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Honda DREAM YUGA, Owner'S Manual

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Honda DREAM YUGA Owner'S Manual Download Page 61

Honda Motorcycle & Scooter India Pvt. Ltd.

53

7.  Inspect the sprocket teeth for possible 

wear or damage. Replace if necessary.

Damaged sprocket  

   Worn sprocket 

Teeth    

 

   

   Teeth

Replace

  

 

           

Replace

    Normal sprocket Teeth 

    GOOD

If the drive chain or sprockets are 

excessive worn or damaged, they should be 

replaced. Never use a new chain with worn 

sprockets;rapid chain wear will result.
8.  Install the chain cases and inspection 

cap.

LOWER CASE

9. First install into the swing arm by 

widening the front side of lower case by 

hand into the stay on swing arm cross 

plate.

10. Fasten the lower case with two bolts.

UPPER CASE

11. Install the upper case into the swing 

arm by prefiting all claws of the upper 

case with ones of the lower case.

12. Right side of case - Total 5 claws 

(Front-1, Mid-3, Rear-1)

13. Left side of case - Total 1 claws (Front-1)

14. Visually  confirm  that  all  claws  are 

installed correctly.

15. Fasten all 4 bolts.

Adjustment:

Drive chain slack should be checked and 

adjusted, if n

ecessary, every 1000 km 

 

(600 miles). When operated at sustained 

high speeds or under conditions of 

frequent rapid acceleration, the chain 

may require more frequent adjustment. 

If the drive chain requires adjustment, the 

procedure is as follows:
1.  Place the vehicle on its center stand  

with the transmission in neutral and the  

ignition switch OFF.

Summary of Contents for DREAM YUGA

Page 1: ...DREAM YUGA OWNER S MANUAL Honda Motor Co Ltd 2016 ...

Page 2: ...SE This vehicle is designed to be used only on the road READ THIS OWNER S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual These messages are fully explained in the A Few Words About Safety section which appears before the contents page This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold ...

Page 3: ...blication is based on the latest production information available at the time of approval for 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 ...

Page 4: ... manual BEFORE YOU RIDE THE VEHICLE As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your vehicle other property or the environment When service is required remember that your Honda dealer knows your vehicle If you have the required mechanical know how and tools your dealer can supply you an official Honda shop ...

Page 5: ...ormation on labels in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a vehicle You must use your own good judgement You will find important safety information in a variety of forms including Safety labels on the vehicle Safety messages precede...

Page 6: ...if you don t follow instructions You CAN be HURT if you don t follow instructions CAUTION DANGER WARNING Safety Heading such as Important Safety Reminders or Important Safety Precautions Safety Section such as vehicle Safety Instructions how to use this vehicle correctly and safely This entire manual is filled with important safety information please read it carefully ...

Page 7: ...cle 12 Suspension 13 Brakes 16 Clutch 17 Fuel 19 Engine Oil 21 Tyres 24 ESSENTIAL INDIVIDUAL COMPONENTS 24 Ignition Switch Page 25 Right Handlebar Controls 25 Left Handlebar Controls 27 FEATURES Not required for operation 27 Steering Lock 27 Right Side Cover 28 Left Side Cover 28 Storage Compartment 29 Headlight Aim Vertical Adjustment 29 OPERATION 29 Pre ride Inspection 30 Starting the Engine 32 ...

Page 8: ... 42 Color Code 43 Engine Oil 45 Crankcase Breather 46 Spark Plug 47 Valve Clearance 49 Idle Speed 50 Throttle Operation 50 Air Cleaner 51 Drive Chain 56 Front and Rear Suspension Inspection Page 57 Side Stand 57 Wheel Removal 61 Battery 63 Fuse Replacement 65 Brake Light Switch Adjustment 66 Bulb Replacement 69 CLEANING 71 STORAGE GUIDE 71 Storage 73 SPECIFICATIONS 76 CATALYTIC CONVERTER ...

Page 9: ... approved helmet and make sure your passenger does the same We also recommend that you wear eye protection sturdy boots gloves and other protective gear page 2 Make Yourself Easy to be Visible Some drivers do not see vehicles because they are not looking for them To make yourself more visible wear bright reflective clothing position yourself so other drivers can see you signal before turning or ch...

Page 10: ...gets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either PROTECTIVE APPAREL For your safety we strongly recommend that you always wear an approved helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete protection is not possible wearing proper gear can reduce the chance of injury wh...

