Honda CRF110F (2022) User guide

Honda CRF110F

OWNER’S MANUAL

© Honda Motor Co., Ltd. 2021

IMPORTANT INFORMATION

The information in this publication relates to the Honda CRF110F, a single-track two-wheeled
motor vehicle, powered by a spark ignited internal combustion engine and driven by a
mounted rider.

This motorcycle is not suitable for novice riders. This motorcycle shall only be used by
trained and experienced riders.
Please receive instructions from your dealer to service and use your vehicle. Also, we
recommend that you obtain from the dealer the pre-delivery document.

• OPERATOR ONLY. NO PASSENGER

This motorcycle is designed and constructed as an operator-only model. The seating
configuration does not safely permit the carr ying of a passenger.

• FOR OFF-ROAD USE ONLY

This motorcycle is designed and manufactured for off-road use only.

• PARENTS: READ IMPORTANT MESSAGE ON PAGE 1.

• READ THIS OWNER’S MANUAL CAREFULLY

Pay special attention to the safety messages that appear throughout the manual. These
messages are fully explained in the ‘‘A Few Words About Safety’’ section which appears
before the ‘‘Contents’’ page.

This manual should be considered a permanent part of the motorcycle and should remain
with the motorcycle when resold.

Honda CRF110F
OWNER’S MANUAL
(Original instructions)

All information in this publication is based on the latest production information
available at the time of approval for printing. Honda Motor Co., Ltd. reserves the
right to make changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written permission.

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
motorcycle, but also the motorcycle’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.

As you read this manual, you will find information that is preceded by a symbol. This
information is intended to help you avoid damage to your motorcycle, other proper ty, or the
environment.

Pleasant riding, and thank you for choosing a Honda !

• The following codes in this manual indicate each country.

ED European direct sales

U Australia, New Zealand

• The specifications may vary with each locale.

• The illustrations here in are based on the ED type.

• This vehicle pictured in this owner’s manual may not match your actual vehicle.

A FEW WORDS ABOUT SAFETY

Your safety, and the safety of others, is very important. And operating this motorcycle safely
is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures
and other information on labels and in this manual. This information alerts you to potential
hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all hazards associated with
operating or maintaining a motorcycle. You must use your own good judgement.

You will find important safety information in a variety of forms, including:

• Safety Labels — on the motorcycle.

• Safety Messages — preceded by a safety alert symbol and one of three signal words:
DANGER, WAR NI NG , or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t
follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.

You CAN be HURT if you don’t follow instructions.

• Safety Headings — such as Important Safety Reminders or Important Safety Precautions.

• Safety Section — such as Motorcycle Safety.

• Instructions — how to use this motorcycle correctly and safely.

This entire manual is filled with impor tant safety information — please read it carefully.

OPERATION

page

1 MOTORCYCLE SAFETY

1 IMPORTANT MESSAGE TO

PARENTS

3 IMPORTANT SAFETY

INFORMATION
6 PROTECTIVE APPAREL
7 RIDING POSITION AND SAFETY

EQUIPMENT
8 LOAD LIMITS AND GUIDELINES

12 LABELS

19 PARTS LOCATION

22 INDICATORS

page

24 MAJOR COMPONENTS

(Information you need to operate
this motorcycle)

24 BRAKES
29 CLUTCH
30 FUEL
33 ENGINE OIL
34 WHEELS & TYRES

39 ESSENTIAL INDIVIDUAL

COMPONENTS

39 IGNITION SWITCH
40 START BUTTON
41 ENGINE STOP SWITCH

page

42 FEATURES

(Not required for operation)

42 LEFT SIDE COVER
43 LEFT FUEL TANK SHROUD
44 RIGHT SIDE COVER
45 CLIP

page

46 OPERATION

46 PRE-RIDE INSPECTION
48 STARTING THE ENGINE
50 Ignition Cut Off
51 RUNNING-IN
52 RIDING
54 BRAKING
55 PARKING
55 ANTI-THEFT TIPS

