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Honda CRF250L 2019 Owner'S Manual Download Page 75

Adjusting the Clutch Lever

Freeplay

#

Minor Adjustment

Attempt adjustment with the minor clutch

cable adjuster first.

1.

Pull back the rubber dust cover.

2.

Loosen the minor lock nut.

3.

Turn the minor clutch cable adjuster until

the freeplay is 10 - 20 mm (0.4 - 0.8 in).

4.

Tighten the minor lock nut and check the

freeplay again.

5.

Install the rubber dust cover.

20161122161659_32KZZE200_eng_BOOK Page 74 Tuesday, November 22 2016 16:19:28 JST

Clutch 

u

 

Adjusting the Clutch Lever Freeplay

Maintenance

71

Continued

Rubber dust

cover

Minor

lock nut

Minor clutch

cable

adjuster

–

+

Summary of Contents for CRF250L 2019

Page 1: ......

Page 2: ...ble before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured in this owner s manual may not match your actual vehicle 2016 Honda Motor Co Ltd 20161122161659_32KZZE200_eng_BOOK Page 1 Tuesday November 22 2016 16 19 28 JST ...

Page 3: ...product To ensure your safety and riding pleasure Read this owner s manual carefully Follow all recommendations and procedures contained in this manual Pay close attention to safety messages contained in this manual and on the motorcycle The following code in this manual indicates the country Country Codes Code Country CRF250L PH Philipines 20161122161659_32KZZE200_eng_BOOK Page 2 Tuesday November...

Page 4: ... own good judgement You will find important safety information in a variety of forms including Safety labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 3WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow ...

Page 5: ... Motorcycle Safety P 2 Operation Guide P 18 Maintenance P 34 Troubleshooting P 76 Information P 94 Specifications P 106 Index P 109 20161122161659_32KZZE200_eng_BOOK Page 4 Tuesday November 22 2016 16 19 28 JST ...

Page 6: ... P 11 Accessories Modifications P 14 Off Road Safety P 15 Loading P 16 20161122161659_32KZZE200_eng_BOOK Page 5 Tuesday November 22 2016 16 19 28 JST This section contains important information for safe riding of your motorcycle Please read this section carefully Motorcycle Safety ...

Page 7: ...ree of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel Instruct your passenger on holding onto the seat strap or your waist leaning with you in turns and keeping their feet on the footpegs even when the motorcycle is stopped Take Time to Learn Practice Even if you have ridden other motorcycles practice riding in a safe area ...

Page 8: ...to use good judgement and ride safely Don t Drink and Ride Alcohol and riding don t mix Even one alcoholic drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink 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 ...

Page 9: ...ntinue riding first turn the ignition switch to the Off position and evaluate the condition of your motorcycle Inspect for fluid leaks check the tightness of critical nuts and bolts and check the handlebar control levers brakes and wheels Ride slowly and cautiously Your motorcycle may have suffered damage that is not immediately apparent Have your motorcycle thoroughly checked at a qualified servi...

Page 10: ...ver run your motorcycle inside a garage or other enclosure 3WARNING Running the engine of your motorcycle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colourless odorless gas can quickly cause unconsciousness and lead to death Only run your motorcycle s engine when it is located in a well ventilated area outdoors 201611...

Page 11: ...re as follows Read instructions contained in Owner s Manual carefully Read instructions contained in Shop Manual carefully In the interest of safety take the motorcycle to be serviced only by your dealer DANGER with RED background You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING with ORANGE background You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions...

Page 12: ...valve begins to open at 1 1 kgf cm2 or SAFETY REMINDER LABEL For your protection always wear helmet protective apparel FUEL LABEL Unleaded petrol only ETHANOL up to 10 by volume 20161122161659_32KZZE200_eng_BOOK Page 11 Tuesday November 22 2016 16 19 28 JST Image Labels Motorcycle Safety 8 ...

Page 13: ...oad conditions Helmet Safety standard certified high visibility correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision or other approved eye protection 3WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Make sure that you and any passenger always wear an approved helmet and protec...

Page 14: ... riding But if you plan on any serious off road riding you will need more serious off road gear In addition to your helmet and eye protection we recommend off road motorcycle boots and gloves riding pants with knee and hip pads a jersey with elbow pads and a chest shoulder protector 20161122161659_32KZZE200_eng_BOOK Page 13 Tuesday November 22 2016 16 19 28 JST Safety Precautions Motorcycle Safety...

Page 15: ...u Where possible reduce speed before turning otherwise you risk sliding out Exercise caution on low traction surfaces u The tyres slip more easily on such surfaces and braking distances are longer Avoid continuous braking u Repeated braking such as when descending long steep slopes can seriously overheat the brakes reducing their effectiveness Use engine braking with intermittent use of the brakes...

Page 16: ...em dry Parking Park on a firm level surface If you must park on a slight incline or loose surface park so that the motorcycle cannot move or fall over Make sure that high temperature parts cannot come into contact with flammable materials Do not touch the engine muffler brakes and other high temperature parts until they cool down To reduce the likelihood of theft always lock the handlebar and remo...