Page 11: ... keep your hands warm and help prevent blisters cuts burns and bruises A vehicle riding suit or jacket for comfort as well as protection Bright coloured and reflective clothing can help make you more noticeable in traffic Be sure to avoid loose clothes that could get caught on any part of your vehicle LOAD LIMITS AND GUIDELINES Your vehicle has been designed to carry you and one passenger When you...

Page 12: ...manual Load Limits Following are the load limits for your vehicle Maximum weight capacity 170 kg 375 lbs Includes the weight of the rider passenger all cargo and all accessories LOADING GUIDELINES Your vehicle is primarily intended for transporting you and a passenger You may wish to secure a jacket or other small items to the seat when you are not riding with a passenger If you wish to carry more...

Page 13: ... weight evenly on both sides Do not attach large or heavy items such as a sleeping bag or tent to the handlebars forks or fender Accessories and Modifications Modifying your vehicle or using non Honda accessories can make your vehicle unsafe Before you consider making any modifications or adding an accessory be sure to read the following information WARNING Improper accessories or modifications ca...

Page 14: ...r interfere with operating any controls Be sure not to use any non genuine electrical equipment or equipment having capacity exceeding vehicle s electrical system capacity page 75 A blown fuse can cause a loss of lights or engine power Do not pull a trailer or sidecar with your vehicle This vehicle is not designed for these attachments and their use can seriously impair your vehicle s handling MOD...

Page 15: ...n signal switch VuZ flxuy fLop Horn button gkuZ cVu Fuel filler cap wy fQYyj dSi Fuel guage wy xst Throttle grip FkzkSVy fxzi Starter button LVkVZj cVu Front brake lever ÝaV czsd yhoj Headlight switch gSMykbV fLop Passinglight switch ikflaxykbV fLop Speedmeter LihM ehVj Headlight dimmer switch gSMykbV fMEej fLop Ignition switch bfXu ku fLop ...

Page 16: ...ndia Pvt Ltd 8 Main fuse eSu wt Battery cSVjh Storage compartment LVksjst dEikVZesaV Oil level cap dipstick vkW y Lrj dSi fMifLVd Passenger footpeg k h QqViSx Footpeg QqViSx Kickstarter fddLVkVZj Rear brake pedal fj j czsd iSMy ...

Page 17: ...Honda Motorcycle Scooter India Pvt Ltd 9 Air Cleaner j Dyhuj Passenger footpeg k h QqViSx Footpeg QqViSx Side stand lkbZM LVSaM Gearshift pedal fx j f k V iSM y Engine oil drain plug batu vkW y Mªsu Iyx ...

Page 18: ...strument panel Their functions are described in the tables on the following pages 1 Speedometer LihMksehVj 2 Gear range fx j jsat 3 Odometer vkWMksehVj 4 Fuel meter wy ehVj 5 High beam indicator gkbZ che bafMdsVj 6 Turn signal indicator VuZ flxuy bafMdsVj 7 Neutral indicator U wVªy bafMdsVj 1 3 4 5 6 7 2 ...

Page 19: ...e for each gear 3 Odometer Shows accumulated mileage 4 Fuel meter Shows approximate fuel function available page 12 5 High beam indicator Indicate when the headlight is glowing on high beam blue 6 Turn signal indicator Flashes when any of the turn signal operates orange 7 Neutral indicator green Indicate when the transmission is in neutral ...

Page 20: ...l 1 Fuel meter wy ehVj 2 Red band jSM cSaM MAJOR COMPONENTS Important Information to operate this vehicle SUSPENSION The shock absorber 1 has 5 adjustment positions for different load or riding conditions Use a pin spanner 2 to adjust the rear shock Turning the spring preload adjuster 3 counterclockwise makes the shock absorber firm and turning clockwise makes it soft Always adjust the shock absor...

Page 21: ... the front brake lever or rear brake pedal moves before the brake starts to engage is called freeplay Measured at the tip of the front brake lever 1 freeplay should be maintained at 10 20 mm 0 4 0 8 in 1 Front brake lever ÝaV czsd yhoj 1 3 2 1 Shock absorber kkWd ctkcZj 2 Pin spanner fiu LiSuj 3 Spring preload adjuster fLfizax izh y M MtLVj 1 Standard position 2 ...

Page 22: ... nut is seated on the brake arm pin 3 after making final freeplay adjustment Apply the brake several times and check for free wheel rotation after the brake lever is released If proper adjustment cannot be obtained by this method see your Honda dealer Other Checks Check the brake cable for kinks or signs of wear that could cause sticking or failure Make sure the brake arm spring and fasteners are ...

Page 23: ...oves before the brake starts to take hold Freeplay should be 20 30 mm 0 8 1 2 in 3 If adjustment is necessary turn the adjusting nut 2 Make sure the cut out on the adjusting nut is seated on the brake arm pin 3 after making final free play adjustment 4 Apply the brake several times and check for free wheel rotation after the brake pedal is released If proper adjustment cannot be obtained by this m...

Page 24: ...he cable Turn the adjusting nut 3 to obtain the specified freeplay Tighten the lock nut and check the adjustment 2 Start the engine pull in the clutch lever and shift into gear Make sure the engine does not stall and the vehicle does not creep Gradually release the clutch lever and open the throttle The vehicle should begin to move smoothly and accelerate gradually 1 1 Clutch lever Dyp yhoj 2 Lock...

Page 25: ...th the fuel knob in the OFF position fuel cannot flow from the tank to the carburetor Turn the knob to OFF position whenever the vehicle is not in use RES With the fuel knob in the RES position fuel will flow from the reserve fuel supply to the carburetor Use the reserve fuel only when the main supply is gone Refill the tank as soon as possible after switching to RES The reserve fuel supply is 1 5...

Page 26: ...l the tank There should be no fuel in the filler neck After refueling to close the fuel fill cap keep the mark of front side of fuel filler cap at front Push the fuel fill cap into the filler neck until it snaps closed and gets locked Remove the key Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away...

Page 27: ...ed It causes damage to the engine parts and considered as misuse damage caused by misuse is not covered under Honda warranty When certain types of petrol containing alcohol are used problem such as hard starting poor performance etc may occur If you notice any undesirable operating symptoms while using a petrol that contains alcohol try another station or switch to another brand of petrol When a p...

Page 28: ...on level ground 3 After 2 3 minutes remove the oil filler cap dipstick wipe it clean and reinsert the oil filler cap dipstick without screwing it in Remove the oil filler cap dipstick The oil level should be between the upper and lower level marks on the oil filler cap dipstick 4 If required add the specified oil up to the upper level mark Do not overfill 5 Reinstall the oil filler cap dipstick Ch...

Page 29: ...ructions in the owner s manual regarding tyre inflation and maintenance under inflated tyres wear unevenly adversely affect handling and are more likely to fail from being overheated Over inflated tyres make your motorcycle ride harshly are more prone to damage from road hazards and wear unevenly We recommend that you visually check your tyres before every ride and use gauge to measure air pressur...

Page 30: ... bulges in the side of the tyre or the tread Replace the tyre if you find any bumps or bulges Cuts splits or cracks in the tyre Replace the tyre if you can see fabric or cord Excessive tread wear Also if you hit a pothole or hard object pull to the side of the road as soon as you safely can and carefully inspect the tyres for damage NOTICE kPa kgf cm2 psi Driver Front 175 1 75 25 Only Rear 225 2 0...

Page 31: ...hile driving CAUTION Installing improper tyres on your vehicle 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 tyres recommended in this owner s manual WARNING Tyre Replacement The tyres that came on your vehicle were designed to match the performance capabilities of your vehicle and provide the best combination ...

Page 32: ...Function Key Removal LOCK Steering is Locked Engine and lights Key can be removed steering lock cannot be operated OFF Engine and lights cannot be operated Key can be removed ON Engine and lights can be operated Key cannot be removed Turn signal passing light control switch and horn can be operated The headlight position light taillight and meter lights operates only when the engine is running ...

Page 33: ...r cranks the engine See page 31 for the starting procedure 1 Start button LVkVZ cVu LEFT HANDLEBAR CONTROLS Headlight Switch 1 The headlight switch 1 has three positions and Headlight positionlight taillight and meter lights on Position light taillight and meter light on OFF Headlight taillight and meter lights off The headlight position light taillight and meter lights operates only when the engi...

Page 34: ...eft turn R to signal a right turn Press to turn off the signal Passing Light Control Switch 4 When this switch is pressed the headlight flashes on to signal approaching cars or when passing Horn Button 5 Press the button to sound the horn 2 Headlight dimmer switch gSMykbV fMEej fLop 3 Turn signal switch VuZ flxuy fLop 4 Passing light control switch ikflax ykbV daVª y fLop 5 Horn button gkWuZ cVu ...

Page 35: ...ehicle control RIGHT SIDE COVER The right side cover must be removed for battery storage compartment and fuse maintenance Removal 1 Insert the ignition key into the side cover key hole and turn it counterclockwise 2 Carefully pull the right side cover 2 out from the grommet 3 and lugs 1 of the rear cowl Installation Installation can be done in the reverse order of removal 1 Lugs yXl 2 Right Side c...

Page 36: ...ents should be stored in this light weight compartment While washing your vehicle be careful not to flood this area with water 1 3 1 2 LEFT SIDE COVER The left side cover must be removed for air cleaner element Removal 1 Remove the screw 1 2 Remove the left side cover 2 from the bosses 3 of the fuel tank and rear cowl Installation Installation can be done in the reverse order of removal 1 Screw LØ...

Page 37: ... sure you take care of it or have it corrected by your Honda dealer WARNING Improperly maintaining this vehicle 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 1 HEADLIGHT AIM VERTICAL ADJUSTMENT ADJUSTMENT Vertical adjustment can be made by moving the headli...

Page 38: ...e clutch before operating the self starter Your vehicle s exhaust contains poisonous carbon monoxide gas High level of carbon monoxide can collect rapidly in enclosed areas such as a garage Do not run the engine with the door open run the engine only long enough to move your vehicle out of the garage Do not use the electric starter for more than 5 seconds at a time Release the start button for app...

Page 39: ...troke With the throttle slightly open operate the kick starter Kick from the top of the through to the bottom with a rapid continuous motion 3 Immediately after the engine starts push the choke lever down to the halfway position 4 Warm up the engine by opening and closing the throttle slightly 5 Continue warming up the engine until it runs smoothly and responds to the throttle when the choke lever...

Page 40: ... fully OFF C Open the throttle fully and crank the engine several times with the kick starter Turn the ignition switch to ON and open the throttle slightly start the engine using the kick starter RUNNING IN Assure your vehicle s future reliability and performance by paying extra attention to how you ride during the first 500 km 300 miles During this period avoid full throttle starts and rapid acce...

Page 41: ...e the throttle and brakes for smooth deceleration 6 Both front and rear brakes should be used at the same time and should not be applied strongly enough to lock the wheel or braking effectiveness will be reduced and control of the vehicle be difficult SHIFTING Proper shifting can prevent damaging the engine and transmission UPSHIFTING The upper limit speed of each gear is shown in gear range page ...

Page 42: ...tering a turn closing the throttle or braking in mid turn may cause wheel slip Wheel slip will reduce control of the vehicle When riding in wet or rainy condition on loose surfaces the ability to maneuver and stop will be reduced All of your conditions Rapid acceleration braking or turning may cause loss of control For your safety exercise extreme caution when braking accelerating or turning When ...

Page 43: ...d or overturning 3 Lock the steering to help prevent theft page 27 ANTI THEFT TIPS 1 Always lock the steering 2 Never leave the key in the ignition switch This sounds simple but people do forget 3 Be sure the registration information for your vehicle is accurate and current 4 Put your vehicle in a locked garage whenever possible 5 Use an additional anti theft device of good quality 6 Put your name...

Page 44: ... your vehicle overturns or becomes involved in a crash be sure your Honda dealer inspects all major parts even if you are able to make some repairs Improperly maintaining this vehicle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual WARNING...

Page 45: ...an parts Keep cigarettes sparks and flames away from the battery and all fuel related parts Remember that your Honda dealer knows your vehicle best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement WARNING Failure to properly follow maintenance instructions and precautions can ...

Page 46: ...echnicians Your Honda dealer meets all of these requirements Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the Official Honda Shop Manual In the interest of safety we recommend these items be serviced only by your Honda dealer Honda recommends that your Honda dealer should road test your vehicle after each peri...

Page 47: ... 15 MONTHS 1 4 8 12 16 20 24 FUEL LINE I I I I I I I FUEL LEVEL I FUEL STRAINER SCREEN C C C C C C THROTTLE OPERATION I I I I I I I I 50 CHOKE OPERATION I I I I I I I I 31 AIR CLEANER NOTE 2 R 50 CRANKCASE BREATHER NOTE 3 C C C C C C C 45 SPARK PLUG I R I R I R 46 VALVE CLEARANCE I I I I I I I 47 ENGINE OIL I R R R R R R R R 43 ENGINE OIL STRAINER SCREEN C C C ENGINE OIL CENTRIFUGAL FILTER C C ENG...

