Honda UNICORN CBF160A 2020 Manual Download Page 66

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Maintenance

Clutch

Checking the Clutch

Checking the Clutch Lever Freeplay

Check the clutch lever freeplay.

Freeplay at the clutch lever:

10 to 20 mm (0.39 to 0.79 in)

Check the clutch cable for 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.

Clutch lever

Freeplay

Summary of Contents for UNICORN CBF160A 2020

Page 1: ...ore 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 permiss...

Page 2: ...vehicle Your selection of a Honda makes you part of a worldwide family of satisfied customers who appreciate Honda s reputation for building quality into every product To ensure your safety and riding...

Page 3: ...st use your own good judgement You will find important safety information in a variety of forms including z z Safety labels on the vehicle z z Safety Messages preceded by a safety alert symbol and one...

Page 4: ...Contents Vehicle Safety P 2 Operation Guide P 14 Maintenance P 27 Troubleshooting P 69 Information P 83 Specifications P 95 Warranty Policy P 98 Index P 106...

Page 5: ...Labels P 6 Safety Precautions P 8 Riding Precautions P 9 Accessories Modifications P 12 Loading P 13 Vehicle Safety This section contains important information for safe riding of your vehicle Please...

Page 6: ...apparel P 8 Before Riding Make sure that you are physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved helmet and protective app...

Page 7: ...k and ride and don t let your friends drink and ride either Keep Your Honda in Safe Condition It s important to keep your vehicle properly maintained and in safe riding condition Inspect your vehicle...

Page 8: ...dorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you run the engine in confined or even partly enclosed area the air you breathe could contain a dangerous...

Page 9: ...re is a specific symbol on each label The meanings of each symbol and label are as follows Read instructions contained in Owner s Manual carefully Read instructions contained in Shop Manual carefully...

Page 10: ...roper handling and hazards of the battery very well Handle the battery electrolyte with extreme care as it contains dilute sulfuric acid Contact with your skin or eyes can burn you or cause loss of yo...

Page 11: ...to avoid loose clothes that could get caught on any part of your vehicle Helmet Safety standard certified high visibility correct size for your head z z Must fit comfortably but securely with the chi...

Page 12: ...aces The tyres slip more easily on such surfaces and braking distances are longer z z Avoid continuous braking Repeated braking such as when descending long steep slopes can seriously overheat the bra...

Page 13: ...engine 2 Using the side stand Push the side stand down Slowly lean the vehicle to the left until its weight rests on the side stand z z The brake lever may recoil slightly when applying the brakes Thi...

Page 14: ...Turn the handlebar fully to the left or right Left handle grip Grab rail Centre stand 3 Turn the ignition switch to the LOCK position and remove the key P 19 Refuelling and Fuel Guidelines Follow thes...

Page 15: ...and make your vehicle illegal to operate on public roads Before deciding to install accessories on your vehicle be certain the modification is safe and legal WARNING Improper accessories or modificat...

Page 16: ...an excessive load and keep within specified load limits Maximum weight capacity P 95 z z Tie all luggage securely evenly balanced and close to the centre of the vehicle z z Do not place objects near...

Page 17: ...t bag P 25 First aid kit P 25 Engine oil fill cap dipstick P 50 Right side cover P 47 Front brake lever Throttle grip P 65 Fuel fill cap P 24 Seat P 46 Crankcase breather P 66 Tool kit P 25 Spark plug...

Page 18: ...15 Operation Guide Engine oil drain bolt P 52 Battery P 43 Centre stand P 11 Side stand P 59 Seat lock P 46 Left side cover P 47 Shift lever P 23 Fuse box P 80 Clutch lever P 63 Data link connector...

Page 19: ...0 0 km Tachometer Trip knob Fuel gauge Needle in the red mark remaining fuel approximately 2 8 litres 0 74 US gal 0 62 Imp gal NOTICE Do not operate the engine in the tachometer red zone Excessive en...

Page 20: ...fly when the ignition switch is turned to the ON position If it comes on while engine is running P 71 Neutral indicator N Comes on when the transmission is in Neutral Turn signal indicator High beam i...

Page 21: ...utton Turn signal switch u Pressing the switch turns the turn signal off Engine stop switch Should normally remain in the 8 Run position u In an emergency switch to the 9 OFF position to stop the engi...