Page 17: ...delines Follow these guidelines to protect the engine fuel system and catalytic converter Use only unleaded petrol Use recommended octane number Using lower octane petrol will result in decreased engine performance Do not use fuels containing a high concentration of alcohol 2 P 104 Do not use stale or contaminated petrol or an oil petrol mixture Avoid getting dirt or water in the fuel tank 2016112...

Page 18: ...stall accessories on your motorcycle be certain the modification is safe and legal 3WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding accessories and modifications Do not pull a trailer with or attach a sidecar to your motorcycle Your motorcycle was not designed for these attachments...

Page 19: ... Familiarity with your motorcycle is critically important should a problem occur far from help Never ride beyond your ability and experience or faster than conditions warrant If you are not familiar with the terrain ride cautiously Hidden rocks holes or ravines could spell disaster A muffler is required in most off road areas Don t modify your exhaust system Remember that excessive noise bothers e...

Page 20: ... Also follow these guidelines when you ride off road on rough terrain Do not carry a passenger Keep cargo small and light weight 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 3WARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed Follow a...

Page 21: ...20161122161659_32KZZE200_eng_BOOK Page 20 Tuesday November 22 2016 16 19 28 JST Motorcycle Safety 17 ...

Page 22: ...ember 22 2016 16 19 28 JST Operation Guide 18 Throttle grip P 73 Coolant reserve tank P 59 Rear brake fluid reservoir P 61 Engine oil filter P 57 Engine oil fill cap P 55 Engine oil level inspection window P 55 Front brake fluid reservoir P 61 Engine oil drain bolt P 57 ...

Page 23: ...19 28 JST Operation Guide 19 Clutch lever P 70 Fuel fill cap P 31 Fuse box P 91 Drive chain P 65 Side stand P 64 Shift lever P 30 Battery P 52 Main fuse P 92 Seat P 53 Left side cover P 54 Crankcase breather P 74 Document bag P 33 Tool box Tool kit P 33 Helmet holder P 32 ...

Page 24: ...ssive engine rpm range Tachometer NOTICE Do not operate the engine in the tachometer red zone Excessive engine speed can adversely affect engine life Display Check When the ignition switch is turned to the On position all the mode and digital segments will show If any part of these displays does not come on when it should have your dealer check for problems ...

Page 25: ...f P 80 Speedometer Clock 12 hour display Odometer TOTAL Tripmeter TRIP A B SEL button switches between the odometer and tripmeters Odometer Total distance ridden Tripmeter Distance ridden since tripmeter was reset press and hold SET button to reset to 0 0 km at the tripmeter display Remaining fuel when only 1st E segment starts flashing When is displayed go to your dealer for service When is displ...

Page 26: ... button until the desired hour is displayed u Press and hold to advance the hour fast d Press the SET button The minute digits start flashing e Press the SEL button until the desired minute is displayed u Press and hold to advance the minute fast 20161122161659_32KZZE200_eng_BOOK Page 25 Tuesday November 22 2016 16 19 28 JST Operation Guide 22 Instruments Continued ...

Page 27: ...djustment can also be set by turning the ignition switch to the Off position If no buttons were pressed for about 30 seconds the display will stop flashing automatically and the adjustment will be cancelled 20161122161659_32KZZE200_eng_BOOK Page 26 Tuesday November 22 2016 16 19 28 JST Operation Guide 23 ...

Page 28: ... Neutral Comes on briefly when the ignition switch is turned to the On position with the engine stop switch in the Run position If it comes on while engine is running P 79 Neutral indicator PGM FI Programmed Fuel Injection malfunction indicator lamp MIL If one of these indicators does not come on when it should have your dealer check for problems ...

Page 29: ...Operation Guide 25 High beam indicator Left turn signal indicator Right turn signal indicator High coolant temperature indicator Comes on briefly when the ignition switch is turned to the On position with the engine stop switch in the Run position If it comes on while running P 78 ...

Page 30: ...e 29 Operation Guide 26 Horn button u Pressing the switch turns the turn signal off Headlight dimmer switch Low beam Turn signal switch High beam Hazard switch Switchable when the ignition switch is turned to the On position ...

Page 31: ...ey can be removed when in the Off or Lock position Steering Lock P 28 Engine stop switch Should normally remain in the run position u In an emergency switch to the Off position the starter motor will not operate to stop the engine Start button Headlight turns off when operating the starter motor On Off Lock Turns electrical system on for starting riding Turns engine off Locks steering ...

Page 32: ... left b Push the key down and turn the ignition switch to the Lock position u Jiggle the handlebar if the lock is difficult to engage c Remove the key Unlocking Insert the key push it in and turn the ignition switch to the Off position 20161122161659_32KZZE200_eng_BOOK Page 31 Tuesday November 22 2016 16 19 28 JST Operation Guide 28 Switches Continued Push Ignition key Turn ...

