Honda CM400E (1981) Owner's Manual

-----IMPORT ANT NO'l'h~I'

• OPERATORANDPASSENGER

This motorcycle is designed to

CU"Y

1111..

",1,,1'),

'-"'ilrllit!

ptlUtlotl;CI.

Never exceed the vehicle capacity load

.1\

,11,,\\

II 'lIl

11",

Ilrl) lIill"iJl!llio)ll

label. .

• ON-ROAD USE

This motorcycle is not equipped with "

~I""~

be used only on the road. Opcrat io u

III

I""!~I. 10'11.1,

,'II

areas may be illegal. Obey local laws

:lIld 11'1'.111,011""

• READ OWNER'S MANUAL CAREFlJI I

Pay special attention to statements

pll·\('tkoi

1111

I"II"

Ilip

wOI;1

[:I1j.'i!

:"Utl

Indicates a strong possibility 01

$('V/'II'

/"'''''1,11/

tll/lll

I' ",'

Iii.!.! j·f

Ii(!'

instructions are not followed,

CAUTION:

Indicates a possibility of

/11'1"'1/1111

III/III)' "" e,/lli/lliiOll

ilWt!,/!

instructions are not fotlowcd.

NOTE: Gives helpful infounatlou.

This manual should be

l'0I1Nilh"l·d II

1"",,1"11' III

1',1,1

III I

ill] \',

lill 11I11I1t1

should remain with the velurle

WIl"11

1I'~"ltI

HONDACM400E OWNER'SMANUAL

,_..-

1981

All information in this publication is based on the latest product 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 writte,n permission.

Honda Motor Co., Ltd. 1980

WELCOME,

Your new motorcycle presents you with an invitation to adventure and a challenge to master the machine. Your safety depends not only on your own alertness and familiarity with the machine, but also the machine's mechanical condition. A pre-ride inspection before every outing and regular maintenance are essential.

To help meet the challenges safely and enjoy the adventure fully, become thoroughly

familiar with this Owner's Manual BEFORE YOU RIDE THE MOTORCYCLE. Also, for your own and your Honda's sake, please read all the written material which came with your new Honda. These items include;

Honda Owner's Identification Card

Set-up and Predelivery Checklist

Honda Motorcycle Emission Control System, Distributor's Warranty

Honda Motorcycle, Distributor's Limited Warranty

When service is required, remember that your Honda dealer knows what it takes to keep your Honda going strong.Ifyou have the required mechanical "know-how" and tools, your dealer can supply you with an official Honda Shop Manual to help you perform many maintenance and repair tasks.

Pleasant riding, and thank you for choosing a Honda!

Page

MOTORCYCLE SAFETY. . . . . . . .. 1

Safe Riding Rules . . . . . . . . . . . .. 1

Protective Apparel 2

Loading and Accessories . . . . . . .. 3

Tires . . . . . . . . . . . . . . . . . . . . . .. 5

Modifications 7

DESCRIPTION , 8

Parts Location. . . . . . . . . . . . . . .. 8

Serial Numbers 12

Parts Function 14

Fuel 23

Engine Oil . . . . . . . . . . . . . . . . . .. 25

OPERATION 27

Pre-ride Inspection 27 Starting the Engine 28 Break-in 31

Riding : 32 Braking 34 Parking 35 Anti-theft Tips 35

SPECIAL PROCEDURES 36

Tool Kit 37

Front Wheel Removal , 38

Page Rear Wheel Removal 40 Fuse Replacement 42

MAINTENANCE 44

Maintenance Schedule 46 Maintenance Record 48

Engine Oil . . . . . . . . . . . . . . . . . . . 49

Oil Filter 50 Spark Plugs 51

Idle Speed . . . . . . . . . . . . . . . . . .. 52

Air Cleaner 53 Crankcase Breather 54 Clutch 55 Front Brake 57

Rear Brake 59 Drive Chain 61

Side Stand 64

Battery 65

CLEANING 67

STORAGE , , ., 67 EMISSION CONTROL SYSTEM 68 CONSUMER INFORMATION 71 SPECIFICATIONS 72

...._._....-~..-.-.--._._.. MOTO RCYCLE SAFETY

rid.i;piiBii

.~~

....

.........

...

* Motorcycle riding requires special efforts on your part to ensure your safety. Know

these requirements before you ride.

SAFE RIDING RULES

1. Always make a Pre-ride Inspection (page 27) before you start the engine. You may prevent an accident or equip- ment damage.

2. Many accidents involve inexperienced riders. Most states require a special motorcycle riding test or license. Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider.

3. Many automobile/motorcycle acci- dents happen because the automobile driver does not "see" the motorcyclist. Make yourself conspicuous to help avoid the accident that wasn't your fault:

• Wear bright or reflective clothing.

• Don't drive in another motorist's "blind spot."

4. Obey all federal, state and local laws and regulations.

• Excessive speed is a factor in many

accidents. Obey the speed limits, and NEVER travel faster than con- ditions warran t.

