of your motorcycle If this happens release the brake controls steer straight ahead until you regain control then reapply the brakes more gently Generally reduce your speed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your ...

Page 39: ...ompression braking 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 have finished braking ...

Page 40: ...Basic Operation Riding 33 Parking Lower the side stand to support your motorcycle Turn the ignition switch OFF and remove the key Always choose a level place to park ...

Page 41: ...after riding thoroughly 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 103 to prevent rusting ...

Page 42: ...out the exhaust emission and noise emission requirements of the U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment and Climate Change Canada ECCC see page 150 For information about replacing fuse see page 132 An optional tool kit may be available Check with your dealer s parts department USA only Maintenance replacement or repair of the emission control...

Page 43: ...Side Cover Removal 53 Service Procedures Fluids Filters Fuel 54 Engine Oil 57 Air Cleaner 64 Crankcase Breather 68 Engine Throttle 69 Clutch System 72 Spark Plug 75 Spark Arrester 77 Chassis Suspension 79 Brakes 82 Wheels 87 Tires Tubes 93 Side Stand 97 Drive Chain 98 Electrical Battery 105 Appearance Care 110 ...

Page 44: ...erage riding conditions More frequent service is needed if you subject your motorcycle to severe use see the Competition Inspection checklist page 46 or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair If your motorcycle overturns or is involved in a crash be sure your dealer inspects all major part...

Page 45: ...icing Your Honda The Importance of Maintenance 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 ...

Page 46: ...efore you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so cont d Failure to properly fo...

Page 47: ...rking 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 Remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new Honda Genuine Parts or their equivalents for repair a...

Page 48: ...ed mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for purchase from your dealer page 158 Because your motorcycle does not have an odometer service intervals in the maintenance schedules are expressed in terms of riding days as well as miles To avoid overlooking required service we urge you to develop a convenient way to rec...

Page 49: ... dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page 158 In the interest of safety we recommend these items be serviced only by your dealer Summary of Maintenance Schedule Notes and Procedures NOTES 1 Service more frequently when ridden in wet or dusty conditions 2 Replace every 2 years Replacement requires mec...

Page 50: ...e serviced only by your dealer Whichever Comes First Initial Maint Regular Maint Interval Refer to page mi 100 600 1 200 1 800 2 400 km 150 1 000 2 000 3 000 4 000 Note Month 1 6 12 18 24 Fuel Line I I Fuel Filter R every 4 800 mi 8 000 km Throttle Operation I I 69 Air Cleaner Note 1 C C C C 64 Crankcase Breather I I I I 68 Spark Plug I I I I 75 Valve Clearance I I I I I Engine Oil R R R R R 57 En...

Page 51: ...t Regular Maint Interval Refer to page mi 100 600 1 200 1 800 2 400 km 150 1 000 2 000 3 000 4 000 Note Month 1 6 12 18 24 Drive Chain Note 1 I L I L every 300 mi 500 km or 3 months 98 Drive Chain Slider I I I I 99 Brake Fluid Note 2 I I I I 83 Brake Pads Wear I I I I 85 Brake System I I I I I 82 Clutch System I I I I I 72 Side Stand I I 97 Suspension I I 79 Spark Arrester C every 1 000 mi 1 600 k...

Page 52: ...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 Miles km or Months Date Performed By Notes 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 ...

Page 53: ...ols Damage from competition use is not covered by the Distributor s Limited Warranty on your Honda NOTE Refer to the Maintenance Schedule page 42 for regular service intervals No Item Inspect For Action Refer to Page 1 all pre ride inspection items 22 2 engine oil contaminants change 57 3 fuel line deterioration damage or leakage replace 4 valve clearance correct clearance adjust ...

Page 54: ...oper operation see NOTE 1 replace 6 air cleaner contamination or tears clean or replace 64 7 spark plug gap tightness proper heat range high tension terminal security tighten replace or secure 75 8 steering head bearings free rotation of handlebar and steering stem nut tightness adjust or retighten 9 front suspension smooth operation oil capacity no oil leaks good boot condition replace or adjust ...

Page 55: ...eration and secure installation replace or tighten 80 13 brake pads wear beyond service limit replace 85 14 drive chain max length pin 25 1 in 638 mm 41 pins replace 100 15 sprockets wear and secure installation replace or tighten 101 16 seat security tighten 17 control cables smooth operation kinks and correct routing lubricate or replace 18 engine mounting bolts tightness tighten ...