Page 33: ... Turn the ignition switch to the On position c Shift the transmission to Neutral N indicator to come on Alternatively pull in the clutch lever to start your motorcycle with the transmission in gear so long as the side stand is raised d Press the start button with the throttle completely closed If the engine does not start a Open the throttle fully and press the start button for 5 seconds b Repeat ...

Page 34: ... 6 forward gears in a one down five up shift pattern If you put the motorcycle in gear with the side stand down the engine will shut off 20161122161659_32KZZE200_eng_BOOK Page 33 Tuesday November 22 2016 16 19 28 JST Operation Guide 30 2 3 4 5 6 1 N ...

Page 35: ...lling align the fuel fill cap latch with the slot in the filler neck b Push the fuel fill cap into the filler neck until it snaps closed and locks c Remove the key and close the lock cover u The key cannot be removed if the fuel fill cap is not locked 3WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and...

Page 36: ... and close the lock cover u Use the helmet holder only when parked 3WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed Use the helmet holder only while parked Do not ride with a helmet secured by the holder 20161122161659_32KZZE200_eng_BOOK Page 35 Tuesday November 22 2016 16 19 28...

Page 37: ...e tool kit is stored in the tool box located on the left side of the motorcycle u Insert the ignition key and turn it clockwise to open the tool box 20161122161659_32KZZE200_eng_BOOK Page 36 Tuesday November 22 2016 16 19 28 JST Operation Guide 33 Document bag Tool box Tool kit Ignition key ...

Page 38: ...P 59 Brakes P 61 Side Stand P 64 Drive Chain P 65 Wheels P 69 Clutch P 70 Throttle P 73 Crankcase Breather P 74 Other Adjustments P 75 Adjusting the Headlight Aim P 75 20161122161659_32KZZE200_eng_BOOK Page 37 Tuesday November 22 2016 16 19 28 JST Please read Importance of Maintenance and Maintenance Fundamentals carefully before attempting any maintenance Refer to Specifications for service data ...

Page 39: ...ns and schedules in this owner s manual Maintenance Safety Always read the maintenance instructions before you begin each task and make sure that you have the tools parts and skills required 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 Follow these guidelines when performing maintenance St...

Page 40: ...nance to help ensure that your motorcycle is properly maintained Make sure that whomever performs the maintenance completes this record All scheduled maintenance is considered a normal owner operating cost and will be charged to you by your dealer Retain all receipts If you sell the motorcycle these receipts should be transferred with the motorcycle to the new owner Honda recommends that your deal...

Page 41: ...ant 5 3 Years 59 Cooling System Secondary Air Supply System Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary tools and are mechanically skilled Procedures are provided in an official Honda Shop Manual Inspect clean adjust lubricate or replace if necessary Lubricate Replace Clean Technical In the interest of safety have your motorcy...

Page 42: ... Clutch System 70 Side Stand 64 Suspension Nuts Bolts Fasteners 4 Wheels Tyres 4 47 69 Steering Head Bearings Notes 1 At higher odometer reading repeat at the frequency interval established here 3 Service more frequently when riding in rain or at full throttle 2 Service more frequently when riding in unusually wet or dusty areas 4 Service more frequently when riding OFF ROAD 5 Replacement requires...

Page 43: ...l Add engine oil if necessary Check for leaks 2 P 55 Coolant level Add coolant if required Check for leaks 2 P 59 Drive chain Check condition and slack adjust and lubricate if necessary 2 P 65 Brakes Check operation Front and Rear check brake fluid level and pads wear 2 P 61 2 P 62 Lights and horn Check that lights indicators and horn function properly Engine stop switch Check for proper function ...

Page 44: ... 69 Be sure the fuel fill cap is securely fastened 2 P 31 Check for loose cables and other parts and anything that appears abnormal Use a wrench to check the tightness of all accessible nuts bolts and fasteners 20161122161659_32KZZE200_eng_BOOK Page 43 Tuesday November 22 2016 16 19 28 JST Maintenance Fundamentals Maintenance 40 ...

Page 45: ... label is attached to the left side of the frame 3WARNING Installing non Honda parts may make your motorcycle unsafe and cause a crash in which you can be seriously hurt or killed Always use Honda Genuine Parts or equivalents that have been designed and approved for your motorcycle 20161122161659_32KZZE200_eng_BOOK Page 44 Tuesday November 22 2016 16 19 28 JST Maintenance Fundamentals Maintenance ...

Page 46: ...p is removed 3WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield or have a skilled mechanic do the battery servicing Cleaning the Battery Terminals 1 Remove the battery 2 P 52 2 If the terminals are starting to corrode and are coated...

Page 47: ...ry and possibly damaging the system Fuses Fuses protect the electrical circuits on your motorcycle If something electrical on your motorcycle stops working check for and replace any blown fuses 2 P 91 Inspecting and Replacing Fuses Turn the ignition switch to the Off position to remove and inspect fuses If a fuse is blown replace with a fuse of the same rating For fuse ratings see Specifications 2...