• Signal before you make a turn or

lane change. Your size and maneu- verability can surprise other motor- ists.

5. Don't let other motorists surprise you. Use extra caution at intersections, parking lot entrances and exits, and driveways.

6. Keep both hands on the handlebars and both feet on the foot pegs while riding. A passenger should hold on to the motorcycle or the operator with both hands and keep both feet on the passenger foot pegs.

PROTECTIVE APPAREL

1. Most motorcycle accident fatalities are due to head injuries: ALWAYS wear a helmet. You should also wear a face shield or goggles as well as boots, gloves, and protective clothing. A pas- senger needs the same protection.

2. The exhaust system becomes very hot during operation, anditremains hot after operation. Never touch any part of the hot exhaust system. Wear cloth-

ing that fully covers your legs.

Do not wear loose clothing which could catch on the control levers, foot pegs, drive chain or wheels.

LOADING AND ACCESSORIES

1'?i''?·!;I:i1Ua

* To prevent an accident, use extreme

care when adding and riding with accessories and cargo. Addition of accessories and cargo can reduce a motorcycle's stability, performance and safe operating speed. Never ride an accessory-equipped motorcycle at spe- eds above 80 mph. And remember that this 80 mph limit may be reduced by installation of non-Honda accessories, improper loading, worn tires and over-

all motorcycle condition, poor road or

weather conditions, etc. These general guidelines may help you decide wheth- er or how to equip your motorcycle, and how to load it safely.

Loading The combined weight of the rider, pas-

senger, cargo and all accessories must not exceed

420

Ibs, the vehicle capacity load. Cargo weight alone should not exceed 401bs.

I. Keep cargo and accessory weight low

and close to the center of the motor- cycle. Load weight equally on both sides to minimize imbalance. As weight is located farther from the motorcycle's center of gravity, handl- ing is proportionally affected.

2. Adjust tire pressure (TIRES, page 5) and shock absorber springs (SHOCK ABSORBERS, page 22) to suit load weight.

Luggage racks are for light weight

.items. Do not carry more than20Ibs.

of cargo on a luggage rack behind the seat. Bulky items too far behind the rider may cause wind turbulence that impairs handling.

All cargo and accessories must be secure for stable handling. Re-check

cargo security and accessory moun ts freq uen tly.

Do not attach large, heavy items to the handlebars, front forks, or fender. Unstable handling or slow steering response may result.

Accessories Genuine Honda accessories have been

specifically designed for and tested on this motorcycle.

Because the factory cannot test all other

accessories, you are personally respon-

sible for proper selection, installation and use of non-Honda accessories. Always follow the guidelines under Loading above, and these:

1. Carefully inspect the accessory to make sure it does not obscure any lights, reduce ground clearance and banking angle or limit suspension travel, steering travel or control oper- ation.

2. Large fork-mounted fairings or wind- shields, or poorly designed or improp- erly mounted fairings can produce aerodynamic forces that cause unsta- ble handling. Do not install fairings that decrease cooling air flow to the engine.

3. Accessories which alter your riding position by moving hands or feet away from controls may increase reaction

time in an emergency.

4. Do not add electrical equipment that

will exceed the motorcycle's electrical

system capacity. A blown fuse could

cause a dangerous loss of lights or engine power at night or in traffic.

5. This motorcycle was not designed to pull a sidecar or trailer. Handling may be seriously impaired if so equipped.

TIRES

Proper air pressure will provide maximum stability, riding comfort and tire life. Check tire pressures frequently and adjust if necessary.

NOTE:

Check tire pressure when the tires are "cold," before you ride.

Front Rear

Tire size

3.50S18-

4.60SI6-

4PR 4PR

Up to 90 kg

1.75 (24)

Cold

(200Ib)

2.0 (28)

tire

load

pres- 90 kg

sures

(200 Ib)

kg/em'

load to

(psi) vehicle

1.75 (24)

2.5 (36)

capacity load

BRIDGE- STONE

S703

L302

Tire

DUNLOP

brand

Fll

K127

YOKO-

HAMA

Y-992

Y-987

Dry weight kg (Ib)

168 (370)

Curb weight (wet) kg (lb)

182 (401)

Gross vehicle weight

374 (825)

rating kg (lb)

Vehicle capacity load

190 (420)

kg (lb)

Check the tires for cuts, imbedded nails, or other sharp objects. See your author- ized Honda Dealer for replacemen t of damaged tires or punctured inner tubes.

f?tn"i

:II

UtJ

Do not attempt to patch a damaged tire or inner tube. Wheel balance and

tire reliability may be impaired.

* Improper tire inflation will cause ab-

normal tread wear and create a safety hazard. Underinflation may result ·in

the tire slipping on, or coming off of the rim.

Operation with excessively worn tires is hazardous and will adversely affect traction and handling.