Page 48: ... I I I I I I I 61 BRAKE SYSTEM I I I I I I I I I 13 BRAKE LIGHT SWITCH I I I I I I I 65 HEADLIGHT AIM I I I I I I I 28 LIGHTS HORN I CLUTCH SYSTEM I I I I I I I I I 16 SIDE STAND I I I I I I I 57 SUSPENSION I I I I I I I 12 NUTS BOLTS FASTENERS I I I I I WHEELS TIRES I I I I I I I I 21 STEERING HEAD BEARINGS I I I I The vehicle must be serviced at every 4000 kms or within 4 months whichever is ear...

Page 49: ... the kit 14 x 17 mm open end wrench Screwdriver Spark plug wrench Tool bag SERIAL NUMBERS The frame and engine serial numbers are required when registering your vehicle They may also be required by your dealer when ordering replacement parts Record the numbers here for your reference FRAME NO _____________________ The frame number 1 is stamped on the right side of the steering head 1 Tool kit Vwy ...

Page 50: ...of the crankcase ENGINE NO __________________ COLOR CODE The color table is attached below It is useful during ordering the replacement parts 2 The above color code table helps in providing the correct color part as per your vehicle color S No Color Color Code 1 Black NH1 2 Sports red R321 3 Pearl amazing white NHB63 ...

Page 51: ...ine oil should be based on average atmospheric temperature in your riding area The following provides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures Recommended Oil 10W 30 MA Engine Oil Engine oil quality is the chief factor affecting engine service life Change the engine oil as specified in the maintenance schedule page 39 When runn...

Page 52: ...il remove the oil filler cap dipstick and oil drain bolt 1 and sealing washer 2 2 Operate the kickstarter several times to aid in complete draining of the remaining oil 3 Check that the sealing washer 2 on the drain bolt is in good condition and install the bolt Replace the sealing washer every other time the oil is changed or each time if necessary Oil Drain Bolt Torque 24 N m 2 4 kgf m 17 Ibf ft...

Page 53: ...cksYV 2 Sealing washer lhfyax ok kj CRANKCASE BREATHER Refer to the Safety Precautions on Page 37 1 Remove the left side cover 2 Remove the crankcase breather tube 1 from the air cleaner housing and drain deposits from the Air cleaner drain tube 2 into a suitable container 3 Reinstall the crankcase breather tube Service more frequently when riding in rain or at full throttle 1 2 1 2 1 Crankcase br...

Page 54: ... heavy replace the plug Clean a carbon or wetfouled plug with a plug cleaner otherwise use a wire brush 4 Check the spark plug gap 4 using a wire type feeler gauge If adjustment is necessary bend the side electrode 5 carefully The gap should be 0 8 0 9 mm 0 031 0 035 in 1 Spark plug Cap LikdZ Iyx dSi 2 Plug wrench Iyx jsap 3 Spanner aLisuj 1 NOTICE 1 Disconnect the spark plug cap 1 from the spark ...

Page 55: ...hten the plug NGK 1 2 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE 8 Reinstall the spark plug cap Take care to avoid pinching any cables or wires VALVE CLEARANCE Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the Official Honda Shop Manual Excessive valv...

Page 56: ...he index mark Check the clearance of both valves by inserting a feeler gauge between the adjusting screw and the valve stem 1 Timing hole cap Vkbfeax gksy dSi 2 T mark Vh ekdZ 3 Index mark baMSDl ekdZ This condition can be determined by moving the rocker arms If they are free it is an indication that the valves are closed 4 Feeler gauge Qhyj xst 5 Adjusting screw MtfLVax LØw 6 Adjusting screw lock...

Page 57: ... 1400 100 min 1 rpm IDLE SPEED Refer to the safety precautions on page 37 The engine must be at normal operating temperature for accurate idle speed adjusting 10 minutes of stop and go riding is sufficient Do not attempt to compensate for faults in other systems by adjusting idle speed See your Honda dealer for regularly scheduled carburetor adjustments 1 1 Throttle stop screw FkzkWVy LVkWi LØw A ...

Page 58: ...uster 2 at regular intervals page 39 Replace more frequently when riding in unusually wet or dusty areas 1 Remove the bolts and left side cover from the grommets page 28 2 Remove the bolt 1 no and screws 2 nos to pull out the left rear cowl 3 Loosen the screws 4 nos and remove the air cleaner cover 2 4 Take out the air cleaner element 3 and replace 1 2 3 1 1 2 1 Screws LØwl 2 Air cleaner cover j D...

Page 59: ...se premature engine wear or performance problem 8 Install the removed parts in the reverse order of removal DRIVE CHAIN Refer to the safety precautions on page 37 The service life of the drive chain is dependent upon proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain and sprockets The drive chain should be checked and lubricated as part of the ...

Page 60: ...peat this procedure several times Drive chain slack should remain constant If the chain is slack only in certain sections some links are kinked and binding Binding and kinking can be eliminated by lubrication 4 Remove the bolts 3 5 Press the lugs 4 6 Release all the claws 7 from both the chain case covers and carefully remove them from swing arm assembly to expose the drive chain 1 Inspection cap ...

Page 61: ... Fasten the lower case with two bolts UPPER CASE 11 Install the upper case into the swing arm by prefiting all claws of the upper case with ones of the lower case 12 Right side of case Total 5 claws Front 1 Mid 3 Rear 1 13 Left side of case Total 1 claws Front 1 14 Visually confirm that all claws are installed correctly 15 Fasten all 4 bolts Adjustment Drive chain slack should be checked and adjus...

Page 62: ...n or counterclockwise to provide more slack Align the chain adjuster index marks 4 with the rear edge 5 of the adjusting slots on both sides of the swing arm 5 2 3 3 5 1 4 4 6 6 1 Rear Axle nut fj j Dly uV 2 Sleeve nut Lyho uV 3 Drive chain adjusting nut Mªkbo psu MtfLVax uV 4 Index marks baMSDl ekDlZ 5 Rear edge of adjusting slot aMtfLaVx LykV dk fiNyk fdukjk 6 Drive chain lock nuts Mªkbo psu ykW...

Page 63: ...pedal freeplay is affected when repositioning the rear wheel to adjust drive chain slack Check rear brake pedal freeplay and adjust as necessary page 15 Lubrication and Cleaning Lubricate every 1000 km 600 miles or sooner if chain appears dry To clean and lubricate the chain visit your nearest Honda Dealer Service Center Replacment chain 420AD 118 NOTICE Removal and Cleaning When the drive chain b...

Page 64: ...master link The master link is the most critical part affecting the security of the drive chain Master links are reusable if they remain in excellent condition but it is recommended that a new master link retaining clip be installed whenever the drive chain is reassembled Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation 6 A...

Page 65: ...tand assembly for freedom of movement 1 Side stand spring lkbM LVSUM fLizax If the side stand is squeaky or stiff clean the pivot area and lubricate the pivot bolt with clean engine oil WHEEL REMOVAL Refer to the Safety Precautions on page 37 Front Wheel Removal 1 Place the vehicle on its center stand 2 Raise the front wheel off the ground by placing a support block under the engine 3 Remove the s...

Page 66: ...Front axle nut torque 54 N m 5 5 kgf m 40 lbf ft Adjust the brake page 14 After installing the wheel apply the brake several times and then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your Honda dealer as soon as possible to verify proper assembly 2 4 3 7 6 5 1 1 Speedometer cable...

Page 67: ...ases page 51 3 Remove the rear brake adjusting nut 1 Disconnect the brake rod 2 from the brake arm 3 4 Disconnect the brake stopper arm 4 from the brake panel by removing the cotter pin 5 stopper arm nut 6 5 Loose the drive chain lock nuts 7 and drive chain adjusting nut 8 1 Brake adjusting nut czsd MtfLaVx uV 2 Brake rod czsd jksM 3 Brake arm czsd vkeZ 4 Brake stopper arm czsd LVkij vkeZ 5 Cotter...

Page 68: ...imes and then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely Always replace used cotter pins with new ones If a torque wrench was not used for installation see your Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity 10 Sleeve nut Lyho uV 11 Drive chain Mªkbo psu 12 Rear axl...

Page 69: ... page 37 It is not necessary to check the battery electrolyte level or add distilled water as NOTICE BRAKE SHOE WEAR Refer to the safety precautions on page 37 The front and rear brakes are equipped with brake wear indicators 4 4 1 1 3 3 2 2 the battery is a maintenance free sealed type If your battery seems weak and or is leaking electrolyte causing hard starting or other electrical troubles cont...

Page 70: ...ration 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 maintenance Keep children away from the battery 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 fas...

Page 71: ...e battery The specified fuse is 10A Both kick and self 1 Turn the ignition switch OFF before checking or replacing the fuses to prevent an accidental short circuit 2 Remove the right side cover page 27 1 Fuse holder wt gksYMj 2 Spare fuse Lis j wt Blown fuse FUSE REPLACEMENT Refer to the safety precautions on page 37 When frequent fuse failure occurs it usually indicates a short circuit or an over...

Page 72: ...Pull Push Installation If the replacement fuse of the same rating burns out in a short time there is probably a serious electrical problem on your vehicle leave the blown fuse in that circuit and have your vehicle checked by your Honda dealer Do not try to open the clips which prevent fuse from coming out you could bend them and cause poor contact with the new fuse A loose fuse could cause damage ...

Page 73: ...ing or replacing the fuses to prevent an accidental short circuit 2 Remove the right side cover pages 27 3 Disconnect the wire connector 2 of the relay comp start self drum 3 4 Pull out the old fuse If the main fuse is blown install a new fuse The spare fuse 4 is located near the battery 5 Reconnect the wire connection and install the right side cover BRAKE LIGHT SWITCH ADJUSTMENT Refer to the saf...

Page 74: ...ecomes very hot while the light is ON and remains hot for a while after it is turned OFF Be sure to let it cool down before servicing Do not put finger prints on the headlight bulb as they may create hot spots on the bulb and cause it to break Wear clean gloves while replacing the bulb If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early fail...

Page 75: ...everse order of removal HEADLIGHT BULB 1 Remove the front cowl page 67 2 Disconnect the connector 3 Remove the dust cover 5 4 Remove the bulb 6 while pressing down the locking pin 7 5 Install a new bulb in the reverse order of removal 6 Install the dust cover with its TOP mark 8 facing up 1 Front cowl ÝaV dkmy 2 Screws LØwl 3 Connector duDsVj 4 Position light bulb iksft ku ykbV cYc 5 Dust cover ML...

Page 76: ...the screw 2 2 Slightly press the bulb 3 and turn it counterclockwise 3 Install a new bulb in the reverse order of removal 3 1 2 BRAKE TAIL LIGHT BULB 1 Remove the screws 1 2 Remove the taillight lens 2 3 Slightly press the bulb 3 and turn it counterclockwise 4 Install a new bulb in the reverse order of removal 1 3 2 1 Screws LØwl 2 Taillight lens Vsy ykbV ysal 3 Bulb cYc ...

Page 77: ...We do not recommend the use of high pressure water spray NOTICE Washing the vehicle 1 Rinse the vehicle thoroughly with cool water to remove loose dirt 2 Clean the vehicle with a sponge or soft cloth using cool water Avoid directing water to muffler outlets and electrical parts 3 Clean the plastic parts using a cloth or sponge dampened with a solution of mild detergent and water Rub the soiled are...

Page 78: ...following point after it runs through such a place 1 Clean the vehicle using cool water Ref page 69 Do not use warm water This worsens the effect of the salt 2 Dry the vehicle and to protect surface of metal apply wax on it 4 After cleaning rinse the vehicle thoroughly with plenty of clean water strong detergent residue can corrode alloy parts 5 Dry the vehicle start the engine and let it run for ...

Page 79: ...ll cap on the tank To assure proper performance after storage lasting more than one month it is important to drain the carburetor WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Refuel only outdoors Wipe up spills immediately 3 To prevent rusting in the cylinder perform the following Remo...

Page 80: ...fe riding area away from traffic Crank the engine several times to distribute the oil Reinstall the spark plug and spark plug cap 4 Remove the battery Store in an area protected from freezing temperatures and direct sunlight 5 Wash and dry the vehicle Wax all painted surfaces Coat chrome with rust inhibiting oil 6 Lubricate the drive chain page 55 7 Inflate the tyres to their recommended pressures...

Page 81: ...43 1 in Wheel base 1 285 mm 50 6 in WEIGHT Dry weight 102 kg 225 lbs CAPACITIES Engine oil After draining 0 9 L 0 9 US qt 0 75 lmp qt After disassembly 1 0 L 1 1 US qt 0 91 lmp qt Fuel tank 8 0 L 2 11 US gal 1 76 lmp gal Fuel tank reserve 1 5 L 0 39 US gal 0 32 lmp gal Passenger capacity Operator and one passenger Maximum weight capacity 170 Kg 375 lbs ...