Page 48: ...sfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB For example the following label shows the MA classification 2 The SAE standard grades oils by their viscosity 3 The API classification specifies the quality and per...

Page 49: ...ct the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration 2 P 65 If the chain does not move smoothly makes strange noises has damaged rollers has loose pins has missing O rings or kinks have the chain inspected by your dealer Also inspect the drive sprocket and driven sprocket If either has worn or damaged teeth have the sprocket replace...

Page 50: ...rasive cleaner chain cleaner or lubricant NOT designed specifically for O ring chains as these can damage the rubber O ring seals Avoid getting lubricant on the brakes or tyres Avoid applying excess chain lubricant to prevent spray onto your clothes and the motorcycle Recommended Coolant Use only genuine HONDA PRE MIX COOLANT without diluting with water Genuine HONDA PRE MIX COOLANT is excellent a...

Page 51: ...ad If you only ride on pavement check the pressure at least once a month or any time you think the tyres look low Always check air pressure when your tyres are cold If you decide to adjust the tyre pressure for a particular off road riding condition make changes a little at a time Inspecting for Damage Inspect the tyres for cuts slits or cracks that exposes fabric or cords or nails or other foreig...

Page 52: ...their positions A tilted valve stem indicates the tube is slipping inside the tyre or the tyre is slipping on the rim See your dealer 3WARNING Riding on tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tyre inflation and maintenance 20161122161659_32KZZE200_eng_BOOK Page 51...

Page 53: ...place the inner tube whenever you replace a tyre The old tube will probably be stretched and it could fail if installed in a new tyre 3WARNING Installing improper tyres on your motorcycle can adversely affect handling and stability and can cause a crash in which you can be seriously hurt or killed Always use the size and type of tyres recommended in this owner s manual 20161122161659_32KZZE200_eng...

Page 54: ... cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust Do not perform the maintenance Should be serviced by your dealer 20161122161659_32KZZE200_eng_BOOK Page 53 Tuesday November 22 2016 16 19 28 JST Maintenance Fundamentals Maintenance 50 ...

Page 55: ...ustments and parts replacement with the tools contained in the kit Standard Phillips screwdriver Screwdriver handle 8 10 mm Open end wrench 12 14 mm Open end wrench 5 mm Hex wrench 6 mm Hex wrench Fuse puller 20161122161659_32KZZE200_eng_BOOK Page 54 Tuesday November 22 2016 16 19 28 JST Maintenance 51 ...

Page 56: ... care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always connect the positive terminal first Make sure that bolts and nuts are tight Make sure the clock information is correct after the battery is reconnected 2 P 22 For proper handling of the battery see Maintenance Fundamentals 2 P 42 Battery Goes Dead 2 P 87 20161122161659_32KZZE200_eng_BOOK Page ...

Page 57: ...to the front stay and rear stays 2 Install the collars onto the hook bolts Tighten the hook bolts Torque 21 N m 2 1 kgf m 15 lbf ft 20161122161659_32KZZE200_eng_BOOK Page 56 Tuesday November 22 2016 16 19 28 JST Removing Installing Body Components u Seat Maintenance 53 Hook bolt Prongs Hook bolt Collar Tab Recess Front stay Seat Rear stays Collar ...

Page 58: ...t 3 Remove the left side cover Installation Install the parts in the reverse order of removal 20161122161659_32KZZE200_eng_BOOK Page 57 Tuesday November 22 2016 16 19 28 JST Removing Installing Body Components u Left Side Cover Maintenance 54 Bolt Left side cover Grommet Prong ...

Page 59: ...3 minutes 3 Place your motorcycle in an upright position on a firm level surface 4 Check that the oil level is between the upper level and lower level marks in the oil level inspection window 20161122161659_32KZZE200_eng_BOOK Page 58 Tuesday November 22 2016 16 19 28 JST Maintenance 55 Oil fill cap Oil level inspection window Upper level mark Lower level mark ...

Page 60: ...vel mark u Make sure no foreign objects enter the oil filler opening u Wipe up any spills immediately 2 Securely reinstall the oil fill cap NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine Do not mix different brands and grades of oil They may affect lubrication and clutch operation For the recommended oil and oil selection guidelines see Maintenance F...

Page 61: ...the ignition switch to the Off position and wait for 2 to 3 minutes 3 Place your motorcycle on a firm level surface 4 Place a drain pan under the drain bolt 5 Remove the oil fill cap drain bolt and sealing washer to drain the oil 6 Remove the oil filter cover oil filter spring and gasket by removing the oil filter cover bolts u Discard the oil and oil filter at an approved recycling centre 2016112...

Page 62: ...with the recommended oil 2 P 44 2 P 107 and install the oil fill cap Required oil When changing oil engine oil filter 1 5 L 1 6 US qt 1 3 Imp qt When changing oil only 1 4 L 1 5 US qt 1 2 Imp qt 11 Check the oil level 2 P 55 12 Check that there are no oil leaks NOTICE Improper installation of the oil filter can result in serious damage to the engine 20161122161659_32KZZE200_eng_BOOK Page 61 Tuesda...