* The use of tires other than those listed

on the tire information label may

adversely affect handling.

Proper wheel balance is necessary for safe, stable handling of the motor- cycle. Do not remove or change any

wheel balance weights. When wheel balancing is required, see your author- ized Honda dealer.

* Replace tires before tread depth at the

center of the tires reaches the follow- ing limit:

Minimum tread depth

Front: Rear:

1.5 mm (1/16 in)

2.0mm(3/32

in)

MODIFICA nONS

fmt<'l

* Modification of the motorcycle, or

removal of original equipment may render the vehicle unsafe or illegal. Obey all federal, state and local equip- ment regulations.

PARTS LOCATION

(1) Horn button (2) Turn signal switch (3) Headlight dimmer switch (4) Clutch lever (5) Choke knob (6) Speedometer (7) Ignition switch (8) Indicator and warning lights

(9) Engine stop switch (10) Front brake lever (11) Throttle grip (12) Starter button (13) Fuel cap cover

(1)

Seat latch

(2) Helmet holder

!~~

(1)

Steering Lock

(2) Fuel valve

(3) Gearshift pedal (4) Foot peg

(5) Side stand (7) Seat latch

(6) Passenger foot peg

(3) Passenger foot peg (4) Foot peg

(5) Rear brake pedal (6)

Oil

filler cap/dipstick

SERIAL NUMBERS

The frame and engine serial numbers are required when registering your motor- cycle. They may also be required by your dealer when ordering replacement parts. Record the numbers here for your refer-

ence.

FRAME NO.3

t).,J(!.

II ~

SlY!

J..~"3

ENGINE NO.

".;).4-

(1)

YIN number

The VIN, Vehicle Indentification Number (1), is on the Safety Certification Label affixed to the left side of the steering head. This number is the same as the

frame number

(2)

stamped on the right

side of the steering head.

(2) Frame number

The engine number

(3)

is stamped on the

top of the crankcase.

(3) Engine number

PARTS FUNCTION

Instruments and Indicators

The indicator and warning lights are grouped above the headlight. Their func- tions are described in the tables on the following pages.

USA model Odometer and tripmeter read in miles.

Canadian model

Odometer and tripmeter read in kilo- meters.

(l)

Speedometer (2) Gear range indicators (3) Odometer

(4) Tripmeter (5) Tripmeter reset knob (6) Turn signal indicator (7) High beam indicator (8) Oil pressure warning light (9) Neutral indicator

Ref. No. Description Function

Speedometer

Shows driving speed, 0 to 85 mph.

Gear range indicators

Show speed range for each gear.

Odometer

Shows accumulated mileage.

4 Tripmeter Shows mileage per trip.

5 Tripmeter reset knob

Resets tripmeter to zero (0). Turn knob in direction shown.

Ref. No.

Description

Function

I I

Turn signal indicator

Flashes when either turn signal operates.

(amber)

High beam indicator

Lights when headlight is on high beam.

(blue)

Lights when engine oil pressure is below normal oper- ating range. Should light when ignition switch is ON

Oil pressure warning

and engine is not running. Should go out when engine

light (red)

starts, except for occasional flickering at or near idling speed when the engine is warm.

CAUTION:

Running the engine with insufficient oil pressure will cause serious engine damage.

Neutral indicator

Lights when transmission is in neutral.

(green)

Ignition Switch The ignition switch (1) is above the head-

light next to the speedometer.

(I)

Ignition switch

Key Position

Function Key Removal

OFF Engine and lights cannot be operated. Remove the key.

Headlight. taillight and meter lights will be on and

Key cannot be

ON (red dot)

other lights can be operated. The engine can be

removed.

started. For parking the motorcycle near traffic. The tail-

light will be on but all other lights will be off. The Remove the key. engine cannot be started.

Engine Stop Switch

The three position engine stop switch (2) is next to the throttle grip. In RUN, the engine will operate. In either OFF posi-

tion, the engine will not operate. This switch is intended primarily as a safety or emergency switch and should normally remain in RUN.

NOTE:

your motorcycle is stopped with the ignition switch ON and the engine stop switch OFF, the headlight and taillight will still be

OD,

resulting in battery

discharge.

Starter Button The starter button

(I)

is below the engine

stop switch (2). When the starter button is pressed the

starter motor will crank the engine and the headlight will automatically go out, bu t the tailligh t will stay on. See pages

28-30

for the starting proce-

dure.

(1)

Starter button

(2)

Engine stop switch

The three controls next to the left han- dlebar grip are:

Headlight Dimmer Switch

(l)

Select HI for high beam, LO for low beam.

Turn Signal Switch (2) Move to L to signal a left turn, R to signal

a right turn. Return to the center (off) when finished.

Horn Button (3) Press the button to sound the horn.

(1)

Headlight dimmer switch

(2)

Turn signal switch

(3)

Horn button

+ 30 hidden pages

Honda CM400E (1981) Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual