Honda Transalp XL650V Owners Manual
Honda Transalp XL650V Owners Manual
XL650V
OWNER'S MANUAL I
• ON/OFF-ROAD USE
Thi s motorcycle is designed for "dual purpose" use.
Indicates a strong possibility of severe personal injury o r death if instructions are not
followed.
IcAUTION: I
Indicates a possibility of personal injury or equipment damage if instructions are not fol-
lowed.
NOTE:
Gives helpful info rmati on . All infor~ation in this publication is based on the latest production information available
at the t1me of approv~l for prin_ting. HONDA ITALIA S.p.A. reserves the right to make
Thi s manual shou ld be considered a perm anent part of the motorcycle and should remain changes at a_ny tim~ w1~hout not1ce and without incurring any obligation.
with the motorcycle when resold. No part of th1s pubhcat1on may be reproduced without written permission.
WELCOME OPERATION
The motorcycle presents you a challenge to master the machine, a challenge to adventure. Page Page
You ride through the wind, linked to the road by a vehicle that responds to your commands
as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, 1 MOTORCYCLE SAFETY 33 Immobilizer system
a pre-ride inspection and regular maintenance are essential to your safety. Your reward is 1 Safe riding rules
freedom. 2 Protective apparel 34 Right handlebar controls
To meet the challenges safely, and to enjoy the adventure fully, you should become thor- 3 Modifications 35 Left handlebar controls
oughly familiar with this owner's manual BEFORE YOU RIDE THE MOTORCYCLE. 4 Load ing and accessories
When services is required , remember that your Honda dealer knows your motorcycle best. if 6 Off-road safety 36 FEATURES
you have the required mechanical "know-how" and tools, your dealer can supply you with an 7 PARTS LOCATION (Not required for operation}
official Honda Service Manual to help you perform many maintenance and repair tasks. 10 Instruments and indicators 36 Steering lock
37 Helmet holder
Pleasant riding, and thank you for choosing a Honda! 16 MAJOR COMPONENTS 38 Right/Left case
(Information you need to operate this motorcycle) 39 Document compartment
• Following codes in this manual indicate each country. 16 Front brake 40 Seat
20 Clutch
ED GERMANY liED GERMANY ED SWITZERLAND 22 Coolant 41 OPERATION
SWEDEN ED ITALY F FRANCE 24 Fuel 41 Pre-ride inspection
FINLAND ED BELGI UM ED AUSTRIA 27 Engine oil 42 Starting the engine
NORWAY ED HOLLAND E UK 28 Tyres 45 Running-in
DENMARK ED SPAIN PORTUGAL 46 Riding
30 ESSENTIAL INDIVIDUAL COMPONENTS 47 Breaking
30 Ignition switch 48 Parking
31 Keys 49 Anti-theft tips
• The specifications may vary with each locale.
MAINTENANCE MOTORCYCLE SAFETY
Page Page
W!IW·hi~IIU4 the accident that wasn't your fau lt:
• Wear bright or reflective clothing.
50 MAINTENANCE 95 Stoplight switch adjustment • Motorcycle riding requires special ef-
forts on your part to ensure your safety. • Don 't ride in another motori st ' s "b lin d
51 Maintenance schedule spot".
54 Tool kit 96 CLEANING Know these requirements before you
ride: 4. Obey all national and local laws and regu-
55 Serial numbers 98 STORAGE GUIDE lations.
56 Colour label 98 Storage SAFE RIDING RULES • Excessive speed is a factor in many acci-
56 Maintenance precautions 100 Removal from storage dents. Obey the speed limits, and NEVER
57 Air cleaner 1 . Always make a pre-ride inspection (page
travel faster than conditions warrant.
59 Crankcase breather 101 SPECIFICATIONS 41) before you start the eng ine. You may
• Signal before you make a turn or lane
60 Engine oil 105 Radio type approvals of immobilizer prevent an accident or equipment damage.
change. Your size and manoeuvrability
64 Spark plugs system 2. Many accidents involve inexperienced rid-
can surprise other motorists.
67 Throttle operation 106 Catalytic converter ers. Most countries require a special mo-
68 Idle speed torcycle riding test or license. Make sure
69 Drive chain you are qualified before you ride.
76 Front and rear suspension inspection NEVER lend your motorcycle to an inex-
77 Side stand perienced rider.
78 Wheel removal 3. Many automobile/ motorcycle accidents
84 Brake pad wear happen because the automobi le driver
86 Battery does not "see" the motorcyclist.
87 Fuse replacement Make yourself conspicuous to help avoid
89 Bulb replacement
MODIFICATIONS
5. Don't let other motorists surprise you. PROTECTIVE APPAREL
Use extra caution at intersections, parking 1. Most motorcycle accident fatalities are
• Modification of the motorcycle, or re-
lot entrances and exits, and driveways. due to head injuries: ALWAYS wear a hel-
moval of original equipment, may ren-
6. Keep both hands on the handlebars and met. You should also wear a face shield
der the vehicle unsafe or illegal.
both feet on the footpegs while riding . A or goggles as well as boots, gloves and
Obey all national and local equipment
passenger should hold on to the motorcy- protective cloth ing. A passenger needs regulations.
cle or the operator with both hands and the same protection .
keep both feet on the passenger footpegs. 2. The exhaust system becomes hot during
operation, and it remains hot for a while
after stopping the engine. Be careful not
to touch the exhaust system while it is hot.
Wear clothing that fully covers your legs.
3. Do not wear loose clothing which could
catch on the control levers, footpegs , dri-
ve chain or wheels.
2 3
LOADING AND ACCESSORIES
Loading 2. All cargo must be secure for stable han- exceed the motorcycle's electrical system
• To prevent an accident, use extreme The combined weight of the rider, passenger, dling. Recheck cargo security frequently. capacity. An electrical failure could cause
care when adding and riding with ac- cargo and additional accessories must not 3. Do not attach large or heavy items (such a dangerous loss of lights or engine power
cessories and cargo. Addition of acces- exceed the maximum weight capacity: as a sleeping bag or tent) to the handle- at night, far from help.
sories and cargo can reduce a motorcy- 180 kg . bars, fork , or fender. Unstable handling or
cle's stability, performance and safe Do not exceed the following cargo weight slow steering response may result.
operating speed. Never ride an acces- limit for the rear carrier:
sory-equipped motorcycle at speed 9.0 kg (20 lbs) Accessories
above 130 km/h (80 mph). Overloading the rear carrier will adversely af- You are personally responsible for proper se-
And remember that this 130 km/h fect stability and handling. lection, installation and use of non-Honda
(80mph) limit may be reduce by installa- 1. Keep cargo weight low and close to the accessories. Always follow the guidelines
tion of non-Honda accessories, improp- center of th e motorcycle. Load weight under Loading, and these:
er loading, worn tyres and overall mo- equally on both sides to minimise imbal- 1. Carefully inspect the accessory to make
torcycle condition, poor road or weath- ance. As weight is located further from the sure it does not obscure any lights, reduce
er conditions. These general guidelines motorcycle's center of gravity, handling is ground clearance and banking angle, or
may help you decide whether or how to proportionally affected. limit suspension travel , steering travel or
equip your motorcycle and how to load control operation .
it safely. 2. Luggage racks are for lightweight items.
Bulky items may snag on a tree or other
nearby object causing loss of control.
3. Do not add electrical equipment that will
4 5
OFF-ROAD SAFETY in most off-road areas. Don't modify your PARTS LOCATION
Learn to ride in an uncongested off-road area exhaust system. Rem ember that exces-
free of obstacles before venturing onto un- sive noise bothers everyone and creates a
Rearview Rearview
familiar terrain. bad image for motorcycling. Indicators
mirror mirror
1. Always obey local off-road riding laws and
regulations .
2. Obtain permission to ride on private prop- Choke
erty. Avoid posted areas and obey "NO lever
Trespassing " signs. Front brake
Passing
3. Ride with a friend on another motorcycle lever
switch
so that you can assist each other in case
of troubl e.
4. Familiarity with your motorcycle is critically
Clutch
lever
I
· ~ y
,:i , Engine stop
im portant should a problem occur far from
help. -I..;- switch
Headlight dimmer
5. Never ride beyond your abil ity and experi-
ence or faster th an conditions warrant.
6. If you are not familiar with the terrain, rid e
switch
\
\ Throttle grip
Turn signal switch
cautiously. Hidd en rocks, holes, or ravines
could spell disaster. \ i/ Starter button
7. Spark arresters and mufflers are requ ired
Ignition switch
Fuel fil l cap
6 7
Air cleaner
Helmet holder
8 9
INSTRUMENTS AND INDICATORS
The instruments are grouped together above (Ref. No) Description Function
the headlight case. (4) (5)
(6) (1) Left turn signal indicator Flashes when the left turn signal operates
Their functions are described in the table o n (3) (7) (8)
(2)
the following page. (2) Speedometer Shows riding speed
(3) Odometer
~' f ~
(1) Left turn signal indicator (1) (9) Show accumulated mileage
"'- .,"~:;;
... .........) ~ _:;-.',,,,.,'f,t
...
(2) Speedometer
(3) Odometer
~
-"' ......
-?.' ·- ,. ~
(4) Low oil pressure indicator (red) Light when engine oil pressure is below normal
operating range. Should light when ign it ion
(4) Low oil pressure indicator
(5) Neutral indicator
·"
'1/," • • • , ,
'..... ~ ' A·
-..:.
r. A i:: ~ ...
switch is ON and engine is not running. Should
go out when engine starts.
(6) Immobilizer system indicator
(7) Tachometer
~-
(13)
... CAUTION:
(8) Tachometer red zone (10) * Running the engine with insufficient oil pres-
(15) (14) (12) (11)
(9) Right turn signal indicator sure may cause serious engine damage.
(1 0) Coolant temperature gauge
(11) Orologio digitale (5) Neutral indicator (green) Lights when the transmission is in neutral
(12) High beam indicator (6) Immobilizer system indicator It lights for a few seconds when the ignition
(13) Tripmeter switch is switched ON. Refer to page 33 if the
(14) Tripmeter reset knob light does not go off.
(15) Fuel level indicator
10
11
(Ref. No) Description Function
Coolant Temperature Gauge (1)
When the needle begins to move above the
!cAUTION I
(7) Tachometer Shows engine rpm • Exceeding maximum running tempera-
C (Cold) mark. the engine is warm enough ture may cause serious engine damage.
.(8) Tachometer red zone Never allow the tachometer needle to enter the for the motorcycle to be ridden. The normal
red zone. even after the engine has been run in operating temperature range is within the
section between the H and C marks. If the
CAUTION: needle reaches the H (Hot) mark, stop the
* Running the engine beyond recommended engine and check the reserve tank coolant
maximum engine speed (tachometer red level. Read pages 22-23 and do not ride the
zone) can damage the engine. motorcycle until the problem has been cor-
(9) Right turn signal indicator Flashes when the right turn signal operates rected .
min·'
(12) High beam indicator (blue) Lights when the headlight is on high beam
(13) Tripmeter Show mileage per trip. ~
Resets trip meter to zero (0) by pushing the
(14) Tripmeter reset knob
kno_b.
(15) Fuel level indicator Indicates the available fuel quantitydisponibile
(page 14)
14 15
MAJOR COMPONENTS (Information you need to operate this motorcycle) Check that the fluid level is above the LOW-
ER level mark (1) with the motorcycle in an
Front Brake upright position.
W!i$'1·1;UIINM Brake fluid must be added to the reservoir (3)
• If the Pre-ride Inspection (page 41) is not Brake Fluid Level:
whenever the fluid level begins to reach the (4)
performed, severe personal injury or vehi- W!l'lfZ.!;UIIUM LOWER level mark (1). Remove the screws
cle damage may result. • Brake fluid may cause irritation. (5)
(2). reservoir cover (3), diaphragm plate (4),
Avoid contact with skin or eyes. In case of and diaphragm (5). Fill th e reservo ir with
BRAKES contact, flush thoroughly with water and
DOT 4 BRAKE FLUID from a sealed contain-
Both the front and rear brakes are the hydraulic call a doctor if your eyes were exposed.
er up to the upper level mark (6). Reinstall
disc types. • KEEP OUT OF REACH OF CHILDREN.
the diaphragm, diaphrag m pl at e, and cove r.
As the brake pads wea r, the brake fluid level
drops. !cAUTION I Tighten the screws securely.
There are no adjustments to perform, but fluid • Handle brake fluid with care because it
level and pad wear must be inspected periodi- can damage plastic and painted surfaces.
cally. Th e system must be inspected frequently • When adding brake fluid, be sure the Other Checks:
Make sure there are no fluid leaks. Check for (1) LOWER level mark
to ensure th ere are no fluid leaks. reservoir is horizontal before the cap is
If the control lever or pedal free travel becomes removed or brake fluid may spill out. deterioration or c racks in th e hoses and fit- (2) Screws
excessive and the brake pads are not worn be- • Use only DOT 4 brake fluid from a sealed ting s. (3) Reservo ir cover
yond the recommen ded limit (page 84), there is contai ner. (4) Diaphragm plate
probably air in the brake system and it must be • Never allow contaminants such as dirt or (5) Diaphragm
bled. See your authorised Honda dealer for this water to enter the brake fluid reservoir. (6) UPPER level mark
service.
16 17
i n~~ co~ethe.inspectiori
Check
windowthe(1)b rake fl uid level fro Brake fl uid must b
torcycle th e right side
upnght position r With the mo-
w enever th
LOW
. e added to th
h ER I e fluid level begi e reservoir
si de co eve l mark (2) . Re ns t o reach th e
ver (page 38
3) , reservoir
move the .
). Rem ove th nght
(3) -
·;t if
( .... "- ,A.
___.,. . (4)
(5)
(an d dia h cover (4), dia h e screws ·'·,~
:R~~gm th~
\ .,,
DOT 4 (6). Fi ll ragm plat e (5) (6)
U~FLUID ;:~ervoir
: : s$~
(~)ed
er up to th e from a wi th
Rein st all th PER level mark contain-
dl ap hrag
and cover. Tieghten m, d .iap hragm
the screws · piat e
Oth securely
er Checks· .
!CAUTION I Make sure th .
deterioration ~e are no fluid leaks
~ecause
• can
Handle brak e fluid with care
dama tlngs . r cracks in the hoses. Check for
and fit-
faces. ge plastic and it (2) LOWER Ievel mark
3) S
• Wh pamted ( crews
en add" sur-
reservoir . mg ~rake fluid
~~ ~onzontal bef~r~et:ure
(4) Reserv ·
(5) Dia Olr cover
oo{~ke
removed the (6) o· phragm plate
• Use only fluid may spill e cap is laphragm
• Never all~
container brake fluid fr out.
om a sealed
(7) UPPER level mark
w conta ·
water to enter bra:~~~?~s such as dirt or
(1) Inspection w1
.ndow
18 reservoir.
19
CLUTCH 2. If the cable adjuster is threaded out near 3. Loosen the lock nut (5) at the lower end of NOTE:
Adjustment: its limit or the correct free play cannot be the cable. Turn the adjusting nut (6) to ob- • If proper adjustment cannot be obtained or
Clutch adjustment may be required if the obtained using the cable adjuster (4) , a tain the specified free play . Tighten the the clutch does not work correctly, see
motorcycle stalls when shifting into gear or major adjustment must be made. Loosen lock nut (5) and check the adjustment. your authorised Honda dealer.
tends to creep; or if the clutch slips, causing the lock nut (3) and turn in the cable ad- 4. Start the engine, pul l in the clutch lever
acceleration to lag behind engine speed . Other Checks:
juster (4) completely. Tighten the lock nut and shift into gear. Make sure the engine
Minor adjustments can be made with the does not stall and the motorcycle does Check the clutch cable for kinks or sign of
(3) and install the rubber dust cover (2) .
clutch cable adjuster (4) at the lever (1 ). not creep. Gradually release the clutch wear that could cause sticking or failure.
Normal clutch lever free play is: lever and open the throttle. The motorcy- Lubricate the clutch cable with a commer-
10-20 mm (0.4-0.8 in) cle and accelerate gradual ly. cially availab le cab le lubricant to prevent
1. Pull back the rubber dust cover (2). premature wear and corrosion .
Loosen the lock nut (3) and turn the ad-
juster (4) . Tighten the lock nut (3) and
check the adjustment.
~
closed securely.
key, and close the protector.
• Be careful not to spill fuel when refu-
Use unleaded petrol with a research octane
number of 91 or higher.
Th e use of leaded petrol will cause prema-
elling. Spilled fuel or fuel when refu-
elling. Spilled fuel or fuel vapour may ig- J~ l
ture damage to the catalytic converter.
nite. If any fuel is spilled, make sure the ~ (4)
area is dry before starting the engine.