Page 63: ... that the coolant level is between the UPPER level and LOWER level marks in the reserve tank If the coolant level is dropping noticeably or the reserve tank is empty you likely have a serious leak Have your motorcycle inspected by your dealer 20161122161659_32KZZE200_eng_BOOK Page 62 Tuesday November 22 2016 16 19 28 JST Maintenance 59 UPPER level mark LOWER level mark Reserve tank Reserve tank ca...

Page 64: ...mark u Make sure no foreign objects enter the reserve tank opening 2 Securely reinstall the reserve tank cap 3WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out potentially scalding you Always let the engine and radiator cool down before removing the radiator cap Changing Coolant Have your dealer change the coolant unless you have the proper tools and are ...

Page 65: ...OWER level and UPPER level marks If the brake fluid level in either reservoir is below the LOWER level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you most likely have a leak Have your motorcycle inspected by your dealer 20161122161659_32KZZE200_eng_BOOK Page 64 Tuesday November 22 2016 16 19 28 JST Maintenance 61 Fron...

Page 66: ...per 2 Rear Inspect the brake pads from the rear right of the motorcycle If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time 20161122161659_32KZZE200_eng_BOOK Page 65 Tuesday November 22 2016 16 19 28 JST Brakes u Inspecting the Brake Pads Maintenance 62 Front Rear Pads Wear indicator Disc Pads Wear indicator Disc Wear indicator Wear ind...

Page 67: ...urn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction B if the switch operates too soon 20161122161659_32KZZE200_eng_BOOK Page 66 Tuesday November 22 2016 16 19 28 JST Brakes u Adjusting the Brakelight Switch Maintenance 63 Brakelight switch Adjusting nut B A ...

Page 68: ...n 3 Sit on the motorcycle put the transmission in Neutral and raise the side stand 4 Start the engine pull the clutch lever in and shift the transmission into gear 5 Lower the side stand all the way The engine should stop as you lower the side stand If the engine doesn t stop have your motorcycle inspected by your dealer 20161122161659_32KZZE200_eng_BOOK Page 67 Tuesday November 22 2016 16 19 28 J...

Page 69: ...e your motorcycle on its side stand on a firm level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive chain slack 25 35 mm 1 0 1 4 in u Do not ride your motorcycle if the slack exceeds 60 mm 2 4 in 4 Roll the motorcycle forward and check that the chain moves smoothly 5 Inspect the sprockets 2 P 45 6 Clean and lubricate the drive chain 2 P 46 20161122...

Page 70: ...r motorcycle on its side stand on a firm level surface 3 Loosen the rear axle nut 4 Loosen the lock nuts on both adjusting bolts 20161122161659_32KZZE200_eng_BOOK Page 69 Tuesday November 22 2016 16 19 28 JST Drive Chain u Adjusting the Drive Chain Slack Maintenance 66 Adjusting plate Adjusting bolt Lock nut Rear axle nut Adjusting bolt Lock nut Reference mark Adjusting plate Index marks ...

Page 71: ...ference mark on both sides of the swingarm Both marks should correspond If the axle is misaligned turn the right or left adjusting bolt until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut Torque 88 N m 9 0 kgf m 65 lbf ft 8 Hold the adjusting bolts and tighten the lock nuts Torque 27 N m 2 8 kgf m 20 lbf ft 9 Recheck drive chain slack If a torque wrench was not used for...

Page 72: ...n Slider Check the condition of the drive chain slider The drive chain slider will need to be replaced if the chain slider is worn to the wear limit indicator or wear limit line To inspect the wear limit line remove the drive sprocket cover by removing the bolts If necessary have the drive chain slider replaced by your dealer 20161122161659_32KZZE200_eng_BOOK Page 71 Tuesday November 22 2016 16 19...

Page 73: ... the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations 2 P 81 1 Inspect the wheel rims and spokes for damage 2 Tighten any loose spokes 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 20161122161659_32KZZE200_eng...

Page 74: ...or kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion NOTICE Improper freeplay adjustment can cause premature clutch wear 20161122161659_32KZZE200_eng_BOOK Page 73 Tuesday November 22 2016 16 19 28 JST Maintenance 70 Clutch lever Freeplay ...

Page 75: ... Turn the minor clutch cable adjuster until the freeplay is 10 20 mm 0 4 0 8 in 4 Tighten the minor lock nut and check the freeplay again 5 Install the rubber dust cover 20161122161659_32KZZE200_eng_BOOK Page 74 Tuesday November 22 2016 16 19 28 JST Clutch u Adjusting the Clutch Lever Freeplay Maintenance 71 Continued Rubber dust cover Minor lock nut Minor clutch cable adjuster ...

Page 76: ...r until the clutch lever freeplay is 10 20 mm 0 4 0 8 in 4 Tighten the major lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your motorcycle should move smoothly and accelerate gradually If proper adjustment cann...