Page 56: ...Servicing Your Honda 49 Maintenance Component Locations fuel fill cap throttle grip front brake lever clutch lever front brake fluid reservoir ...

Page 57: ...50 Servicing Your Honda Maintenance Component Locations engine oil fill cap dipstick spark arrester air cleaner rear brake pedal engine oil filter rear brake caliper rear brake fluid reservoir ...

Page 58: ...Servicing Your Honda 51 Maintenance Component Locations crankcase breather tube front brake caliper engine oil drain bolt side stand battery drive chain spark plug sub fuse main fuse ...

Page 59: ...s Refer to Safety Precautions on page 39 The spoke wrench is delivered with your motorcycle for tightening or loosening the spokes USA only You will need to provide your own tools to perform any owner maintenance 1 1 spoke wrench ...

Page 60: ...e the battery main fuse and sub fuse Removal 1 Remove the bolt 2 2 Pull out the prongs 3 from the rubber grommets 4 and the boss 5 from the hole 6 on the shroud Installation 1 Slide the top of the side cover under the bottom edge of the seat 2 Align the prongs with the rubber grommets and the boss with the hole on the shroud 3 Install the bolt and tighten it securely RIGHT SIDE 2 3 1 1 right side ...

Page 61: ...ad to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your dealer Use only unleaded fuel in your Honda If you ride your Honda in a country where leaded fuel might be available take...

Page 62: ...2 Add fuel until the level reaches the bottom of the filler neck 4 Avoid overfilling the tank There should be no fuel in the filler neck cont d Refueling Procedure 2 4 3 1 1 fuel fill cap 2 breather tube 3 steering stem nut 4 bottom of the filler neck Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame ...

Page 63: ...ur Honda Fuel 3 After refueling turn the fuel fill cap clockwise until it clicks 4 Insert the breather tube in the steering stem nut If you replace the fuel fill cap use a Honda Genuine replacement part or equivalent ...

Page 64: ...ne Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine and transmission Oil Recommendation API classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label viscosity weight SAE 10W 30 JASO T 903 standard MA suggested oil Pro Honda GN4 4 stro...

Page 65: ...r 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 or resource conserving service label on the container They may affect lubrication and clutch performance Do not use non detergent vegetabl...

Page 66: ...ding 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 1 2 1 oil code 2 oil classification ...

Page 67: ...ht 6 Insert the oil fill cap dipstick until it seats but do not screw it in 7 Remove the oil fill cap dipstick and check the oil level If the oil is at or near the upper level mark 2 you do not have to add oil If the oil is below or near the lower level mark 3 add the recommended oil until it reaches the upper level mark Do not overfill 8 Insert the oil fill cap dipstick and screw it in tightly 9 ...

Page 68: ... off Wait 2 3 minutes for the oil to settle 2 Park your motorcycle on its side stand on a firm level surface 3 Place a drain pan under the crankcase 4 To drain the oil remove the oil fill cap dipstick oil drain bolt 1 and sealing washer 2 cont d Changing Engine Oil UNDER ENGINE 1 2 1 oil drain bolt 2 sealing washer ...

Page 69: ...environment 7 Install the spring and then install a new oil filter with the OUT SIDE mark 8 facing out Use only the Honda Genuine oil filter or a filter of equivalent quality sprcified for your model Using the wrong Honda filter or a non Honda filter which is not of equivalent quality may cause engine damage Improper installation of the oil filter can cause serious engine damage 5 6 3 oil filter c...

Page 70: ... oil drain bolt to the specified torque 18 lbf ft 24 N m 2 4 kgf m 12 Pour the recommended oil into the crankcase If the oil filter was replaced 1 5 US qt 1 4 If the oil filter was not replaced use approximately 1 5 US qt 1 4 13 Install the oil fill cap dipstick securely 14 Start the engine and let it idle for 3 5 minutes Stop the engine Wait 2 3 minutes 15 With the motorcycle held upright on leve...

Page 71: ...r 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 Honda Genuine air cleaner specified for your model or an air cleaner of equal quality Using the wrong air cleaner may result in premature engine wear Proper air cleaner maintenance can prevent premature engine wear or damage expensive r...

Page 72: ...rews 1 and air cleaner housing cover 2 3 Unhook the set spring 3 take care to avoid bending the set spring and set spring holder 4 4 Remove the air cleaner 5 cont d Cleaning 1 1 screws 2 air cleaner housing cover RIGHT SIDE 2 1 RIGHT SIDE 3 set spring 4 set spring holder 5 air cleaner 5 3 4 ...