Page 22: ...ring Lock Lock the steering when parking to help prevent theft A U shaped wheel lock or similar device is also recommended Locking a Turn the handlebar all the way to the left or right b Push the key...

Page 23: ...ge could result Do not apply excessive force on the kickstarter Fold up the kickstarter after the kickstarter is returned to the pedal stop Start your engine using the following procedure regardless o...

Page 24: ...rate the kickstarter starting from the top of the stroke kick through to the bottom with a rapid continuous motion If you cannot start the engine Open the throttle slightly about 3 mm without freeplay...

Page 25: ...tarter a a Turn the ignition switch to OFF b b Open the throttle fully and crank the engine several times with the kickstarter c c Turn the ignition switch to ON d d Repeat the starting procedure e e...

Page 26: ...23 Operation Guide Shifting Gears Your vehicle transmission has 5 forward gears in a one down four up shift pattern 1 2 3 4 5...

Page 27: ...cap Closing the Fuel Fill Cap a After refuelling push the fuel fill cap closed until it locks b Remove the key and close the lock cover u The key cannot be removed if the fuel fill cap is not locked R...

Page 28: ...orage Equipment Tool Kit Document Bag First Aid Kit Tool kit and first aid kit are located under the seat Document bag is located under side of the seat Document bag Removing the seat P 46 Tool kit Fi...

Page 29: ...ked WARNING Riding with a helmet attached to the holder can interfere with your ability to safely operate the vehicle and could lead to a crash in which you can be seriously hurt or killed Use the hel...

Page 30: ...46 Side Cover P 47 Spark Plug P 48 Engine Oil P 50 Brakes P 53 Side Stand P 59 Drive Chain P 60 Clutch P 63 Throttle P 65 Crankcase Breather P 66 Other Adjustments P 67 Adjusting the Headlight Aim P 6...

Page 31: ...recommendations 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 requ...

Page 32: ...all of these requirements Keep an accurate record of maintenance to help ensure that your vehicle is properly maintained Make sure that whomever performs the maintenance completes this record All sch...

Page 33: ...I Engine Oil I R R R R R R R R 50 Engine Oil Strainer Screen C C C Engine Oil Centrifugal filter C C C Engine Idle Speed I I I I I I I I Evaporative Emission Control System I I Drive Chain I 1000 km 6...

Page 34: ...efer to page 1 000 km 1 6 12 18 24 30 36 1 000 mi 0 6 4 8 12 16 20 24 Months 1 6 12 18 24 30 36 Brake Fluid 4 I I I I I I I I 2 Years 53 Brake Shoes Pads Wear I I I I I I I I 57 54 Brake System I I I...

Page 35: ...heck for smooth opening and full closing in all steering positions 2 P 65 z Engine oil level Add engine oil if necessary Check for leaks 2 P 50 z Drive chain Check condition and slack adjust and lubri...

Page 36: ...le NOTICE Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed NOTICE An improperly disposed of battery can be harmful to the environment and human health...

Page 37: ...lectrolyte splashes into your mouth Rinse mouth thoroughly with water and do not swallow WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the bat...

Page 38: ...3 If the terminals are heavily corroded clean and polish the terminals with a wire brush or sandpaper Wear safety glasses 4 After cleaning reinstall the battery The battery has a limited life span Con...

Page 39: ...ou use non Honda engine oil check the label to make sure that the oil satisfies all of the following standards z JASO T 903 standard 1 MA z SAE standard 2 10W 30 z API classification 3 SJ or higher 1...

Page 40: ...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 r...

Page 41: ...oid applying excess chain lubricant to prevent spray onto your clothes and the vehicle Cleaning and Lubricating After inspecting the slack clean the chain and sprockets while rotating the rear wheel U...

Page 42: ...Replacing Checking the Air Pressure Visually inspect your tyres and use an air pressure gauge to measure the air pressure at least once a month or any time you think the tyres look low Always check ai...

Page 43: ...epth Inspect the tread wear indicators If they become visible replace the tyres immediately For safe riding you should replace the tyres when the minimum tread depth is reached Have your tyres replace...

Page 44: ...n this vehicle Excessive heat build up can cause the tube to burst z Use only tubeless tyres on this vehicle The rims are designed for tubeless tyres and during hard acceleration or braking a tube typ...