Page 77: ...or if the cable is damaged have the motorcycle inspected by your dealer Freeplay at the throttle grip flange 2 6 mm 0 1 0 2 in Adjusting the Throttle Freeplay 1 Loosen the lock nut 2 Turn the adjuster until the freeplay is 2 6 mm 0 1 0 2 in 3 Tighten the lock nut and inspect the throttle action again 20161122161659_32KZZE200_eng_BOOK Page 76 Tuesday November 22 2016 16 19 28 JST Maintenance 73 Fre...

Page 78: ...itable container under the crankcase breather tube 2 Remove the crankcase breather tube and drain deposits 3 Reinstall the crankcase breather tube 20161122161659_32KZZE200_eng_BOOK Page 77 Tuesday November 22 2016 16 19 28 JST Maintenance 74 Crankcase breather tube ...

Page 79: ...he headlight for proper alignment Turn the pinion using a Phillips screwdriver provided in the tool kit 2 P 51 in or out as necessary Obey local laws and regulations 20161122161659_32KZZE200_eng_BOOK Page 78 Tuesday November 22 2016 16 19 28 JST Maintenance 75 Lower Raise Pinion ...

Page 80: ...ction Indicator Lamp MIL P 79 Other Warning Indications P 80 Fuel Gauge Failure Indication P 80 Tyre Puncture P 81 Electrical Trouble P 87 Battery Goes Dead P 87 Burned out Light Bulb P 87 Blown Fuse P 91 Unstable Engine Operation Occurs Intermittently P 93 20161122161659_32KZZE200_eng_BOOK Page 79 Tuesday November 22 2016 16 19 28 JST Troubleshooting ...

Page 81: ...oon as possible Starter Motor Does Not Operate Check the following items Check the correct engine starting sequence 2 P 29 Make sure engine stop switch is in the Run position 2 P 27 Check for a blown fuse 2 P 91 Check for a loose battery connection or battery terminal corrosion 2 P 42 2 P 52 Check the condition of the battery 2 P 87 If the problem continues have your motorcycle inspected by your d...

Page 82: ...t the radiator fan is operating and then turn the ignition switch to the Off position If the fan is not operating Suspect a fault Do not start the engine Transport your motorcycle to your dealer If the fan is operating Allow the engine to cool with the ignition switch in the Off position 3 After the engine has cooled inspect the radiator hose and check if there is a leak 2 P 59 If there is a leak ...

Page 83: ...mp MIL If the indicator comes on while riding you may have a serious problem with the PGM FI system Reduce speed and have your motorcycle inspected by your dealer as soon as possible 20161122161659_32KZZE200_eng_BOOK Page 82 Tuesday November 22 2016 16 19 28 JST Troubleshooting 79 ...

Page 84: ...n If the fuel system has an error the fuel gauge indicators will be displayed as shown in the illustration If this occurs see your dealer as soon as possible 20161122161659_32KZZE200_eng_BOOK Page 83 Tuesday November 22 2016 16 19 28 JST Troubleshooting 80 ...

Page 85: ... a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before you ride again Anytime a tube is replaced the tyre should be carefully inspected as described 3WARNING Riding your motorcycle with a temporary tyre or tube 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 tyre or ...

Page 86: ... the ground using a maintenance stand or a hoist 5 Remove the front axle shaft side collars and wheel u Avoid getting grease oil or dirt on the disc or pad surfaces u Do not pull the brake lever while the brake caliper is removed 20161122161659_32KZZE200_eng_BOOK Page 85 Tuesday November 22 2016 16 19 28 JST Tyre Puncture u Removing Wheels Troubleshooting 82 Axle pinch bolts Front axle shaft ...

Page 87: ...m 51 lbf ft 4 Lower the front wheel on the ground 5 Apply the brake lever several times Then pump the fork several times 6 Tighten the axle pinch bolt Torque 22 N m 2 2 kgf m 16 lbf ft 7 Raise the front wheel off the ground again and check that the wheel rotates freely after you release the brake 8 Lower the front wheel on the ground again If a torque wrench was not used for installation see your ...

Page 88: ... be moved all the way forward for maximum drive chain slack 4 Remove the rear axle nut 5 Remove the drive chain from the driven sprocket by pushing the rear wheel forward 6 Remove the rear axle shaft and adjusting plates 20161122161659_32KZZE200_eng_BOOK Page 87 Tuesday November 22 2016 16 19 28 JST Tyre Puncture u Removing Wheels Troubleshooting 84 Adjusting plate Adjusting bolt Lock nut Rear axl...

Page 89: ...el reverse the removal procedure u Take care to prevent the brake caliper from scratching the wheel during installation NOTICE When installing a wheel or caliper into original position carefully fit the brake disc between the pads to avoid scratching them 2 Make sure that the slot on the brake caliper bracket is positioned in the lug on the swingarm 20161122161659_32KZZE200_eng_BOOK Page 88 Tuesda...

Page 90: ...heel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity 20161122161659_32KZZE200_eng_BOOK Page 89 Tuesday November 22 2016 16 19 28 JST Tyre Puncture u Removing Wheels Troubleshooting 86 ...