Page 73: ...cleaning gently squeeze out the remaining solvent Avoid twisting or wringing the air cleaner This can tear the foam 7 Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged 8 Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully absorb the oil 7 5 air cleaner 6 air cleaner holder 8 5 8 6 7 tabs 8 air clean...

Page 74: ...ding the oil into the air cleaner 10 Assemble the air cleaner and holder Insert the tabs 7 in the air cleaner holes 8 11 Clean the inside of the air cleaner housing 12 Apply a thin coat of grease to the sealing surface of the air cleaner 13 Install the air cleaner assembly by inserting the tabs 9 on the air cleaner holder into the holes 10 in the air cleaner housing Hook the set spring Check that ...

Page 75: ...l throttle or after the motorcycle is washed or overturned If the drain tube overflows the air filter may become contaminated with engine oil causing poor engine performance 1 Place a suitable container under the crankcase breather tube 2 Drain the deposits into a suitable container by pinching the crankcase breather tube 1 1 LEFT SIDE 1 crankcase breather tube ...

Page 76: ...t to the specified range Upper Adjustment Minor adjustments are generally made with the upper adjuster 1 Pull the rubber dust cover 1 back 2 Loosen the upper lock nut 2 on the throttle cable mechanism 3 Turn the upper adjuster 3 cont d Throttle Freeplay 1 RIGHT SIDE 1 freeplay 1 RIGHT SIDE 1 rubber dust cover 2 upper lock nut 3 upper adjuster 2 3 ...

Page 77: ...r Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the throttle body It is also used if you can not get the proper adjustment with the upper adjuster 1 Loosen the lower lock nut 4 2 Turn the lower adjuster 5 3 Tighten the lock nut If you can t get the freeplay within the specified range contact your dealer LEFT SIDE 4 lower...

Page 78: ...sitions If there is a problem see your dealer 3 Inspect the condition of the throttle cables 2 from the throttle grip down to the throttle body If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion Throttle Inspection 1 throttle...

Page 79: ...tch wear Upper Adjustment Minor adjustments are generally made with the upper clutch cable adjuster Upper clutch assembly adjuster 1 Pull the rubber dust cover 2 off 2 Loosen the upper lock nut 3 3 Turn the upper clutch cable adjuster 4 to obtain the specified freeplay Clutch Freeplay 1 LEFT SIDE 1 clutch lever 4 LEFT SIDE 2 rubber dust cover 3 upper lock nut 4 upper clutch cable adjuster 2 3 incr...

Page 80: ... 4 all the way in to provide maximum freeplay 2 Tighten the upper lock nut and pull the rubber dust cover 2 back to its normal position 3 Pull the cable boot 5 off the clutch cable lower adjuster 6 4 Hold the lower clutch cable adjuster and loosen the lock nut 7 5 Turn the clutch cable lower adjuster to obtain the specified freeplay Hold the lower clutch cable adjuster and tighten the lock nut Ret...

Page 81: ...t 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 dealer or refer to the official Honda Service Manual page 158 Check that the clutch lever assembly is positioned properly and the securing bolts are tight Check the clutch cable for kinks or signs of wear If necessary have it replaced Lubricate the clutch cable with a c...

Page 82: ...mended type of spark plugs in the recommended heat range Using spark plugs with an improper heat range can cause engine damage 1 Clean any dirt from around the spark plug base 2 Disconnect the spark plug cap 3 Using a spark plug wrench remove the spark plug cont d Spark Plug Recommendation Standard LMAR7H 9DS NGK 3 1 2 1 center electrode 2 side electrode 3 spark plug gap ...

Page 83: ... have to install a new plug first check the gap 6 With the plug washer attached thread the spark plug in by hand to prevent cross threading 7 Tighten the spark plug If the old plug is good 1 5 turn after it seats If installing a new plug tighten it twice to prevent loosening a First tighten the plug 1 4 turn after it seats b Then loosen the plug c Next tighten the plug again 1 5 turn after it seat...

Page 84: ... 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 1 Allow the engine and muffler to cool 2 Remove the bolts 1 and tail cover 2 the spark arrester 3 and the gasket 4 from the muffler 5 cont d 1 RIGHT REAR 1 bolts 2 tail cover 3 spark...

Page 85: ...ster screen 6 Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary 4 Install the new gasket the spark arrester and tail cover and tighten the bolts to the speci fied torque 9 lbf ft 12 N m 1 2 kgf m 6 spark arrester screen 6 ...

Page 86: ... qualified to determine whether or not replacement parts or repairs are needed 1 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 2 Check the security of all handlebar and fork mounting bolts 1 If any front suspension components appear worn or damaged see ...

Page 87: ...d Push hard against the side of the rear wheel and feel for any freeplay which indicates worn swingarm bearings 1 Rear Suspension Inspection 1 RIGHT SIDE 1 swingarm bearing 2 shock absorber attachment points 3 suspension linkage attachment points 2 3 LEFT SIDE 1 swingarm bearing 1 ...

Page 88: ... fasteners for the shock absorber attachment points 2 and rear suspension linkage attachment points 3 are secure 3 Check for oil leaks in the shock absorber If any rear suspension components appear worn or damaged see your dealer for further inspection ...

Page 89: ...r wear If the front brake lever or brake pedal freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page 85 there is probably air in the brake system See your dealer to have the air bled from the system Never use adjusters other than those designed for this motorcycle Install a new adjuster from the lever side with the l...

Page 90: ...ster counterclockwise 4 Tighten the lock nut Return the dust cover to its normal position 5 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times Front Brake Fluid Level With the motorcycle in an upright position check the fluid level It should be above the LWR mark 1 If the level is at or below the LWR mark check the brake pads for wea...

Page 91: ...brake fluid is Honda DOT 4 brake fluid from a sealed container or an equivalent Brake fluid can damage plastic and painted surfaces Handle with care Wipe up spills immediately Avoid brake fluid contact with skin or eyes If it comes in contact with your eyes wash them out with clean water and immediately call a doctor If it comes in contact with your skin wash with clean water and if necessary call...

Page 92: ...will wear faster on wet and dirty riding terrain Inspect the pads at each regular maintenance interval page 44 Check the cutouts 2 in each pad If either pad is worn to the cutout replace both pads as a set See your dealer for this service Brake Pad Wear LEFT FRONT 2 1 front brake caliper 2 cutouts 1 RIGHT REAR 1 rear brake caliper 2 cutouts 2 1 ...

Page 93: ...tioned properly and the securing bolts are tight Brake fluid should be added and replaced by your dealer The recommended brake fluid is Honda DOT 4 Brake Fluid or any brake fluid of equal quality and performance Use fresh brake fluid from a sealed container Other Inspections More About Brake Fluid ...

Page 94: ...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 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...

Page 95: ...or damage 2 Tighten any loose spokes or rim locks 3 3 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 dealer for inspection Wheel Rims Spokes 2 1 3 REAR 1 wheel rim 2 spoke 3 rim lock ...

Page 96: ... and side collars 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 dealer for this service Avoid getting grease oil or dirt on the disc or pad surfaces Any contamination can cause poor brake performance or rapid pad wear ...

Page 97: ...htly seated then tighten the lower axle holder nuts until lightly seated 5 Operate the front brake and pump the fork several times 6 First tighten the upper axle holder nuts to the specified torque then tighten the lower axle holder nuts to the same torque 9 lbf ft 12 N m 1 2 kgf m 7 After installing the wheel apply the brake several times and then check if the wheel rotates freely Recheck the whe...

Page 98: ...rward and derail the drive chain from the driven sprocket 5 Remove the rear axle chain adjusters rear wheel and side collars Avoid depressing the brake pedal when the wheel is off the motorcycle This will force the caliper piston out of the cylinder The result will be a loss of brake fluid If this occurs the brake system will require service See your dealer for this service Avoid getting grease oi...

Page 99: ...usters are installed properly 2 Adjust the drive chain page 102 3 Tighten the rear axle nut to the specified torque 80 lbf ft 108 N m 11 0 kgf m 4 After installing the wheel apply the brake pedal several times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used to install the wheel see your dealer as soo...

Page 100: ...t combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also cause wheel damage in rocky terrain Overinflated tires make your motorcycle ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure I...

Page 101: ...ecommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding condition make changes a little at a time A flat tire or blowout is inconvenient and may even cause a crash Take time to inspect your tires and wheels before you ride For more information about handling flat tires see page 131 Front 15 psi 100...

Page 102: ...traction Check the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim See your dealer If a tube is punctured or damaged you should replace it as soon as possible A repaired tube may not have the same reliability as a new one and it may fail while you are riding For information on making a temporary repair see page 131 ...

Page 103: ...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 is installed We recommend that tires be replaced by your dealer Tire Replacement Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recomm...