• Avoid repeated or prolonged contact
with skin or breathing of vapour.
I CAUTION I KEEP OUT OF REACH OF CHILDREN.
• If "spark knock" or "pinking" occurs at
a steady engine speed under normal (1) Fuel filler cap
load, change brands of petrol. If spark (2) Protector (4) Filler neck
knock or pinking persists, consult your (3) Key
24 25
Petrol Containing Alcohol NOTE: ENGINE OIL
If you decide to use a petrol containing alco - • Fuel sys tem damage or engine perfor- Engine Oil Level Check
!CAUTION I
hol (gasohol), be sure it' s octane rating is a mance problems resulting from the use of Check the engine oil level each day before • Running the engine with insufficient oil
least as high as th at recomm ended by Hon - fuels that contain alcohol is not covered can cause serious engine damage.
riding the motorcycle.
da. There are t wo types of "gasohol ": one under the warr ant y. Hond a can not en- The level must be maintai ned between the
containing ethanol , and the other containing dorse the u se o f fuels co ntaining upper (2) and lower (3) level marks on the
methanol. Do not use petrol that co ntains methanol since evidence of th eir suitabili- dipstick (1).
more than 10% eth anol. Do not use petrol ty are as yet incomplete. 1. Start the engine and let it id le for a few
containing methanol (methyl or wood alco - • Before buying fuel from an unfamiliar sta- mi nutes. Make sure the low oil pressure
hol) that does not also contain coso/vents tion , try to find out if th e fu el contains al- indicator goes off. If the light remains on,
and corrosion inhibitors for methanol. Never cohol. If it does, confirm the type and per- stop the engine immediately.
use petrol co nt a inin g more than 5% centage of alcohol used . If you notice any 2. Stop the engine and hold the motorcycle
methanol , even if it has coso /vents and cor- undesirable operati ng symp t o ms while in an uprig ht position on firm, level ground.
rosion inhi bitors. using a petro l that co ntain s alco hol , or 3. After a few minutes, remove the oil filler
one that yo u think contains a lcohol , cap/d ipstick, wipe it clean , and reinsert
switch to a petrol that you know does not the dipstick without screwing it in.
contain alcohol. Remove the dipstick. The oil level should
be between the upper and lower marks on
the dipstick.
4. If required, add the specified oil (see page 60)
up to the upper level mark. Do not overfill.
(1) Upper level mark
5. Reinstall the oil filler cap/d ipstick . Check
(2) Lower level mark
for oil leaks.
(3) Filler cap/d ipstick
26 27
TYRES
Proper air pressure will provide maximum W!i~!J.hUIIUW W!i!J11·1;U11UW
stability, riding comfort and tyre life. • Do not attempt to patch a damaged • Maintenance of spoke tension and
Check tyre pressure frequently and adjust if Front Rear tyre or inner tube. Wheel balance and wheel trueness are critical to safe mo-
tyre reliability may be impaired. torcycle operation. During the first
necessary. Tyre 90/90-21 120/90-17 • Improper tyre inflation will cause abnor- 1,000 km (600 miles) spokes will loosen
size 54S 64S
mal tread wear and create a safety haz- more rapidly due to initial setting of
NOTE: ard. Underinflation may result in the tyre
Rider only 200 (2.0) 200 (2.00) parts. Excessively loose spokes may
• Tyre pressure shou ld be checked before slipping on, or coming off of the rim result in high speed instability and pos-
you ride wh ile the tyres are "cold". Cold lyre pres- causing tyre deflation that may result in
sures sible loss of control.
On/off-road tyres are standard on th is Rider and a loss of vehicle control.
kpa 200 (2 .0) 225 (2 .25)
model. Select the right replacement tyres passenger • Operation with excessively worn tyres Replace tyres before tread depth at the cen-
(kfg/cm')
in accordance whit the fo llowing spec ifica- is hazardous and will adversely affect ter of the tyre reaches the fol lowing limit:
tions. tracti on and handling.
Tyre brand • The use of tyres other than those listed
MINIMUM TREAD DEPTH
Check the tyres for cuts, embedded nails, or on the tyre information label may ad-
Front TW47 FRONT: 1.5 MM (0.06 IN}
other sharp objects . See your authorised BRIDGESTONE
versely affect handling.
REAR: 2.0 MM (0.08 IN)
Honda dealer for replacement of damaged Rear TW48
tyres or punctured inner tubes. Front MT60 NOTE: (For Germany)
PIRELLI • German law prohibits use of tyres whose
Rear MT60
tread depth is less than 1.6 mm.
28 29
ESSENTIAL INDIVIDUAL COMPONENTS KEYS
OFF ON This motorcycle is provided with two keys
IGNITION SWITCH
The ignition switch (1) is below the indicator and a plate reporting the key number.
(1)
panel.
LOCK
! I
OFF Engine and lights can not be operated . Key can be removed .
(1)
ON Eng ine and light s can be operated. Key cannot be removed (1) Keys
(2) Plate
30 31
Referring to the key number will be neces- NOTE: IMMOBILIZER SYSTEM
sary when ordering extra keys. Store the • If all the key copies are lost, the ignition
plate in a safe place. unit must be replaced. In order to avoid The immobilizer system protects your motor- NOTE:
this problem , we suggest the user should cycle from thefts. A properly-coded key must • The system may not recognise the key 's
immediately replace any lost copies. coding if any other immobilizer key is near
To have your keys copied , take the keys, the be used in the ignition switch for the engine
• The keys contain electronic circuits activat- the ignition switch.To make sure the sys-
plate and the motorcycle to your Honda au- ed by the blocking system. Therefore, if the to start. If an improperly-coded key (or other
thorized dealer. device) is used the engine's starting circuit is tem recognize the key code, keep each im-
circuits are damaged the engine will not mobilizer key on a separate ring.
start. disabled.
• Do not attempt to alter the immabilizer sys-
• Do not drop the keys or place anything tem or add other devices to do it. Electrical
With this blocking system, four keys can be heavy on them. When the ignition switch is turned ON, the problems may result and starting the en-
recorded, including the ones the user is pro- • Do not file, punch holes or modify the key immobilizer system indicator lights for a few gine would be impossible.
vided with. original shape. seconds on, it means the system does not • If all keys are lost, the ignition control
• Keep your keys away from magnetic mate- module must be replaced .
recognize the coding of the key.
rials.
Turn the ignition switch to OFF, remove the
key, reinsert and turn the switch ON again .
32 33
RIGHT HANDLEBAR CONTROLS The starter button (2) is below the engine LEFT HANDLEBAR CONTROLS Turn Signal Switch (4)
l
stop switch (1). When the starter button is Move to signal ~ a left turn , to signal c:> a
Engine Stop Switch Headlight Switch (1) right turn . Press to turn signal off.
pressed, th e starter motor cranks the engine.
The engine stop switch is in the RUN posi- The headlight switch I ~DO~ I has three posi-
See pages 42-43 for the startin g procedure.
tion , the engine wi ll operate.
When the switch is in the OFF position , the
tions: I~DGO"I R!~ marked by a white dot. Horn Button (5)
36 37
RIGHT CASE LEFT CASE DOCUMENT COMPARTMENT
To remove the right case (1 ), remove the To remove the left case (1 ), remove the seat
seat (page 40) and the three bolts (2). (page 40) and the th ree bolts (2). The document bag (1) is located in the doc-
For installation , reverse the removal proce- Unlook the seat lock cable (3), and remove ument compartment (2) under the seat.
dure. the left case. When washing your motorcycle, be careful
For installation, reverse the removal proce- not to flood this area with water.
dure.
38 39
SEAT OPERATION 6. Drive chain-check condition and slack
PRE-RIDE INSPECTION (page 69) . Adjust and lubricate if neces-
To lift the seat, insert the key (2), turn the sary.
key clockwise (1 ), and pull it lightly back- 7. Throttle-check for smooth opening and
ward to unlock. • If the Pre-ride InspeCtion is not per- full closing in all steering positions.
To install the seat, align the hooking points formed, severe personal injury or vehi- 8. Lights and horn-check that headlight ,
with their seats and push down to secure. cle damage may result. tail/ brake light, turn signals, indicators
Remove the key. Inspect your motorcycle every day before and horn function properly.
you ride it. The items listed here will only 9. Engine stop switch-check for proper
function (page 34).
!cAUTION I take a few minutes to inspect, and in the
long run they can save time, expense, and 10. Side stand ignition cut-off system-check
• Make sure the seat is properly secured. for proper function (page 77).
possibly your life.