MAINTENANCE

page

56 MAINTENANCE

56 THE IMPORTANCE OF

MAINTENANCE

57 MAINTENANCE SAFETY
58 SAFETY PRECAUTIONS
59 MAINTENANCE SCHEDULE
62 TOOL KIT
63 SERIAL NUMBERS
64 AIR CLEANER
66 CRANKCASE BREATHER
67 ENGINE OIL
72 SPARK PLUG
74 THROTTLE OPERATION
77 SPARK ARRESTER
79 DRIVE CHAIN
84 WHEEL RIMS AND SPOKES
85 WHEEL REMOVAL
88 BRAKE SHOES WEAR
89 BATTERY
91 FUSE REPLACEMENT
94 FRONT SUSPENSION
95 REAR SUSPENSION

page

96 SIDE STAND

97 CLEANING

100 TRANSPORTING

102 STORAGE GUIDE

102 STORAGE
104 REMOVAL FROM STORAGE

105 TAKING CARE OF THE

UNEXPECTED

107 SPECIFICATIONS

111 MANUFACTURER, AUTHORIZED

REPRESENTATIVE AND
IMPORTER

MOTORCYCLE SAFETY

OPERATION

IMPORTANT MESSAGE TO
PARENTS

Your child’s safety is very important to
Honda. That’s why we urge you to read this
message before you let any young person
ride this motorcycle. Off-road riding can be
fun. But as with riding a bicycle, bad
judgements can result in injuries, and we
don’t want that to happen ! As a parent, you
can help prevent crashes by making good
decisions about if, when, and how your
youngster rides this motorcycle.

Riding Readiness

The first decision you’ll need to make is
whether your youngster is ready to ride.
Riding readiness varies widely from one
person to another, and age and size are not
the only factors.
PHYSICAL ABILITY is an important
consideration. For example, riders must be
big enough to hold the motorcycle up, get
on, and comfortably sit on the seat with
both feet touching the ground. They should
also be able to easily reach and work the
brakes, the throttle and all other controls.

ATHLETIC ABILITY is necessary for riding
a motorcycle. Generally speaking, your
youngster should be good at riding a bicycle
before getting on a motorcycle. Can your
youngster judge speeds and distances on a
bicycle and react with proper hand and foot
actions ? Anyone who does not have good
coordination, balance, and agility is not
ready to ride this motorcycle.

MENTAL AND EMOTIONAL MATURITY
are requirements for safe riding. Does your
youngster think through problems and
come to logical solutions ? On a bicycle,
does your youngster obey safe riding rules ?
Be honest ! Young people who take
unnecessary risks, make bad judgements
and don’t obey rules are not ready to ride
this motorcycle.

1

Instruction and Supervision

If you decide that your youngster is ready to
safely operate this motorcycle, make sure
both of you carefully read and understand
the Owner’s Manual before riding. Also be
sure that your youngster has a helmet and
other appropriate riding equipment and
always wears it when operating the vehicle
or sitting on it. And, it is important for your
youngster to finish the training course.

GOOD INSTRUCTION is an important part
of hands-on training. The teacher can either
be you or another responsible adult who
has experience with off-road motorcycle
riding. (For help in finding a qualified
instructor, talk with your dealer.) Even if
you’re not the main teacher, it’s up to you to
ensure your youngster’s safety. Remember,
learning to ride a motorcycle is a gradual
step-by-step process. It takes time, patience
and practice – many hours over a period of
weeks or months.

2

SUPERVISION is another important
obligation of parents. Even after youngsters
have become skilled off-road riders, they
should always ride with adult supervision. It
helps to regularly remind young riders of
basic safety rules and cautions. And
remember, it’s your responsibility to see
that the vehicle is properly maintained and
kept in safe operating condition.

SAFE AND RESPONSIBLE RIDING must
be an ongoing commitment – by you and
your youngster. When you both put safety
first, you can enjoy more peace of mind, and
your youngster can enjoy more hours of
safe off-road riding.

For your convenience, this CRF110F comes
with an ignition switch and key. Remove the
key when the motorcycle is parked to help
prevent unauthorized use.

IMPORTANT SAFETY INFORMATION

Your motorcycle can provide many years of
service and pleasure – if you take
responsibility for your own safety and
understand the challenges you can meet
while riding.

Throttle Limiter for New Riders

Your motorcycle came with an optional
throttle stopper screw that can be installed
to restrict the maximum engine speed for
new riders. See page 76 for instructions on
how to install this screw.

This motorcycle has been designed for
younger riders, as well as for smaller adults.
However, not all youngsters are physically
or emotionally ready to ride. Therefore,
before parents allow any youngster to ride
this motorcycle, we urge them to carefully
read the Important Message to Parents on
page 1.

There is much that you can do to protect
yourself when you ride. You’ll find many
helpful recommendations throughout this
manual. Following are a few that we
consider to be most important.

Until your youngster becomes familiar with
operating the motorcycle, it is
recommended to keep the transmission in
first gear.

Check this screw regularly to ensure that it
is properly tightened.

3

Always Wear a Helmet

It’s a proven fact: helmets significantly
reduce the number and severity of head
injuries. So always wear an approved
motorcycle helmet. We also recommend
that you wear eye protection, sturdy boots,
gloves and other protective gear (page 6).

Never Carry a Passenger

Your motorcycle is designed for one person
only. There are no handholds, footrests, or
seat for a second person – so never carry a
passenger. A passenger could interfere with
your ability to move around to maintain
your balance and control of the motorcycle.

4

Ride Off-Road Only

Your motorcycle is designed and
manufactured for off-road use only. The
tyres are not made for pavement, and the
motorcycle does not have turn signals and
other features required for use on public
roads. If you need to cross a paved or public
road, get off and walk your motorcycle
across.

Take Time to Learn and Practice

Developing appropriate off-road riding skills
is important to your safety and is a gradual,
step-by-step process. You can start by
practicing at low speeds in a safe area and
slowly build your skills. Getting personal
instruction from an experienced rider or a
qualified riding instructor can also be ver y
valuable. If you need assistance in locating a
training course closest to you, contact your
dealer or the member organization of the
International Motorcycle Federation (FIM)
in your country. Contact information can be
found at: www.fim-live.com under “affiliated
federations.”

Be Alert for Off-Road Hazards

The terrain can present a variety of
challenges when you ride off-road.
Continually ‘‘read’’ the terrain for
unexpected turns, drop-offs, rocks, ruts,
and other hazards. Always keep your speed
low enough to allow time to see and react to
hazards.

Ride Within Your Limits

Pushing the limits is another major cause of
motorcycle crashes. Never ride beyond
your personal abilities or faster than
conditions warrant. Remember that alcohol,
drugs, fatigue and inattention can
significantly reduce your ability to make
good judgements and ride safely.

Don’t Drink and Ride

Alcohol and riding don’t mix. Even one
drink can reduce your ability to respond to
changing conditions, and your reaction time
gets worse with every additional drink. So
don’t drink and ride, and don’t let your
friends drink and ride either.

Keep Your Bike in Safe Condition

For safe riding, it’s important to inspect
your motorcycle before every ride and
perform all recommended maintenance.
Never exceed load limits, and only use
accessories that have been approved by
Honda for this motorcycle. See page 8 for
more details.

Others

• This motorcycle is not equipped with
lights. Don’t ride at night.

5

PROTECTIVE APPAREL

For your safety, we strongly recommend
that you always wear an approved
motorcycle helmet, eye protection, boots,
gloves, trousers, and a long-sleeved jersey,
shirt or jacket whenever you ride. Although
complete protection is not possible, wearing
proper gear can reduce the chance of injur y
when you ride.
Following are suggestions to help you
choose proper gear.

Not wearing a helmet increases the
chance of serious injury or death in a
crash.

Be sure you always wear a helmet, eye
protection and other protective apparel
when you ride.

6

Helmets and Eye Protection

Your helmet is your most important piece of
riding gear because it offers the best
protection against head injuries. A helmet
should fit your head comfortably and have a
chin strap that can be tightened securely.