Page 91: ... using an automobile battery is not recommended as this can damage your motorcycle s electrical system Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ignition switch to the Off or Lock position Allow the bulb to cool before replacing it Do not use bulbs other than those specified Check the replacement bulb for correct operation before riding For the li...

Page 92: ...he reverse order of removal u Install the dust cover with its tabs positioned vertically Do not touch the glass surface with your fingers If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol 20161122161659_32KZZE200_eng_BOOK Page 91 Tuesday November 22 2016 16 19 28 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 88 Headlight assembly Bolts Bolts T...

Page 93: ...ounterclockwise and remove it 6 Slightly press the bulb and turn it counterclockwise 7 Install a new bulb and parts in the reverse order of removal 20161122161659_32KZZE200_eng_BOOK Page 92 Tuesday November 22 2016 16 19 28 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 89 Continued Hook bolt Rear fender Collar Collar Hook bolt Grommet Prong Bulb Socket ...

Page 94: ... parts in the reverse order of removal License Plate Light The license plate light use a LED If there is a LED which is not turned on see your dealer for this servicing 20161122161659_32KZZE200_eng_BOOK Page 93 Tuesday November 22 2016 16 19 28 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 90 Turn signal lens Screw Bulb License plate light ...

Page 95: ...fuses out with the fuse puller in the tool kit one by one check for a blown fuse Always replace a blown fuse with a spare of the same rating 4 Close the fuse box cover 5 Install the left side cover 20161122161659_32KZZE200_eng_BOOK Page 94 Tuesday November 22 2016 16 19 28 JST Electrical Trouble u Blown Fuse Troubleshooting 91 Continued Fuse box cover Spare fuses ...

Page 96: ... fuse with a spare of the same rating u Spare main fuse is provided in the starter magnetic switch 5 Reinstall parts in the reverse order of removal NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your motorcycle inspected by your dealer 20161122161659_32KZZE200_eng_BOOK Page 95 Tuesday November 22 2016 16 19 28 JST Electrical Trouble u Blown Fuse Troubleshooting 92 St...

Page 97: ...ittently 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 20161122161659_32KZZE200_eng_BOOK Page 96 Tuesday November 22 2016 16 19 28 JST Troubleshooting 93 ...

Page 98: ...rcycle P 97 Storing Your Motorcycle P 100 Transporting Your Motorcycle P 101 You the Environment P 101 Serial Numbers P 103 Fuels Containing Alcohol P 104 Catalytic Converter P 105 20161122161659_32KZZE200_eng_BOOK Page 97 Tuesday November 22 2016 16 19 28 JST Information ...

Page 99: ...take the spare key or the key number to your dealer If you lose all keys and the key number the ignition switch assembly will probably have to be removed by your dealer to determine the key number A metal key holder may cause damage to the area surrounding the ignition switch 20161122161659_32KZZE200_eng_BOOK Page 98 Tuesday November 22 2016 16 19 28 JST Keys Information 95 ...

Page 100: ...ometer The display locks at 999 999 when the read out exceeds 999 999 Tripmeter The tripmeter A and B return to 0 0 when each read out exceeds 9 999 9 Document Bag The owner s manual registration and insurance information can be stored in the plastic document bag located under the seat Ignition Cut off System A banking lean angle sensor automatically stops the engine and fuel pump if the motorcycl...

Page 101: ...ing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water and dry with a soft clean cloth 4 After the motorcycle dries lubricate any moving parts u Make sure that no lubricant spills onto the brakes or tyres Brake discs pads drum or shoes contaminated with oil will suffer greatly reduced braking effectiveness and can lead to a crash 5...

Page 102: ...belongings Do not direct water at the air cleaner u Water in the air cleaner can prevent the engine from starting Do not direct water near the headlight u The headlight s inside lens may fog temporarily after washing or while riding in the rain This does not impact the headlight function u Any condensation inside the headlight should dissipate after a few minutes of running the engine with the hea...

Page 103: ...ve stubborn stains use diluted detergent and rinse thoroughly with plenty of water Avoid getting petrol brake fluid or detergents on the instruments panels or headlight Exhaust Pipe and Muffler 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 y...

Page 104: ...n a maintenance stand and position a block so that both tyres are off the ground After rain remove the body cover and allow the motorcycle to dry Remove the battery 2 P 52 to prevent discharge Charge the battery in a shaded well ventilated area u If you leave the battery in place disconnect the negative terminal to prevent discharge After removing your motorcycle from storage inspect all maintenan...

Page 105: ...torcycle can cause serious damage to the transmission You the Environment Owning and riding a motorcycle can be enjoyable but you must do your part to protect the environment Choose Sensible Cleaners Use a biodegradable detergent when you wash your motorcycle Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protective ozone layer 20161122161659_32KZZ...

Page 106: ...rea and to get instructions on how to dispose of non recyclable wastes Do not place used engine oil in the trash or pour it down a drain or on the ground Used oil petrol coolant and cleaning solvents contain poisons that can hurt refuse workers and contaminate drinking water lakes rivers and oceans 20161122161659_32KZZE200_eng_BOOK Page 105 Tuesday November 22 2016 16 19 28 JST You the Environment...