1. Engine oil level-add engine oil if required Correct any discrepancy before you ride.
(page 27) . Check for leaks. Contact your authorised Honda dealer
2. Fuel level-fill fuel tank when necessary for assistance if you cannot correct the
(page 24). Check for leaks. problem .
3. Coolant level-add coolant if required.
Check for leaks (pages 22-23).
4 . Front and rear brakes-check operation;
make sure there is on brake fluid leakage
(1) Seat lock (pages 16-19).
(2) Key 5. Tyres - check condition and pressure
(pages 28-29).
40 41
STARTING THE ENGINE NOTE: Starting Procedure 3. Immed iately after the engi ne starts, oper-
Thi s motorcycle is equipped with a side • Do not use the electric starter for more To restart a warm engine, follow the proce- ate the choke lever (1) to keep fast idle at:
st and ignition cut-off system. The engine t han 5 seconds at a time. Rel ease th e dure for " High Air Temperature". 2.000-3.000 min-1 (rpm)
cannot be started if the side stand is down, starter button for approximately 10 sec- Normal Air Temperature 4. About a half minut e after the engi ne
unless the transmi ssion is in neutral. If the onds before pressing it again. 1oo- 35°C (50° - 95°F) starts, push the choke lever (1) forward all
side st and is up , the engine can be started Before starting , insert the key, turn the igni- 1. Pul l the choke lever (1) back al l the way to the way to Fully OFF (B).
in neutral or in gear w ith the clutch lever tion switch ON and confirm the fol lowing: Fully ON (A), if the engine is cold . 5. If idling is unstabl e, ope n the throttle
pulled in . After starting with the side stand • The transm ission is in NEUTRAL (neutral 2. Start the engine, le av ing th e throttle slightly.
down , th e engine will shut off if th e trans- indicator light ON). closed .
mission is put in gear before raising the side • The engine stop switch is at RUN . !cAUTION I
stand.To protect th e catalytic converter in • The red low oil pressure indicator is ON . NOTE: • The red low oil pressure indicator
your motorcyc le' s exhaust syst em,avo id • Do not open the throttle when startin g the should go off a few seconds after the
extending idling and use of leaded petrol. eng ine with the choke ON. Thi s will lean engine starts. If the light stays on, stop
th e mixture, resulting in hard start ing . the engine immediately and check en-
gine oil level. Operating the engine with
insufficient oil pressure can cause seri-
• Never run the engine in an enclosed ous engine damage. ·
area. The exhaust contains poisonous
carbon monoxide gas that can cause
\
I
loss of consciousness and lead to
death.
(1) Choke lever
(A) Fully ON
(B) Fu lly OFF
42 43
High Air Temperature 35°C (95°F) or above Flooded Engine RUNNING-IN
1. Do not use the choke. If the eng ine fai ls to start after repeated at- Help assure your motorcycle's future relia-
2. Open the throttle slightly. tempts, it may be flooded with excess fuel. bility and performance by paying extra at-
3. Start the engine. To clear a flooded engine, leave the engine tention to how you ride during the first 500
stop switch on RUN and push the choke Km(300 miles).
Low Air Temperature 1ooc (1 0°F) or below
lever forward to Fully OFF (B) . Open the During this period ,avoid full-throttle starts
1. Follow steps 1 - 2 under "Normal Air Tem- throttle fully and crank the engine for 5 sec- · and rapid acceleration.
perature". onds. If the engine starts, quickly close the
2. When engine speed begins to pick up, op- throttle, then open it slightly if idling is unsta-
erate the choke lever to keep fast idle at: ble. If the engine does not start, wait 10 sec-
2,000 - 3,000 min-1 (rpm) onds, then follow the Starting Procedure.
3. Continue warn ing up the engine until it
runs smoothly and responds to the throt-
tle when the choke lever (1) is at Fully
OFF (B).
44 45
111DING speed by opening th e throttl e. BREAKING
*''~2'1;1~11UW
Co-ord ination of the throttle and clutch 1. For normal braking , gradually apply both the
w,pz,!;l~i!Utii • When riding in wet or rainy conditions, or
lever will assure a smooth positive start. front and rear brakes wh ile downshifting to suit on loose surfaces, the ability to manoeuvre
• Review Motorcycle Safety (pages 1-6)
4. When the motorcycle attains a moderate your road speed. and stop will be reduced.
before you ride.
speed , close the throttle, pull in the clutch 2. For maximum deceleration, close th e throttle All of your actions should be smooth under
lever and shift to 2nd gear by raising the and apply the front and rear brakes firmly. Pull these conditions. Rapid acceleration, brak-
NOTE: 1n the clutch lever before coming to a complete
gearshift pedal. ing or turning may cause loss of control.
• Make sure you understand the function of stop to prevent stalling the engine.
5. This sequence is repeated to progressive- For you safety, exercise extreme caution
the side stand mechanism. (See MAINTE- when breaking, accelerating or turning.
NANCE SC HEDULE on page 52 and ex- ly shift to 3rd, 4th and 5th (top) gears.
6. Raise the pedal to shift to a lower gear. • When descending a long, steep grade, use
planation for SIDE STAND on page 77). engine compression braking by downshift-
Each stroke of the pedal engages the next • Independent use of only the front or rear
• Make sure flammabl e materials such as ing, with intermittent use of both brakes.
gear in sequence. The pedal automatically brake reduces st opping performance. Ex-
dry grass or leaves do not come in con- Continuous brake application can overheat
returns to the horizontal position when re- treme braking may cause either wheel to
tact w ith the exhaust sys tem when lock, reducing control of the motorcycle. the brakes and reduce their effectiveness.
rid ing ,id ling,or parking your motorcycle. leased . • Riding with your foot resting on the brake
• When possible, reduce speed or brake be-
pedal or your hands on the brake lever may
fore entering a turn; closing the throttle or
actuate the brakelight, giving a false indica-
braking in mid-turn may cause wheel slip.
1. After the eng ine has been warmed up, the tion to other drivers. It may also-overheat
Wheel slip will reduce control of the mo-
motorcycle is ready for riding . the brake, reducing effectiveness. -
torcycle.
2. While the engine is idling, pull in the clutch
lever and depress the gearshift pedal to
shift into 1st (low) gear.
3. Slowly release the clutch lever and at the
same time gradual ly increase engine
46 47
ARKING NOTE: ANTI-THEFT TI PS NAM E: ________________________
I . Arter stopping the motorcyc le, shift t he • Make sure flammable materials such as
tran smission into neutral, turn th e hand le- dry grass or leaves do not come in contact 1. Always lock th e steering and never leave ADDRESS: ___________________
bar fully to t he left, turn the ignition switch wi t h t he exhaust syst em w hen parkin g the key in the ignition switch. This sounds
OFF and remove the key. your motorcycle. simple but people did forget.
2. Use the side stand to support the motor- 2. Be sure the registration information for
cycle wh ile parked. your motorcycle is accurate and current.
3. Park your motorcycle in a locked garage
PHON E NO:___________________
whenever possible.
I CAUTION I 4. Put your name, address, and phone num-
• P ark the motorcycle on firm, level ber in thi s Owner's Manual and keep it on
ground to prevent it from falling over. your motorcycles at all times.
• If you must park on a slight incline, aim
Many tim es stolen motorcycles are identi-
the front of the motorcycle uphill to re-
duce the possib ility of rolling off the f ied by i nformatio n in the Ow ner ' s
side stand or overturning. Manuals th at are still with them.
48 49
MAINTENANCE MAINTENANCE SCHEDULE
The following M~intenance Schedule all maintenance required to keep your motorcycle in peak
operat1ng cond1t1on. Maintenance work should be performed in accordance with standards and
• The Required Maintenance schedule specifies how often you should have your motorcycle specifications of Honda by properly trained and equipped technicians. Your authorised Honda deal-
served, and what things need attention. It is essential that your motorcycle be served as er meets all of these requirements.
scheduled to retain its high level of safety, dependability, and emission control performance. Perform the Pre-ride Inspection (page 41) at each scheduled maintenance period.
• These instructions are based on the assumption that the motorcycle w ill be used exclusive- 1: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
ly for its designed purpose. Sustained high speed operation, or operation in unusually wet C: CLEAN R: REPLACE A:ADJUST L: LUBRICATE
~
or dusty conditions, will require more frequent service than specified in the MAINTENANCE WHICHEVER -+ ODOM ETER READING [NOTE (1)]
SCHEDULE. Consult your authorised Honda dealer for recommendations applicable to COMES FIRST
18 24
x 1000 km 1 6 12 30 36
your individual needs and use. ! x1000mi 0,6 4 8 12 16 20 24 Ref. pag.