Page 45: ...it is stored under the seat 2 P 25 You can perform some roadside repairs minor adjustments and parts replacement with the provided tools z 14 x 17 mm Open end wrench z Spark plug wrench z Standard Phi...

Page 46: ...onnect the negative terminal from the battery 4 Disconnect the positive terminal from the battery 5 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the r...

Page 47: ...e Chain Case Removal 1 Remove the bolts and screw 2 Remove the drive chain case Installation Install the parts in the reverse order of removal Ensure that the stay on swingarm is inserted into lower c...

Page 48: ...ght Case Headlight Case Removal 1 Remove the screws 2 Remove the headlight case by releasing the snap fit clips and disconnect the connector Installation Install the parts in the reverse order of remo...

Page 49: ...ckwise then pull the seat up and back Installation 1 Insert the prongs into the stays on the frame 2 Push forward and down on the rear of the seat until it locks in place Make sure that the seat is lo...

Page 50: ...covers can be removed in the same manner Removal 1 Remove the seat 2 P 46 2 Remove the screw A screw B and screw C 3 Remove the prongs from the grommets 4 Remove the side cover Installation Install t...

Page 51: ...gine damage 1 Disconnect the spark plug cap from the spark plug 2 Clean any dirt from around the spark plug base 3 Remove the spark plug using provided spark plug wrench 2 P 42 4 Inspect the electrode...

Page 52: ...de electrode Spark plug gap Plug washer 5 Check the spark plug gap using a wire type feeler gauge If adjustment is necessary bend the side electrode carefully 6 Make sure the plug washer is in good co...

Page 53: ...lace your vehicle on its centre stand on a firm level surface 4 Remove the oil fill cap dipstick and wipe it clean 5 Insert the oil fill cap dipstick until it seats but don t screw it in 6 Check that...

Page 54: ...in bolt Adding Engine Oil If the engine oil is below or near the lower level mark add the recommended engine oil 2 P 36 96 1 Remove the oil fill cap dipstick Add the recommended oil until it reaches t...

Page 55: ...e oil at an approved recycling centre 6 Install a new sealing washer onto the drain bolt Tighten the drain bolt Torque 30 N m 3 1 kgf m 22 lbf ft Required oil When changing oil 1 0 litres 1 1 US qt 0...

Page 56: ...rvoir is horizontal and that the fluid level is above the LWR level mark If the brake fluid level in the reservoir is below the LWR mark or the brake lever freeplay becomes excessive inspect the brake...

Page 57: ...e pad wear indicator The pads need to be replaced if a brake pad is worn to the bottom of the indicator 1 Inspect the brake pads from below the brake caliper If necessary have the pads replaced by you...

Page 58: ...he brake takes hold Freeplay at the tip of the brake pedal 20 to 30 mm 0 78 to 1 18 in Freeplay Adjusting nut Brake arm pin Make sure the the brake rod brake arm spring and fastener are in good condit...

Page 59: ...edal Make sure the brake rod brake arm spring and fastener are in good condition NOTICE Do not turn the adjuster beyond its natural limits 1 Adjust by turning the rear brake adjusting nut a half turn...

Page 60: ...ed an arrow attached to the brake arm moves toward a reference mark on the brake panel If the arrow aligns with the reference mark on full application of the brake the brake shoes must be replaced See...

Page 61: ...akelight Switch Check the operation of the brake light switch Hold the brakelight switch and turn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction...

Page 62: ...the Side Stand Side stand spring 1 Check that the side stand operates smoothly If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clean grease 2 Check the sp...

Page 63: ...lace your vehicle on its centre stand on a firm level surface 3 Remove the inspection hole cap 4 Move the drive chain up and down with your finger Drive chain slack 30 to 40 mm 1 2 to 1 6 in Do not ri...

Page 64: ...le nut 5 Turn both adjusting nuts an equal number of turns until the correct drive chain slack is obtained Turn the adjusting nuts clockwise to tighten the chain Turn the adjusting nuts counterclockwi...

Page 65: ...brake pedal freeplay and adjust as necessary 2 P 55 11 Reinstall the inspection hole cap If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly...

Page 66: ...lever 10 to 20 mm 0 39 to 0 79 in Check the clutch cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubrican...