Page 107: ...red in order to register your motorcycle They may also be required when ordering replacement parts You should record these numbers and keep them in a safe place 20161122161659_32KZZE200_eng_BOOK Page 106 Tuesday November 22 2016 16 19 28 JST Serial Numbers Information 103 Frame number Engine number ...

Page 108: ...l may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may Damage the painting of the fuel tank Damage the rubber tubes of the fuel line Cause corrosion of the fuel tank Cause poor drivability NOTICE Use of blended fuels containing higher than approved percentages can damage metal rubber plastic parts of your fuel system If you notice any undesirable operating s...

Page 109: ...ollution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your motorcycle s catalytic converters Always use unleaded petrol Leaded petrol will damage the catalytic converters Keep the engine in good running condition Have your motorcycle serviced if your engine is misfiring backfiring stalling or otherwise n...

Page 110: ... m 7 5 ft Displacement 249 cm3 15 2 cu in Bore x stroke 76 000 x 55 037 mm 2 9921 x 2 1668 in Compression ratio 10 7 1 Fuel Unleaded petrol Recommended 91 RON or higher Fuel containing alcohol ETHANOL up to 10 by volume Tank capacity 7 8 L 2 06 US gal 1 72 Imp gal Battery YTZ8V 12 V 7 0 Ah 10 HR Gear ratio 1st 3 333 2nd 2 117 3rd 1 571 4th 1 304 5th 1 103 6th 0 967 Reduction ratio primary final 2 ...

Page 111: ...ing SAE 10W 30 JASO T 903 standard MA Engine oil capacity After draining 1 4 L 1 5 US qt 1 2 Imp qt After draining filter change 1 5 L 1 6 US qt 1 3 Imp qt After disassembly 1 8 L 1 9 US qt 1 6 Imp qt Recommended brake fluid Honda DOT 3 or DOT 4 Brake Fluid Cooling system capacity 1 02 L 1 08 US qt 0 90 Imp qt Recommended coolant HONDA PRE MIX COOLANT Drive chain slack 25 35 mm 1 0 1 4 in Recommen...

Page 112: ...k bolt 21 N m 2 1 kgf m 15 lbf ft Engine oil drain bolt 24 N m 2 4 kgf m 18 lbf ft Oil filter cover bolt 10 N m 1 0 kgf m 7 lbf ft Front axle shaft 69 N m 7 0 kgf m 51 lbf ft Front wheel axle pinch bolt 22 N m 2 2 kgf m 16 lbf ft Rear axle nut 88 N m 9 0 kgf m 65 lbf ft Drive chain adjusting lock nut 27 N m 2 8 kgf m 20 lbf ft 20161122161659_32KZZE200_eng_BOOK Page 111 Tuesday November 22 2016 16 ...

Page 113: ...Motorcycle 97 Clock 21 Clutch Freeplay 71 Colour Label 41 Coolant 59 Crankcase Breather 74 Crash 5 D Drive Chain 45 65 Drive Chain Slider 68 E Electrical Trouble 87 Engine Idle Speed 37 Number 103 Oil 44 55 Oil Filter 57 Overheats 78 Starting 29 Stop Switch 27 96 Stopping 96 Will Not Start 77 F Flooded Engine 29 Frame Number 103 20161122161659_32KZZE200_eng_BOOK Page 112 Tuesday November 22 2016 1...

Page 114: ...26 I Ignition Cut off System Banking Sensor 96 Ignition Key 95 Ignition Switch 27 96 Image Labels 7 Indicators 24 Instruments Controls Other Features 96 K Keys 95 L Labels 7 Load Limit 16 Loading Guidelines 16 M Maintenance Fundamentals 39 Importance 35 Safety 35 Schedule 36 Maximum Weight Limit 16 Modifications 14 N Neutral Indicator 24 20161122161659_32KZZE200_eng_BOOK Page 113 Tuesday November ...

Page 115: ... Removal Battery 52 Left Side Cover 54 Seat 53 Riding Precautions 11 S Safety Guidelines 3 Safety Precautions 9 Serial Numbers 103 Shifting Gears 30 Side Stand 64 Specifications 106 Speedometer 21 Start Button 27 Starting the Engine 29 Steering Lock 28 Stopping Engine 96 Storage Equipment 32 Owner s Manual 33 Tool Kit 33 Storing 100 Switches 26 T Tachometer 20 20161122161659_32KZZE200_eng_BOOK Pag...

Page 116: ...Signal Indicators 25 Turn Signal Switch 26 Tyres Air Pressure 47 Puncture 81 Replacing 47 81 W Washing 97 Weight Limit 16 106 Wheels Front Removal 82 Rear Removal 84 Rims Spokes 69 20161122161659_32KZZE200_eng_BOOK Page 115 Tuesday November 22 2016 16 19 28 JST Index 112 ...

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