IT NOTE MONTHS 6 12 18 24 30 36
' FUEL LINE I I I -
' FUEL STRAINER SCREEN c c c c c c
• THROTILE OPERATION I I I 67
• CARBUR ETOR CHOKE I I I -
• AIR CLEANER (NOTE 2) R R 57
CRANK CASE BREATHER (NOTE 3) c c c c c c -
SPARK PLUG I R I R I R 64
VALVE CLEARANCE I I I I -
ENGINE OIL R R R R 60
ENG INE IOL FILTER R R R R 61
CARBURETOR CYNCHRONIZATION I I I I
ENGINE IDLE SPEED I I I I I I I 68
50 51
- .~
WHICHEVER ..... ODOMETER READING [NOTE (1)) SHOULD BE SERVICE BY YOUR AUTHORIZED HONDA DEALER , UNLESS THE OWNER
COMES FIRST HAS PROPER TOOLS AND SERVICE DATA AND MECHANICALLY QUALIFIED. REFER TO
x 1000 km 1 6 12 18 24 30 36 THE OFFICIAL HONDA SHOP MANUAL.
! x 1000 mi 0,6 4 8 12 16 20 24 Ref. pag. '* IN THE INTEREST OF SAFETY, WE RECOMMED THESE ITEM S BE SERVICED ONLY BY
ITEMS NOTE MONTHS 6 12 18 24 30 36 YOUR AUTHORIZED HONDA DEALER.
RADIATOR COOLANT (NOTE 4) I I R
' COOLING SYSTEM I I I 22
Honda recommend s that your authorised Honda dealer should road test your motorcycle after
• SECONDARY AIR SUPPLY SYSTEM I I I each periodic maintenance is carried out.
DRIVE CHAIN (NOTE5) EVERY 1000 Km (600 ml) I,L 69
DRIVE CHAIN SLIDER I I I I I I NOTES:
BRAKE FLUID (NOTE 4) I I R I I R 16
BRAKE PADS WEAR
(1) At higher odometer readings, repeat at the frequency interval establ ished here.
I I I I I I 84
BRAKE SYSTEM
(2) Service more frequently when riding in unusually wet or dusty areas.
I I I I 16-18
BRAKE LIGHT SWITCH I I
(3) Service more freq uently when riding in rain or at full throttle.
I 92
HEADLIGHT AIM I I I (4) Replace every 2 years, or at indicated odometer interval, whichever comes first.
CLUTCH SYSTEM I I I I I I I 20 Replacement requires mechanical skill.
SIDE STAND I I I 77 (5) Service more frequently when riding OFF-ROAD.
• SUSPEN SION I I I 76
• NUTS,BOLTS,FASTNERS (NOTE 5) I I I I
•• WHEELSffiRES (NOTE 5) I I I I I I I
•• STEERING HEAD BEARINGS I I I I
52
53
TOOL KIT SERIAL NUMBERS Th e fram e number (1) on the right side of the
The tool kit (1) is in the tool box (2) under The frame and engine serial numbers are steering.
side of the seat. required when registering your motorcycle. Th e eng in e number (2) is stamped on the
In sert the ignition key to remove the seat They may also be required by your dealer right side of the cylinder.
(pag.41.) when ordering replacement parts.
Some roadside repairs, minor adjustments Record the numbers here for your reference.
and parts replacement can be performed
with the tools contained in the kit.
FRAMEN. ______________________
• 10 x 12 mm open end wrench ENGINE N. - - - - - - - - - - - - - - - - - - -
• 14 x 17 mm open end wrench
• Ch iave aperta da 8x12
• Pliers
• No. 2 screwdriver
• No. 2 Phillips screwdriver
• No. 3 Phillips screwdriver
• No.5 Hex wrench
• 10 x 12 mm box end wrench
• • Screwdriver handle
• 17 mm box end wrench (1) Tool kit
• 24 mm box end wrench (2) Tool box
• Extension bar
• Spark plug wrench
• Tool bag (1) Frame N. (2) Engine N.
54 55
COLOUR LABEL MAINTENANCE PRECAUTIONS AIR CLEANER 3. Remove the fuel tank mounting bolts and
(Refer t o the maintenance precautions on the bushing.
The colour label (1) is attached to the frame.
page 56).
It is helpful w hen ordering replacement • If your motorcycle is overturned or
parts. Record the colour and code here for involved in a collision, inspect control
your reference. levers, cables, brake hoses, callipers, The air cleaner shou ld be serviced at regu lar
accessories, and other vital parts for intervals (page 51). Service more frequently
damage. Do not ride the Motorcycle if when riding in unusually wet or dusty areas.
COLOUR ______________________ damage impairs safe operation. Have
your authorised Honda dealer inspect Air cleaner replacement:
the majo r components, including 1. Remove the seat (page 40)
frame, suspension and steering parts,
for misalignment and damage that you 2. Remove the left and right front cover 4. Disconnect the ventilation tub es of th e
may not be able to detect. bolts, and disconnect them from the hold- cap overfill device.
• Stop the engine and support the motor- ers on the fuel tank. 5. Disconnect the float connector, th e vacu-
cycle securely on a firm, level surface um tube, and the fu el cock feed ing tube.
before performing any maintenance.
• Use new, genuine Honda parts or their
equivalent for maintenance and repair.
Parts which are not of equivalent quali-
ty may impair the safety of your motor-
cycle.
I
1/ ,
@ r.
I (
(1) Colour label ... 1 II"
56
57
6. Remove the fuel tank. CRANKCASE BREATHER
7. Remove the screws of the air cleaner (Refer to the maintenance precautions ori
case cover. page 56).
Take out and discard the air cleaner.
8. Install a new air cleaner. Use genuine air 1. Remove the crankcase breather tube plug
cleaner. a suitable container.
2. Reinstall th e crankcase breather tube
Install the parts in the reverse order of plug.
removal.
NOTE:
• Service more frequently when riding in
rain , at full throttle, or after the motorcycle
is washed or overturned.
Service if the deposit level can be seen in
the transparent section of the drain tube.
58 59
ENGINE OIL Engine Oil and Filter
!CAUTION I
(Refer to the maintenance precautions on Eng ine oil quality is the chief factor affecting
• To prevent oil leaks and filter damage,
page 56) engine life. Change the engine oil as speci- never support the engine on the oil filter.
fied in the maintenance schedule (page 51) .
Engine Oil . Chang ing the oil filter requires a special oil
Good engine oil has many desirable quali- filter tool and a torque wrench. If you do not
ties. Use only high detergent, quality motor have these tool s and the necessary skill, we
oil certified on the container to meet or recom mend that you have your authorised
exceed requirements for API Service Honda dealer perform thi s service . If a
Classification SE, SF or SG. torq ue wrench is not used for this installa-
tion, see your authorised Honda dealer as
Viscosity ® soon as possible to verify proper assembly.
Viscosity grade of engine oil should be
based on average atmospheric temperature NOTE:
in your riding area. The following provides a -10 10 20 • Change the engine oil with engine at nor-
guide to the selection of the proper grade or mal operating temperature and the motor-
20 40 60 10 IOfF cycle on its side stand to assure complete
viscosity of oil to be used at various atmos-
and rapid draining.
pheric temperature in your riding area. The
following provides a guide to the selection of (1) Single
the proper grade or viscosity of oil to be (2) Multigrade
used at various atmospheric temperatures.
60 61
I . Remove the oi l filter cap and crankcase 2. Rem ove the oil filter (3) with a filter 3. Apply a thin coat of engine oil to the new 5. Check that the sea ling washer on the
drain plug (1) and sealing washer (2). wrench and let the remaining oil drain out. oi l filter rubber seal (7) . drain plug is in good condition and install
Discard th e oil filter. 4. Using a special tool and a torque wrench, the plug. Repla ce the sealing was her
install the new oi l filter and tighten to a every other time the oil is changed, or
W!Vt.!;1~11UW torque of: each time if necessary.
• A warmed-up engine and the oil in it are 10 N•m (1.0 kgf•m, 7 lbf-ft) Oil Drain Plug Torque:
hot; be careful not to burn yourself. Use only the Honda genuine oil filter or a fil- 34 N•m (3.5 kgf•m , 25 lbf-ft)
ter of equivalent quality specified for your 6. Fill the crankcase with the recommended
model. Using the wrong Honda filter or a grade oil; approximately:
non-Honda filter which is not of equivalent 2.4 t (2.5 US qt, 2.1 Imp qt)
quality may cause engine damage.