Page 82: ... plug NGK CPR7EA9 Spark plug gap 0 8 0 9 mm 0 03 0 04 in Idle speed 1 400 100 min 1 rpm Valve clearance Intake 0 10 0 0039 in Exhaust 0 15 0 0059 in CHASSIS AND SUSPENSION Caster 260 18 Trail 93 mm 3 66 in Tyre size front 80 100 18M C 47P Tyre size rear 80 100 18M C 54P Suspension Front Telescopic Fork Rear Twin Turning radius 1 90 m FUEL SYSTEM Type Carburetor ...

Page 83: ...reduction 2 928 ELECTRICAL Battery 12V 3Ah MF Maintenance Free Generator 0 14 kW 5 000 min 1 rpm LIGHTS Headlight 12V 35 35W Position light 12V 3W Brake Taillight 12V 21 5W Turn signal light 12V 10W X 4 Turn signal indicator 12V 1 7W X 1 High beam indicator 12V 1 7W X 1 Neutral indicator 12V 1 7W X 1 FUSE Main fuse 15A x 1 Other fuse 10A x 1 ...

Page 84: ...perature for the chemical reactions to take place It can set on fire any combustible materials that come near it Park your vehicle away from high grasses dry leaves or other flammables A defective catalytic converter contributes to air pollution and can impair your engine s performance Follow these guidelines to protect your vehicle catalytic converter Always use unleaded petrol Even a small amoun...

Page 85: ... battery are warranted by their respective manufacturers and should be claimed on them directly by customer NOTE Battery Warranty is applicable from 21 months from Date Of Charging at manufacturer or 18 Months from the Date Of Sale or 20000 Kms whichever is earlier In all such cases the decision of the respective manufacturer will be final and binding HMSI shall not be liable in any manner to repl...

Page 86: ...roduces Owner s Manual in original to enable that dealer to verify the details It must be expressly understood that claims forwarded directly to us by the wner customer will not be entertained at all and such defective part parts thus forwarded by them will lie at our factory at their own risk and this warranty shall not be enforceable Further this warranty is not applicable to 1 Any Dream Yuga on...

Page 87: ...grease non genuine parts 9 For two wheelers which have been used for any commercial purposes as taxi etc 10 For maintenance repairs required due to misuse while driving or due to adulteration of oil petrol or due to bad road conditions 11 Recommended fuel quality not used 12 Parts of the vehicle that have been subjected to misuse accident negligent treatment or which have been used in conjunction ...

Page 88: ...on or warranty whether statutory or otherwise not herein expressly set out EMISSION WARRANTY Subject to other terms of the warranty policy and other conditions and obligations laid down hereunder the manufacturer certifies that the components liable to affect the emission of the gaseous pollutants in the vehicle in normal use despite the use to which it may be subjected comply with provisions of r...

Page 89: ...od based on the vehicle category For a two wheeler the emission warranty period is 30 000 kms or 3 years whichever is earlier 3 Warranty claim for the components under Emission warranty as per annexure II will be admitted for a prima facie examination in the event of failure of the vehicle to meet the emission standard as specified in sub rule 2 of Rule No 115 of the Central Motor vehicle Rules 4 ...

Page 90: ...warranty or the associated parts are not independently replaceable on account of their being integral parts of a complete assembly the manufacturer will have the sole discretion to replace either the entire assembly or by using some of the parts of the system through suitable repairs or modifications 8 Any consequential repairs or replacement of parts which may be found necessary to establish comp...

Page 91: ...if a Observes all the important instructions and any other precautions listed in the Owner s Manual for use of the vehicle b Under all circumstances uses lubricants and fuel as recommended by manufacturer c Regularly obtains and carries out maintenance in accordance with the manufacturers guidelines and enters the details in the Logbook d Immediately approaches the nearest authorized service cente...

Page 92: ...le A valid Pollution Under Control certificate as described in customer obligation D 6 above is not produced A vehicle which is not serviced by Authorized service center as per the service schedule described in the maintenance chart given in the Owner s Manual A vehicle which has been subjected to abnormal use abuse neglect and improper maintenance or has met with an accident Use of replacement pa...

Page 93: ... and shall run parallel to the product warranty for the vehicle as per the scope and limit described in the Owner s Manual and all conditions described there in will apply in addition to those exclusively stipulated in this warranty 2 The emission warranty covers only compliance with the emission standard as specified in the sub rule 2 of rule 115 of CMVR It does not cover any other performance of...

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