Page 104: ...page 39 1 Check the side stand spring 1 for damage and loss of tension 2 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 LEFT SIDE 1 1 side stand spring ...

Page 105: ...r 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 1 Check slack in the lower drive chain 1 run midway between the sprockets Drive chain slack should a...

Page 106: ...may allow the drive chain to damage the engine cases 3 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear damaged or missing O rings Replace the drive chain page 104 if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page 103 if it appears dry or shows signs of rust Lubricate any kinked or bind...

Page 107: ... guide slider if the chain is visible through the wear inspection window 6 Replace the chain roller if it is smaller than 0 7 in 18 mm 5 Replace the drive chain if chain slack is excessive when the rear axle is moved to the farthest limit of adjustment Excessive slack indicates the chain is worn beyond its service limit 2 chain slider 3 chain guide slider 4 chain roller LEFT SIDE 6 3 2 4 5 5 cutou...

Page 108: ...ink drive chain which requires a special tool for cutting and staking Do not use an ordinary master link with this chain 6 Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your dealer replace a worn sprocket Use of a new chain with worn sprockets will cause rapid chain wear New Chain 25 0 in 635 mm Service Limit 25 1 in 638 mm Measure a span of 41 pins Damag...

Page 109: ...ster index marks 4 align with the stopper pins 5 on both sides of the swingarm 4 Tighten the rear axle nut to the specified torque 80 lbf ft 108 N m 11 0 kgf m 5 Recheck drive chain slack If a torque wrench is not used for this installation see your dealer as soon as possible to verify proper assembly Adjustment LEFT REAR 4 1 rear axle shaft 2 rear axle nut 3 chain adjusters 4 index marks 5 stoppe...

Page 110: ...dry The O rings in this chain can be damaged by steam cleaning high pressure washers and certain solvents Recommended lubricant Pro Honda HP Chain Lube or equivalent Commercial chain lubricants not designed for motorcycle drive chains may contain solvents which could damage the O rings Lubrication ...

Page 111: ...ith a dry cloth Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rings 2 Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceable Replacement chain DID 520VD2 3 Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever ...

Page 112: ...charge If you have electrical accessories on your motorcycle or do not ride frequently we recommend that you charge the battery frequently see Battery Charging page 109 If you do not expect to ride your motorcycle for at least two weeks we recommend you remove the battery or at least disconnect the battery cables negative cable first If you plan to store your motorcycle see Battery Storage page 10...

Page 113: ...You will get the best storage results from removing the battery and slow charging it every 30 days see Battery Charging page 109 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label Battery Storage The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enou...

Page 114: ... side cover page 53 3 Remove the battery holder bolt 1 4 Disconnect the negative terminal 2 from the battery 5 Disconnect the positive terminal 3 from the battery 6 Raise the battery holder 4 then remove the battery 5 taking care not to drop the terminal nuts cont d LEFT SIDE 5 1 1 battery holder bolt 2 negative terminal 3 positive terminal 4 battery holder 5 battery 3 2 4 ...

Page 115: ... in an area protected from freezing temperatures and direct sunlight 9 Clean the battery box after removing the battery for storage 10 Slow charge the battery see following section once every 30 days Installation 1 Reinstall in the reverse order of removal Be sure to connect the positive terminal first then the negative terminal 2 Check all bolts and other fasteners are secure ...

Page 116: ... 1 designed specifically for your Honda which can be purchased from your dealer These units can be left connected for long periods 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 a...

Page 117: ...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 still war...

Page 118: ...water or air can damage certain parts of your motorcycle 1 Rinse your motorcycle thoroughly with cool water to remove loose dirt 2 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 3 Wash your motorcycle with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild ...

Page 119: ...es The engine heat will help dry moist areas 8 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 When the exhaust pipe and muffler are painted do not use a commercially available abrasive kitchen cleaning compound Use a neutral detergent to clean the painted surface on the exhaust pipe and muffler If you are...

Page 120: ...r sponge plenty of water and a mild detergent to clean the matte paint Dry with a soft clean cloth Do not use polishing compounds or wax containing polishing compounds These can damage or discolor the paint To keep your Honda looking new clean and polish it frequently Clean the Matte Painted Surface ...

Page 121: ...114 Servicing Your Honda BLANK PAGE ...

Page 122: ...how to prepare 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 116 Transporting Your Honda 118 Storing Your Honda 120 You the Environment 123 ...