Page 67: ...the locknut and check the clutch lever freeplay 4 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the vehicle does not creep Gradually release the...

Page 68: ...othly from fully closed to fully open in all steering positions and throttle freeplay is correct If the throttle does not move smoothly close automatically or if the cable is damaged have the vehicle...

Page 69: ...eaning the Crankcase Breather 1 Remove the right side cover 2 P 47 2 Place a suitable container to receive deposits 3 Remove the crankcase breather tube and drain deposits 4 Reinstall the crankcase br...

Page 70: ...Adjusting the Headlight Aim You can adjust vertical aim of the headlight for proper alignment To move the headlight loosen the bolt Tighten the bolt after adjustment Obey local laws and regulations H...

Page 71: ...an adjust the spring preload by the adjuster to suit the load or the road surface Use the pin spanner to turn the adjuster Position 1 is for a decrease spring preload soft or turn the position 2 to 3...

Page 72: ...P 71 PGM FI Programmed Fuel Injection Malfunction Indicator Lamp MIL P 71 ABS Anti lock Brake System Indicator P 71 Tyre Puncture P 72 Electrical Trouble P 77 Battery Goes Dead P 77 Burned out Light B...

Page 73: ...on u uIf the indicator lamp is on contact your dealer as soon as possible Starter Motor Does Not Operate Check the following items z z Check the correct engine starting sequence 2P 20 z z Make sure en...

Page 74: ...nd have your vehicle inspected by your dealer as soon as possible z z Indicator comes on or starts flashing while riding z z Indicator does not come on when the ignition switch is in the ON position z...

Page 75: ...r kit Follow the instructions provided with the emergency tyre repair kit Riding your vehicle with a temporary tyre repair is very risky Do not exceed 50 km h 30 mph Have the tyre replaced by your dea...

Page 76: ...a maintenance stand or a hoist 3 Remove the speedometer cable by pushing the tab 4 Remove the front axle nut 5 Remove the front axle shaft front wheel side collar and speedometer gear box u uAvoid ge...

Page 77: ...ing them Torque 59 N m 6 0 kgf m 44 lbf ft 5 After installing the wheel apply the brake lever several times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel...

Page 78: ...onnect the brake rod from the brake arm by pushing down on the rear brake pedal 3 Disconnect the brake stopper arm from the brake panel by removing the cotter pin stopper arm nut washer and rubber gro...

Page 79: ...1 8 Adjust the rear brake freeplay 2P 55 9 Tighten the rear axle nut 10 Reassemble the drive chain case 2P 44 11 After installing the wheel apply the brake pedal several times then check if the wheel...

Page 80: ...recover after recharging contact your dealer NOTICE Jump starting using an automobile battery can damage your vehicle s electrical system and is not recommended Burned out Light Bulb Follow the proce...

Page 81: ...ess the pin down and pull out the bulb without turning it Rubber dust cover TOP mark Pin Bulb 4 Install a new bulb and parts in the reverse order of removal u uInstall the dust cover with its TOP mark...

Page 82: ...the screws 2 Slightly press the bulb and turn it counterclockwise 3 Install a new bulb and parts in reverse order of removal 1 Remove the turn signal lens by removing the screw 2 Turn the socket count...

Page 83: ...problem Have your vehicle inspected by your dealer 1 Remove the left side cover 2 P 47 2 Open the fuse box cover 3 Pull out the fuses one by one with the fuse puller provided in the tool kit 2 P 25 to...

Page 84: ...terminal from the battery 2 P 43 3 Pull out the starter magnetic switch 4 Disconnect the wire connector of the starter magnetic switch 5 Pull the main fuse out and check for a blown fuse Always repla...

Page 85: ...filter is clogged unstable engine operation will occur intermittently while riding Even if this symptom occurs you can continue to ride your vehicle If unstable engine operation occurs even if suffici...

Page 86: ...trols Other Features P 85 Caring for Your Vehicle P 86 Storing Your Vehicle P 89 Transporting Your Vehicle P 90 You the Environment P 91 Serial Numbers P 92 Fuels Containing Alcohol P 93 Catalytic Con...

Page 87: ...fe location To make a duplicate take the spare key or the key number to your dealer If you lose all ignition keys and the key number the ignition switch assembly will probably have to be removed by yo...