7. Install the oil filler cap.
(1) (3) 8. Start the eng ine and let it idle for 2-3 min-
utes.
9. Stop the engine and check that the oil
level is at the upper. level mark on the dip-
stick with the motorcycle upright on firm,
(2) (3) Oil filter level ground. Make sure there are no oil
leaks.
(4) Oil filter rubber seal
62 63
NOTE: SPARK PLUGS Right park plug: access from th e right side Right spark plu g: remove the rear fixing
• When running in very dusty conditions, oil (Refer to the maintenance precautions on o f cowl . bolts from in strum ent pane l, remove the
changes should be performed more fre- page 51). Recommended plugs: lower fixing bolts of left and right cowl.
quently than specified in the maintenance Di sco nnect th e cow ls from the co upling
schedule. Standard: points on the tank.
• Please dispose of used engine oil in a DPR8EA-9 (NGK) or Remove the tank fi xing bolt.
manner that is compatible with the envi- X24EPR-U9 (NIPPODENSO)
ronment. We sugges t you take it in a
sealed container to your local recycling
j l
For extended high speed riding:
center or service station for reclamation .
Do not throw it in the rubbish or pour it on
DPR9EA-9 (NGK) or \\(Jl_
the ground or down a drain. X27 EPR-U9 (NIPPODENSO
!v,~&.
~_-_,Nr~~
\ ,0~
Replacement: Front cylinder head ~~~ViJ ·~ ~
I CAUTION I Left spark plug: access from the front left side Rear cylinder head Lift slowly the tank to allow the tool kit torque
• Used engine oil may cause skin cancer cowl air guide hole. Left spark plug: remove from the left side. extension between the tank and the frame.
if repeatedly left in contact with the skin The exten sion should be placed in th e spe-
for prolonged periods. c ific grooves locat ed on the frame and on
Although this is unlikely unless you han- the tank rubber.
dle used oil on a daily basis, it is still
advisable to thoroughly wash your
hands with soap and water as soon as
possible after handling used oil.
64 65
For most riding conditions this spark plug heat 5. With the plug washer attached, thread the THROTTLE OPERATION
range number is satisfactory. However, if the spark plug in by hand to prevent cross-
(Refer t o t he maintenance precautions on
motorcycle is going to be operated for extended threading.
page 56).
periods at high speed or near maximum power in 6. Ti ghten a new spark plug 1/2 turn with a
hot climates, the spark plug should be changed spark plug wrench to compress the wash- 1.Check for smooth rotation of the throttle
to a colder heat range (a higher number). er. If you are reusing a plug , it should only grip from the fully open to the fully closed
position at both full steering positions.
)
1. Clean any dirt from around the spark plug base. take 1/ 8-1 /4 turn after the plug seats.
2. Disconnect the spark plug cap and remove Reinstall the spark plug caps. 2. Measure the throttle grip free play at the
throttle grip flange.
the spark plug with the spark plug wrench ~+-- -= - - (3)
provided in the tool bag . The standards free play should be
3. Visually inspect the spark plug electrodes / - approx.:
for wear. The center electrode should not (2) 2-6 mm (0.08-0.24 in)
(1) Lock nut
be eroded . To adjust the free play, loosen the lock (2) Adjuster
Discard the spark plug if there is apparent (2) Spark plug gap nut (1) and turn the adjuster (2).
wear or if the insulator is cracked or (3) Side electrode
chipped .
4. Check the spark plug gap (2) using a
wire-type feeler gauge. If adjustment is
ICAUTION I
• The spark plug must be securely tight-
necessary , bend the side electrode (3) ened. An improperly tightened plug can
carefully. become very hot and possibly damage
The gap should be: the engine.
0.80-0.90 mm (0.031-0.035 in) • Never use a spark plug with an improp-
Make sure the plug washer is in good er heat range. Severe engine damage
condition. could result.
66
67
DRIVE C HAIN 3. Roll the motorcycle forward. Stop. Check
IDLE SPEED (Refer to th e maintenance precautions on drive chain slac k. Repeat this procedure
(Refer to the maintenance precautions on several time s. Drive c hain slack should
page 56).
page 56) . . The service life of the drive chain is depen- remain constant. If the chain is slack only
The engine must be at normal operat1ng
dent upon proper lubrication and adjustment. in certain sections, some links are kicked
temperature for accurate idle speed adjust-
Poor maintenance can cause premature wear and binding. Binding and kicking can fre-
ment. Ten minutes of stop-and-go nd1ng IS quently be eliminates by lubrication.
or damage to the drive chain and sprockets.
sufficient. The drive chain should be checked and
lubricated as part of the Pre-ride Inspection
NOTE: (page 41 ). Under severe usage, or when the
• Do not attempt to compensate for faults in
motorcycle is ridden in unusually dusty or
the other systems by adjusting idle speed.
muddy areas, more frequent maintenance
See your authorised Honda dealer for reg-
will be necessary.
ularly scheduled carburettor adjustments,
including individual carburettor adjustment Inspection:
and synchronisation . 1. Turn the engine off, place the motorcycle
on its side stand and shift the transmis-
1. Warm up the engine, shift to neutral and sion into neutral.
place the motorcycle on its side stand. (1) Throttle stop screw 2. Check slack in the lower drive chain run
2. Adjust idle speed with the throttle stop (A) Increase (B) Decrease midway between the sprockets .
screw (1). Drive chain slack should be adjusted to
Idle speed allow the following vertical movement by
1 ,200 ± 100 min-1 (rpm) (In neutral) hand:
(1) Drive chain
35-45 mm (1.4-1.8 in)
69
68
4. Rotate the rear wheel slowly and inspect Damage Worn 5. Check the chain slider for wear. When the
the drive chain and sprockets for any of Sprocket Teeth Sprocket Teeth thickness of the chain slider reaches the
the following conditions: limit, the chain slider must be replaced.
DRIVE CHAIN See your authorised Honda dealer. Chain
REPLACE REPLACE
• Damaged Rollers slider thickness limit:
• Loose Pins 2.0 mm (0.08 in)
• Dry or Rusted Links
• Kinked or Binding Links
• Excessive Wear
• Improper Adjustment
• Missing 0-rings
(2)
SPROCKETS
• Excessively Worn Teeth
• Broken or Damage Teeth (2) Chain slider
A drive chain with damage rollers, loose Normal Sprocket Teeth (3) Thickness
pins, or missing 0-rings must be replace.
A chain which appears dry, or shows signs GOOD
of rust, requires supplementary lubrication .
Kinked or binding links should be thoroughly
lubricated and worked free.
If links cannot be freed, the chain must be
replaced .
70 71
Ad ·ustment: If the drive chain requires adj ustment, the Both left and right marks should correspond.
!CAUTION I
Drive chain slack should be checked and procedure is as follows: If the axle is misal igned , turn the left or right
• Damage to the bottom part of the frame
adj usted , if necessary, every 1,000 km (600 1. Loosen the axle nut (1 ). adjusting nut until th e marks correspond on
may be caused by excessive drive chain
miles) . When operated at sustained high 2. Loosen the lock nuts (2) on both adjusting t he rear edge of the adjusting slots and slack of more than:
speeds or under conditions of frequent rapid nuts (3). recheck chain slack. 60 mm (2.4 in)
acceleration, the chain may require more 3. Turn both adjusting nuts (3) an equal 5. Tighten th e axle nut to specified torque.
frequent adjustment. number of turns until the correct drive Axle nut torque:
chain slack is obtained. Turn the adjusting 88 N•m (8,8 kgf•m , 69 lbf-ft)
nuts c lockwise to tighten the cha in , or 6. Tighten the adjust in g nuts lightly, then
cou nterclockwise to provide more slack. tighten the lock nuts by holding the
Adjust the chain slack at a point midway adjusting nuts with a spanner.
between the drive sprocket and the rear 7. Recheck chain slack .
whee l sprocket. Rotate th e rear w hee l
and recheck slack at other sections of the
chain.