Page 123: ...Natural Resources Canada only riding clubs and off road magazines are good sources of information Along with your motorcycle and riding gear you should take along some tools and supplies in case you have a problem For some of the difficulties you might encounter see Taking Care of the Unexpected which begins on page 125 We recommend that you always take water food a first aid kit and your owner s ...

Page 124: ...e 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 What to Take on the Trail ...

Page 125: ...position using motorcycle tie down straps Avoid using rope which can loosen and allow the motorcycle to fall over To secure your motorcycle brace the front wheel against the front of the truck bed or trailer 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 for...

Page 126: ...raps until the front 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 ...

Page 127: ...cycle running again USA For more information about storage refer to the Honda Winter Storage Guide available from your dealer Canada For more information about storage visit our website at www honda ca and look up Storage Tips under the Honda Warranty in the Warranty tab for your model We suggest you perform the following procedures to keep your motorcycle in top condition These storage procedures...

Page 128: ...Tips 121 Storing Your Honda 1 Change the engine oil page 61 2 Fill the fuel tank Make sure the fuel fill cap is properly installed cont d Preparation for Storage ...

Page 129: ...ly temperature variation 8 Cover your motorcycle with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate 1 Uncover and clean your motorcycle 2 If your motorcycle has been stored for more than four months change the engine oil page 61 3 If your motorcycle has been stored for more than two months drain and ...

Page 130: ...as approved for off road vehicles Keep the Noise Down 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 Choose Sensible Cleaners Use a biodegradable detergent when you was...

Page 131: ...fuse workers and 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 recyc...

Page 132: ...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 Preparing for a Ride page 116 General Guidelines 126 If Your Engine Quits or Won t Start 127 If You Have a Flat Tire 131 If a Fuse Blows 132 If You Crash 135 If You Lose Your Key 136 If a Component Fails 137 If Your Battery Is Low or Dead 138 ...

Page 133: ...ide what to do 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 serious or you don t have the tools supplies experience...

Page 134: ... 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 dealer If your motorcycle won t start listen as you press the start button If you don t hear the starter motor t...

Page 135: ...tion switch ON transmission not in neutral Shift into neutral blown fuse Replace with a new fuse of the same rating page 132 battery lead loose Tighten the battery lead low or dead battery Charge the battery page 109 If charging doesn t help see your dealer faulty starter motor If all possible causes are negative the starter motor may be faulty See your dealer ...

Page 136: ...cted spark plug cap Install the spark plug cap securely If the engine still won t start see your dealer loose battery cables Tighten the battery terminal bolts weak battery Charge the battery page 109 If charging doesn t help see your dealer SYMPTOM Engine starts but runs poorly POSSIBLE CAUSE WHAT TO DO idles roughly too fast stalls See your dealer runs erratically misfires See your dealer blubbe...

Page 137: ...HAT TO DO sooty exhaust rich fuel mixture See your dealer detonates or pings under load If applicable switch to the recommended octane gasoline page 54 or change your brand of gasoline If the problem persists see your dealer afterfires backfires See your dealer pre ignition runs on after ignition switched OFF See your dealer ...

Page 138: ...ch 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 96 Replacing a tube or tire involves removing and re installing the wheel pages 89 91 If you are unable to repair a flat tire on the trail you will need to push the motorcycle back to your...

Page 139: ...the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuse and check component operation The main fuse and sub fuse are located behind the left side cover Recommended Fuses Riding your motorcycle with a temporary tire repair can be risky If the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tire rep...

Page 140: ...ide cover page 53 Main Fuse Access 3 Remove the starter magnetic switch 3 from the ribs 4 of the battery box 4 Disconnect the wire connector 5 of the starter magnetic switch 5 Pull the fuse out If the main fuse is blown 6 install the spare main fuse 7 6 Reconnect the wire connector 7 Install the starter magnetic switch 5 1 main fuse 3 starter magnetic switch 4 ribs LEFT SIDE 1 5 wire connector 6 b...

Page 141: ...se out If the fuse is blown 10 replace it with a spare fuse 11 10 Install the left side cover If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Replacing a f use with one that has a higher rating greatly increases the chance of damage to the electrical system 2 sub fuse 8 fuse case 9 rib 8 11 10 blown fuse 11 spare fuse 2 9 10 ...

Page 142: ...ur motorcycle If the engine is still running turn it off and look it over carefully inspect it for fluid leaks check the tightness of critical nuts and bolts and secure 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 dama...

Page 143: ... key made If you 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 where you purchased your Honda They may have it listed in their records If they don t transport your motorcycle to them or the nearest dealer The dealer will probably have to remove the ignition switch assembly to find the key number so they can ma...