Page 88: ...turn off making riding unsafe If you stop the engine using the engine stop switch turn the ignition switch to the OFF position Failing to do so will drain the battery Odometer The odometer returns to...

Page 89: ...and other plastic components with extra care to avoid scratching them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your vehicle with plenty of clean water...

Page 90: ...the seat u u Water under the seat can damage your documents and other belongings z z Do not direct water at the air cleaner u u Water in the air cleaner can prevent the engine from starting z z Do no...

Page 91: ...ches and blemishes z z Wash gently using a soft sponge and plenty of water z z To remove stubborn stains use diluted detergent and rinse thoroughly with plenty of water z z Avoid getting petrol brake...

Page 92: ...oil z z Lubricate the drive chain 2 P 38 z z Place your vehicle on its centre stand and position a block so that both tyres are off the ground z z After rain remove the body cover and allow the vehicl...

Page 93: ...nsported it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform and motorcycle tie down straps Never try to tow your vehicle with a whee...

Page 94: ...protective ozone layer Recycle Wastes Put oil and other toxic wastes in approved containers and take them to a recycling centre Call your local or state office of public works or environmental servic...

Page 95: ...and engine serial numbers uniquely identify your vehicle and are required in order to register your vehicle They may also be required when ordering replacement parts You should record these numbers an...

Page 96: ...z z Ethanol ethyl alcohol up to 10 by volume u u Petrol containing ethanol may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may z z Damage the painting of the f...

Page 97: ...afe compounds A defective catalytic converter contributes to air pollution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guideli...

Page 98: ...09 lb Maximum weight capacity 1 170 kg 375 lb Passenger capacity Rider and 1 passenger Minimum turning radius 2 16 m 7 09 ft Displacement 162 71 cm3 9 925 cu in Bore x stroke 57 300 x 63 096 mm 2 2559...

Page 99: ...to 0 04 in Idle speed 1400 100 rpm Recommended engine oil Honda 4 stroke motorcycle oil API Service Classification SJ or higher excluding oils marked as Energy Conserving or Resource Conserving SAE 5...

Page 100: ...x 2 J Torque Specifications Engine oil drain bolt 30 N m 3 1 kgf m 22 lbf ft Rear axle nut 88 N m 9 0 kgf m 65 lbf ft Front axle nut 59 N m 6 0 kgf m 44 lbf ft J Bulbs Headlight 12 V 35 35 W Brakeligh...

Page 101: ...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 respectiv...

Page 102: ...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 UNICORN on which any free and paid se...

Page 103: ...to misuse accident negligent treatment or which have been used in conjunction with parts and an equipment not manufactured or recommended for use by HMSI if in the sole judgment of HMSI such use prem...

Page 104: ...authorized by the manufacturer the vehicle is discovered to be failing to meet the emission standard as specified in the said rule the authorized service center shall take such corrective measures as...

Page 105: ...examination to determine the warrantable condition of the components will be at the sole discretion of manufacturers and or their Authorized service centers and results of such examination will be fin...

Page 106: ...lity of the vehicle during the period of lodging of a warranty claim and examination by the manufacturer and repairs 11 The manufacturer will not be responsible for any penalties that may be charged b...

Page 107: ...ipts covering maintenance of the vehicle as specified in the Owner s Manual from the date of original purchase of the vehicle h Produces valid certificate of insurance and RTO registration 14 Conditio...

Page 108: ...oduct warranty 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...

Page 109: ...ing 9 Bulb Brake Tail Light 79 Front Turn Signal 79 Headlight 78 Rear Turn Signal 79 C Caring for Your Vehicle 86 Clutch 63 Catalytic Converter 94 Compartment Document Bag 25 85 Owner s Manual 85 Tool...

Page 110: ...Instruments 16 K Keys 84 L Labels 6 Load Limits 13 Loading Guidelines 13 M Maintenance Fundamentals 32 Importance 28 Safety 28 Schedule 29 Maximum Weight Limit 13 95 Modifications 12 N Neutral Indica...

Page 111: ...tions 95 Speedometer 16 Start Button 18 Starting the Engine 20 Steering Lock 19 Storage Equipment 25 Storing Your Vehicle 89 Switches 18 T Throttle 65 Tool 42 Transporting Your Vehicle 90 Tripmeter 16...

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