Chain slack shou ld be:
35-45 mm (1 .4-1 .8 in)
4. Check rear axle alignment by making sure
(1) Axle nut the chain adjuster index marks (4) align
(2) Lock nut with the rear edge
(3) Drive chain adjustment nut
(4) Index mark
(5) Rear edge of adjusting slot
72 73
Wear inspection: Lubrication and cleaning :
Check the chain wear label when adjusting Lubricate every 1,000 km (600 miles) or
the chain. If the red zone (6) on the label sooner if chains appears dry.
aligns with the arrow mark (7) on the chain The 0-rings in thi s chain can be damaged
adjuster plates after the chain has been by steam cleaning , high pressure washers,
adjusted to the proper slack, the chain is and certain so lvents . Clean the chain with
excessively worn and must be replaced. The high flash-point solvent, such as paraffin.
proper slack is: Wipe dry and lubricate only with SAE 80 or
35-45 mm (1.4-1.8 in) 90 gear oil. Commercia l chain lubricants
may contain solvents which could damage
Replacement chain: the rubber 0-rings.
010525 112-120L
(6) Red zone
or
(7) Arrow mark !cAUTION I
RK525 112-120L
• The drive chain on this motorcycle is
equipped with small 0-rings between
the link plates. These 0-rings retain
grease inside the chain to improve its
service life. However, special precau-
tions must be taken when adjusting,
lubricating, washing, and replacing the
chain.
74 75
FRONT AND REAR SUSPENSION SIDE STAND
INSPECTION (Refer to the maintenan ce precautions on
(Refer to the maintenance precautions on page 56) .
page 56). Check the side st and system for proper
1. Check the fork assembly by locking the function.
front brake and pumping the fork up and • Check th e spring (1) for damages or loss
for tension and the side stand assembly
down vigorous ly . Suspension action
for freedom of movement.
should be smooth and there must be no • Check th e side stand ignition cut-off sys-
oil leakage. tem:
2. Swingarm bearings should be checked by 1. Sit astrid e the motorcycle; put the side
pushing hard against the side of the rear stand up and the transmission in neutral .
wheel while the motorcycle is on a sup- 2. Start the engine and with the clutch lever
port blocked . Free play indicates worn pulled in , shift the transmission into gear.
bearings. 3. Lower the side stand. The engine shou ld
3. Carefu ll y inspect al l front and rear sus- stop as you put the side stand down.
pension fasteners for tightness . If the side stand system does not operate
as described , see you authorised Honda
dealer for service.
(1) Spring
76 77
WHEEL REMOVAL Front Wheel Removal 3. Remove the calip er assembly from the
(Refer to the maintenance precautions on 1. Rai se the front wheel off the .ground by fork leg by removing th e fixing bolts (6).
page 56). placing a support block under the engine. 4. Remove the front axle holder nuts (3) and
2. Remove the speedometer cable set screw (1) the frontal axle holder (4).
NOTE: and disconnect the speedometer cable (2). 5. Unscrew the axle (5). Remove the wheel.
• This motorcycle is equipped with as id e
stand only. Therefore, if front or rear wheel NOTE:
removal is required, it will be necessary to
• Do not depress the brake lever when the
raise the center of the motorcycle with a
wheel is off the motorcycle. The calliper
jack or other firm support. If none avail-
piston will be forced out of the cylinder
able, see your authorised Honda dealer for
with subsequent loss of brake fluid. This
this service .
occurs, servicing of the brake system will
be necessary. See your authorised Honda
dealer service. (6) Fixing bolts
(1) Screw
(2) Speedometer cable
(3) Axle holder nuts
(4) Axle holder
(5) Axle
78
79
Installation Notes: Rear Wheel Removal 5. Remove th e ax!e shaft (5), rear wheel from
• Reverse the removal procedure. 1. Raise the rear whee l off th e ground by the swing arm .
• If a torque wrench was not used for
• Insert the axle through the wheel hub and installation, see your authorised Honda placing a support block under th e engine.
left fork leg. dealer as soon as possible to verify 2. Loosen the drive chain adjusting nut lock NOTE:
• Make sure that leg lug (7) on the speedome- proper assem bly. Improper assembly nuts (1) and adjusting nuts (2) . • Do not d press th e brake pedal whi le the
ter gearbox is located behind the lug (8) on may lead to loss of braking capacity. 3. Remove the rear axle nut (3). whee l is off th e motorcyc le. The calliper
the right fork leg (9). pistons will b forc ed out of th e cylinders
4. Remove the drive chain (4) from the dri-
• Install the axle holder with the UP mark with subsequent loss of brake fluid. if th is
ven sprocket by pushing the rear wh eel
(1 0) upward and approach the upper hold- occurs, servicing of th e brake system will
forward.
er nuts first , then the lower holder nuts be necessary. See your authorised Honda
• Tighten the axle to the specified torque. dealer for thi s service.
Front axle torque:
64 N•m (6.5 kgf-m)
• Tighten th e axle holder nut to the specified
torqu e:
12 N•m (1.2 kgf-m)
Install the brake caliper and tighten to spe-
cific torque.
33 N•m (3.4 kgf-m)
• After installing the wh eel, apply the brake
several times and then check if th e wheel
rotate freely . Recheck if the brake drags or (7) lug (1) Lock nuts
if th e wheel does not rotate freely. (8) lug (2) Adju sting nuts
(9) Right front fork (3) Axle nut (4) Drive chain
(1 0) UP mark (5) Axle shaft
80 81
Installation Notes: WJVh1;t:I!UtW
• To install the rear wheel, reverse the • If a torque wrench was -not used for • T h e r ea r shock absorbed assembly
removal procedure. installat!on, see your authorised Honda inc ludes a damper unit that contains
• Make sure the tang (6) on the swingarm is dealer as soon as possible to verify hig h pressure nitrogen gas. Do not
located in the slot (7) in the brake panel (8). proper assembly. Improper assembly attempt to disassemble, disconnect or
• Tighten the axle nut to the specified may lead to loss of braking capacity. service the damper unit; an explosion
torque. cau sing serious injury may result.
Axle nut torque: • Pun cture or exposure to flame may
88 N•m (8,8 kgf•m , 69 lbf-ft) als o result in an explosing, causing
• Adjust the drive chain (page 712) . serious injury.
• After installing the wheel, apply the brake • Service or disposal should only be done
several times and then check if the wheel by your authorised Honda dealer or a
rotates freely . Recheck the wheel if the qua lified mechanic, equipped with the
brake drags or if the wheel does not rotate proper tools, safety equipment and the
freely. offi cial Honda Shop Manual.
(6) Tang
(7) Slot
(8) Brake panel
83
82
<FRONT BRAKE> Rear Brake <R -A 8 1 /\1 I .
BRAKE PAD WEAR
Check the wear indication mark (2) on each
(Refer to the maintenance precautions on
pad.
page 56).
Brake pad wear depends upon the severity If either pad is worn to the wear indicator
of usage, the type of riding, and road condi- mark, replace both pads as a set. See your
authorised Honda dealer for this service.
tions. (Generally, the pads will wear faster on
a wet and dirty roars).
Inspect the pads at each regular mainte-
nance interval (page 52).
Front Brake
Check the cut-out (1) in each pad.
If either pad is worn to the cut-out, replace
both pads as a set. See your authorised
Honda dealer for this service.
!cAUTION I
• Do not put finger prints on the headlight
....
(1)
(2) "' ..
r \
' (2)
If l?)r.~ \
90 91
Stop/Taillight bulb Front turn signal bulb
(1) Cover
1. Remove the rear handle by removing the (2) Screws
1. Remove the in strum ent panel cover by
four locking screws. re moving the two front screws (1) and the
2. Remove the rear tail. other four screws (2).
3. Turn the bulb-holder clockwise and 2. Remove the bulb-holder and replace the
remove the bulb (1). bulb.
4. Install a new bu lb and follow the reverse
order of removal.
(1) Bulb
(1) .,..
~"'--.._ (2)
92 93
Rear turn signal bulb STOPLIGHT SWITCH ADJUSTMENT
(Refer t o th e maintenance precautions on
1. Lo ose n the rear turn signal screw (1) page 56) .
remove the bulb and install a new one. Check the operation of the stoplight switch
(1) at the ri ght side behind the engine.
Adjustment is done by turning the adjusting
nut (2). Turn th e nut in the direction (A) if the
switch operates too late, and in direction (B)
if it operates too soon.