Page 144: ... a trailside repair 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 If the clutch lever breaks you may be able to temporarily switch the front brake lever to the clutch side then ride carefully back to base using the rear brake for slowing or stopping If you damage a throttle cable or other criti...

Page 145: ...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 dealer If Your Battery Is Low or Dead ...

Page 146: ...gine operation will occur intermittently while riding Even if this symptom occurs you can continue to ride your motorcycle If unstable engine operation occurs even if sufficient fuel is available have your motorcycle inspected by your dealer as soon as possible If Unstable Engine Operation Occurs Intermittently ...

Page 147: ...140 Taking Care of the Unexpected BLANK PAGE ...

Page 148: ...ion contains dimensions capacities and other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification 142 Specifications 144 Break in Guidelines 149 Emission Control Systems 150 Oxygenated Fuels 155 ...

Page 149: ...are required when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of the manual The VIN 1 is stamped on the right side of the steering head Serial Numbers 1 1 VIN RIGHT SIDE ...

Page 150: ...Technical Information 143 Vehicle Identification The engine number 2 is stamped on the left side of the engine 2 LEFT SIDE 2 engine number ...

Page 151: ...85 mm Wheelbase 55 9 in 1 420 mm Fuel Lubricants Fuel tank capacity 1 59 US gal 6 0 including reserve Fuel tank reserve 0 34 US gal 1 3 Fuel recommendation unleaded gasoline pump octane number of 86 or higher Engine oil capacity after draining 1 5 US qt 1 4 after draining and oil filter change 1 5 US qt 1 4 after disassembly 1 8 US qt 1 7 ...

Page 152: ... GN4 4 stroke oil USA Canada or Honda 4 stroke oil or an equivalent motorcycle oil Drive chain lubricant Pro Honda HP Chain Lube or equivalent Fuel Lubricants Air cleaner oil Pro Honda USA only or Honda Foam Filter Oil or an equivalent Capacities Passenger capacity operator only no passenger Maximum weight capacity 220 lb 100 kg Cargo capacity none Engine Specifications Displacement 15 2 cu in 249...

Page 153: ...ntake 0 004 in 0 10 mm Exhaust 0 006 in 0 15 mm Spark plug standard LMAR7H 9DS Spark plug gap 0 03 0 04 in 0 8 0 9 mm Idle speed 1 400 100 rpm Power Transmission Primary reduction 2 863 Gear ratio 1st 2 846 2nd 1 900 3rd 1 400 4th 1 083 5th 0 896 Final reduction 3 846 Final drive chain ...

Page 154: ... limit length 25 1 in 638 mm distance between a span of 41 pins Chassis Suspension Caster 26 5 Trail 4 0 in 102 mm Tire size front 80 100 21 51R NHS Tire size rear 100 100 18 59R NHS Tire type bias ply tube Tire pressure front cold 15 psi 100 kPa 1 0 kgf cm2 Tire pressure rear cold 15 psi 100 kPa 1 0 kgf cm2 Suspension front 8 5 in 216 mm axle travel Suspension rear 9 1 in 230 mm axle travel ...

Page 155: ... Main 10 A Sub 7 5 A Torque Specifications Oil drain bolt 18 lbf ft 24 N m 2 4 kgf m Front wheel axle 44 lbf ft 59 N m 6 0 kgf m Axle holder nuts 9 lbf ft 12 N m 1 2 kgf m Rear wheel axle 80 lbf ft 108 N m 11 0 kgf m Oil filter cover bolt 9 lbf ft 12 N m 1 2 kgf m Muffler tail cover bolt 9 lbf ft 12 N m 1 2 kgf m ...

Page 156: ... Guidelines Help 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 ...

Page 157: ... to the instructions provided The Vehicle Emission Control Information Label 1 2 is attached to the rear fender Noise Emission Requirements 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 maintained according to the instructions p...

Page 158: ...cal smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons Exhaust Emission Control System The exhaust emission control system includes a PGM FI system No adjustment to this system should be made although periodic inspection of the components is recommen...

Page 159: ...tem to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the throttle body Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED U S federal law prohibits or Canadian provincial laws may prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by an...

Page 160: ...May Affect Motorcycle Emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired by your Honda Motorcycle Dealer 1 Hard starting or stalling after starting 2 Rough idle 3 Misfiring or backfiring during acceleration 4 After burning backfiring 5 Poor performance driveability and poor fuel economy Federal regulations prohibit removing or disabling a device or ...