94 95
CLEANING NOTE: Aluminium Wheel Maintenance
Clean your motorcycle regularly to protect • Clean the fairing , headlight lens and other Aluminum may corrode from contact with
the surface finishes and inspect for damage, plastic parts using a cloth or sponge dirt, mud, or road salt. Clean the wheels after
wear, and oil, coolant or brake fluid leakage. dampened wi th a solution of mild deter- riding through any of these substances. Use
gent and water. Rub the soiled area gently
!CAUTION I ri si ng it frequently with fresh water.
a wet sponge and mild detergent, or a com-
• High pressure water (or air) can dam- mercially-avail able spray cleaner/degreaser
age certain parts of the motorcycle. 2. Dry the motorcycle, start th e engine, and designed for use on aluminum. Avoid stiff
let it run for several minutes. brushers, steel wool, or cleaners contain ing
Avoid spraying high pressure water (typical
3. Test the brakes before rid ing th e motor- abrasives or harsh chemical compounds.
in coin -operated car washes) at th e follow -
cycle. Several applications may be neces- After washing ,rinse with plenty of water and
ing areas:
sary t o restore normal braking p erfor - dry with a c lean cloth; Then app ly a mild,
Wh eel Hubs
mance. commercially-avai lable spray c leaner/polish
Carburettor
Instrum ents or wax.
Under Seat Fo r sta in ed or du ll - looking wheels, use a
Drive Chain
W!i?Z.!;UIIUM qual ity c hrome/al uminum polish to restore
• Braking efficiency may be temporarily
Ignition Switch the finish.
impaired immediately after washing the
Muffler Outlets Aft er you fini sh c lean in g the w hee ls, it ' s
motorcycle. Anticipate longer stopping
Under Fuel Tank im portant to c heck for and remove any
distance to avoid a possible accident.
Brake Master Cylinder cleaner or polish residue found on the brake
Handlebar Switches
4. Lubri cate the drive c hai n immediately discs or pads. Use Honda Contact/Brake
1. After cleaning, rin se the motorcycle thor- after wash ing and drying the motorcycle. Cleaner or an equ ivalent brake degreasing
oug hly with plenty of clean water. Strong agent.
detergent residue can corrode alloy parts.
96 97
STO RAGE GUIDE NOTE: 4. To prevent rusting in the cylinders, per- 6. Wash and dry the motorcycle. Wax all
I xtended storage, such as for winter, requires • If storage will last more than one month, form the following: painted surfaces. Coat chrome with
111al you take certain steps to reduce the carburetor draining is very important, to • Remove the spark plug caps from the rustinhibiting oil.
effects of deterioration from non-use of the assure proper performance after storage. spark plug s. Using tape or string, 7. Lubricate the drive chain (page 75).
motorcycle. In addition, necessary repair secu re the caps to any conven ient 8. Inflate the t yres to thei r recommended
should be made BEFORE storing the motor- plastic body part so that they are posi- press ures. Place the motorcycle on
cycle; otherwise, these repairs may be forgot- A WARNING blocks to raise both tyres off the ground.
tioned away from the spark plugs.
ten by the time the motorcycle is removed • Petrol is extreme ly fla mmable and is • Remove the spark plugsfrom the engine 9. Cover the motorcycle (don't use plastic or
from storage. explosive under certain conditions. and store them in a safe place. Do not other coated materials) and store in an
Perform this operation in a wellventilat- connect the spark plugs to the spark unheated area, free of dampness with a
ed area with the engine stopped. Do not plug caps. minimum of daily temperature variation. Do
STORAGE smoke or allow flames or sparks in the not store the motorcycle in directsunlight.
• Pour a tablespoon (15-20 cc) of clean
1. Change the engine oil and filter. area where petrol is drained or stored
2. Make sure the cooling system is filled engine oil into each cylinder and cover
and where the fuel tank is refuelled. the spark plug holes with a piece of
with a 50150% antifreeze solution.
3. Empty the fuel tank into approved petrol cloth.
container using a commercially available • Crank the engine several times to
hand siphon or an equivalent method. distribute the oil.
Spray t he inside of the tank with an • Reinstall the spark plugs and spark
aerosol rust-inhibiting oil. plug caps.
Reinstall the fuel fill cap on the tank.
5. Remove the battery. Store in an area pro-
tected from freezing temperatures and
direct sunlight. Charge the battery once a
month.
98 99
REMOVAL FROM STORAGE SPECIFICATIONS
1. Uncover and clean the motorcycle. DIMENSIONS
Change the engine oil if more than 4 Dry weight 196 (kg)
month have passed si nce th e start of Empty weight 211 (kg)
storage. Overall width 2260 (mm)
2. Check the battery electrolyte level and Max. width 920 (mm)
Max. height 1315 (mm)
charge the battery as required. Install the
Wheel base 1505 (mm)
battery. Saddle height 841 (mm)
3. Drain any excess aeroso l ru st- inhibiting Minimum ground clearance 186 (mm)
oil from the fuel tank with fresh petrol. Steering angle inclination 43° (deg.)
4. Perform all Pre-ride In spection checks Trail 108 (mm)
(page 41). Fuel tank capacity 19.6 (lit.)
Test ride the motorcycle at low speeds in Battery 12V12AH (AH)
a safe riding area away from traffic.
FRAME
Frame type Semi-double cradole
Front suspension Telescopic type
Rear shock absorber Pro-link
Wheel rim type Spokes
Tyres Front 90/90-21
Rear 120/90-17
Brakes Front Hydraulic double disc
Rear Hydraulic single disc
100 101
LNG IN E POWER TRANSMISSION
I ypo Bi-cylinder, V-t ype, 4-stroke, single head camshaft, water cooling system Primary reduction 1,763
Gear ratio 1: 2,500
Displacement 647 (cc) II: 1,722
Bore x stroke 79x66 (mm) Ill: 1,333
Compression 9.2 IV: 1'111
Transmission Constant mesh , 5 speed V: 0,961
Final trasmission Chain Final reduction: 3,200
Clutch Multi plate wet
Starting system Electric ELECTR ICAL
Alternator 310W (W) Battery 12V- 12AH
Engine oil capacity 2.9 (lit) Generator 0,31 OkW I 5.000 min·' (giri/min)
DPR8EA - 9 (NGK) o
Normal
X24EPR - U9 (DENSO)
Spark plug
DPR9EA - 9 (NGK) o
For extended high speed riding
X27EPR - U9 (DENSO)
102 103
LIGHTS Radio type approvals of· immobilizer sys- The radio type approval label of immobilizer
tem system (1) is attached in front of the ignition
Headlight: 12V- 60/55W
switch (2).
Tail/lbrake light: 12V- 21/5W The system is certified under the regulation
Turn signal light Front: 12V- 21W on Telecommunications and Electromagnetic (1
Rear: 12V- 21W Compatibility by the appropriate National
Instruments lights: 12V- 3,4W X 3,12V- 3W Competent Authority shown in the below.
Neutral indicator: 12V- 3W
Turn signal indicator: 12V- 3,4W Manufacturer: KANSEI CORPORATION
High beam indicator: 12V- 3W Model number: BSSEU10
Low oil pressure indicator: 12V -1 ,7W
Side stand indicator: 12V- 1,7W (1) Radio type approval label of immobilizer
system Ignition swith
FUSE (2) Ignition starter
Main fuse: 30A
UK See label Norvway N098000398-R
Other fuses: 10A, 15A Austria See label Portugal ICP-046TC-98
Greece See label Switzerland BAKOM 98.0363.G.P.
Holland
France
ltaliy
See label
See label
DG PGFI 4/2/04/339456/FO
0002383 del 11-9-98
Germany
[at
__
a oaoo'
~244K j
Belgium RTT/ D/X 1659 Spain E 08 98 0608
Ireland IRL TRA 24/5/129/1 Luxembourg L 2431/10425-011
104 105
CATALYTIC CONVERTER • Always use unleaded petrol. Even a small
This motorcycle is equipped with a catalytic amount of leaded petrol can contaminate
converter. th e catalyst metals, making the catalytic
The cat alytic converter contains precious converter ineffective.
metals that serve as catalysts , promoting • Keep the engine tuned-up.
chemical reactions to convert the exhaust • Have your motorcycle diagnosed and
gasses without affecting the metals. rep laced if it is misfiring , backfiring,
The catalytic converter acts on HC, CO, and stalli ng or otherwise not running properly.
Nox. A rep lacement unit must be an original
Honda part or its equivalent.
The catalytic converter must operate at a
high temperature for the chem ical reactions
to take place. It can set on fire any com-
bustible materials that come near it. Park
your motorcycle away from high grasses,
I I dry leaves, or other flammables.
A defective catalytic converter contributes to
air pollution , and can impair your eng in e's
performance. Follow these guidelines to pro-
tect your motorcycle's catalytic converter.
106