Page 161: ...vehicle complies with the Fuel Permeation Emission Control regulations of the U S Environmental Protection Agency EPA the California Air Resources Board CARB and Environment and Climate Change Canada ECCC The fuel tank fuel hoses and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control technologies Tampering with the fuel tank fuel hoses or fuel vapor charge hoses to re...

Page 162: ...tes provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol up to 10 by Volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol METHANOL methyl or wood alcohol up to 5 by Volume You may use gasoline containing methanol containi...

Page 163: ...e 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 Oxygenated fuels can damage paint and plastic Damage caused by spilled fuel is not covered under warranty ...

Page 164: ...onsumer Information This section contains information on your warranty and how to get an official Honda service manual Authorized Manuals 158 Warranty Coverage 159 Warranty Service 160 Contacting Honda 161 Your Honda Dealer 162 ...

Page 165: ...l and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician However if you possess the proper tools observe the safety standards and are mechanically capable you should find them easy to use Special Honda tools are necessary for some procedures Order On Line www helminc com Order Toll Free 1 ...

Page 166: ...et posted on our website at www honda ca It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the proper tools and serv...

Page 167: ...ll give you the 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 dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s h...

Page 168: ...hip 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 Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 9...

Page 169: ...Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage USA only Your dealer can inform you about competition and oth...

Page 170: ...Consumer Information 163 BLANK PAGE ...

Page 171: ...le sensor ignition cut off system 28 battery 105 brakes fluid level 83 lever front 16 lever front adjustment 82 pad wear 85 pedal rear 17 braking 31 break in guidelines 149 button engine stop 16 start 16 capacity fuel 55 cleaner air 64 cleaning appearance care 110 clutch system adjustment 72 lever 17 competition inspection 46 A B C Index ...

Page 172: ...der 3 162 emission control systems 150 emission requirements 150 engine number 143 engine flooded 28 pinging 54 starting 27 stop button 16 stopping 28 won t start 127 environment protecting 123 filter air 64 flat tire 131 flooded engine starting 28 fork 79 front brake lever 16 lever freeplay 82 front suspension 79 front wheel removal 89 D E F Index ...

Page 173: ...tank capacity 55 fuse 132 gap spark plug 75 gasohol 155 gasoline 54 gears shifting 29 Honda service manual 158 Honda contacting 161 ignition switch 15 inspection competition 46 post ride 34 pre ride 22 key lost 136 lever clutch 17 front brake 16 shift 17 G H I K L Index ...

Page 174: ...dule 41 manual service 158 modifications 8 oil engine 57 operating controls 11 operation component locations 12 oxygenated fuels 155 parking 33 pedal rear brake 17 pgm fi malfunction indicator lamp MIL 18 pinging engine 54 plug spark 75 post ride inspection 34 pre ride inspection 22 M O P Index ...

Page 175: ...ty 2 rim lock 88 schedule maintenance 41 service customer 161 manuals 158 warranty 160 shifting gears 29 side cover removal 53 side stand 17 97 spark arrester 77 spark knock 54 spark plug 75 specifications 144 stand side 17 97 start button 16 starting engine 27 stop button engine 16 stopping engine 28 storage 120 suspension front 79 rear 80 R S Index ...

Page 176: ...ure 93 flat 131 replacing 96 tools 52 towing 30 training rider 3 162 transporting 118 troubleshooting starting 127 vehicle identification no VIN 142 warranty coverage 158 extended 158 service 160 washing your motorcycle 111 weight limit 6 wheels 87 T V W Index ...

Page 177: ...s premature wear and damage Frequent causes of costly engine repairs are Engine oil insufficient quantity improper oil Air cleaner dirty cleaned but not oiled leaking because of improper installation poor seal Frequent causes of costly chassis repair are Chain A loosely adjusted chain or a chain stretched because of lack of lubrication may come off and damage an engine case or wheel hub Spokes Loo...

Page 178: ...Quick Reference Quick Reference Record important information here VIN Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr ...

Page 179: ...ngine Oil Capacity API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil or an equivalent motorcycle oil after draining 1 5 US qt 1 4 after draining and oil filter change 1 5 US qt 1 4 Maximum Weight Capacity 220 lb 100 kg...

Page 180: ...Quick Reference Quick Reference These symbols are used in Operating Controls section SYMBOL COMPONENT SEE PAGE ON ignition switch 15 OFF OFF ignition switch 15 START button 16 fuel reserve indicator 18 ...

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