An open-face helmet offers some protection,
but a full-face helmet offers more. Always
wear a face shield or goggles to protect your
eyes and help your vision.

Additional Riding Gear

In addition to a helmet and eye protection,
we also recommend:

• Sturdy of f-road motorcycle boots to help
protect your feet, ankles, and lower legs.

• Off-road motorcycle gloves to help
protect your hands.

• Riding trousers with knee and hip pads, a
riding jersey with padded elbows, and a
chest/shoulder protector.

RIDING POSITION AND SAFETY EQUIPMENT

Helmet and Eye Protection

Off-road motorcycle gloves

Riding trousers with Protector Off-road motorcycle boots

Long-sleeved apparel and
Protector

Sit on the vehicle as shown below, keeping your hands on the handlebars and feet on the
footpegs.

7

LOAD LIMITS AND GUIDELINES

Your Honda was designed as a rider-only
motorcycle. It was not designed to carry a
passenger or cargo. A passenger or cargo
could interfere with your ability to move
around to maintain your balance and control
of the motorcycle.

In addition, exceeding the weight limits or
carr ying an unbalanced load can seriously
affect your motorcycle’s handling, braking,
and stability. Adding accessories or making
modifications that change this motorcycle’s
design and performance can also make it
unsafe. Also, the weight of any accessories
will reduce the maximum load the
motorcycle can carr y.

The following pages give more specific
information on loading, accessories and
modifications.

8

Loading

How much weight you put on your
motorcycle, and how you load it, are
important to your safety. If you decide to
carr y cargo, you should be aware of the
following information.

Overloading or carrying a passenger
can cause a crash and you can be
seriously hurt or killed.

Follow all load limits and other loading
guidelines in this manual.

Load Limits

Following are the load limits for your
motorcycle:

Maximum weight capacity:

60 kg (132 lb)

Includes the weight of the rider and any
accessories

Loading Guidelines

As discussed on page 8, we recommend that
you do not carry any cargo on this
motorcycle. However, if you decide to carry
cargo, ride at reduced speeds and follow
these common-sense guidelines:

• Keep cargo small and light. Make sure it
cannot easily be caught on brush or other
objects, and that it does not interfere with
your ability to shift position to maintain
balance and stability.

• Place weight as close to the centre of the
motorcycle as possible.

• Do not attach large or heavy items (such
as a sleeping bag or tent) to the
handlebar, fork, or front fender.

• Make sure that all cargo is tied down
securely.

• Never exceed the maximum weight limit.

• Check that both tyres are properly
inflated (page 34).

9

Accessories and Modifications

Modifying your motorcycle or using non­Honda accessories can make your
motorcycle unsafe. Before you consider
making any modifications or adding an
accessory, be sure to read the following
information.

Accessories

We strongly recommend that you use only
Honda Genuine Accessories that have been
specifically designed and tested for your
motorcycle. Because Honda cannot test all
other accessories, you must be personally
responsible for proper selection, installation
and use of non-Honda accessories. Check
with your dealer for assistance and always
follow these guidelines:

Improper accessories or modifications
can cause a crash in which you can be
seriously hurt or killed.

Follow all instructions in this owner’s
manual regarding accessories and
modifications.

10

• Make sure the accessory does not reduce
ground clearance and lean angle, limit
suspension travel or steering travel, alter
your riding position or interfere with
operating any controls.

Modifications

We strongly advise you not to remove any
original equipment or modify your
motorcycle in any way that would change its
design or operation. Such changes could
seriously impair your motorcycle’s
handling, stability and braking, making it
unsafe to ride.

Because safety, vehicle movement, and
clearance must be taken into consideration,
you must consult your tyre maker or Honda
dealer before changing your tyre model
type.

Removing or modifying your exhaust
system (such as the spark arresters or
mufflers) or other equipment can also make
your motorcycle illegal.

11

LABELS

The following pages describe the label
locations and their meanings. Some labels
warn you of potential hazards that could
cause serious injury. Others provide
important safety information. Read this
information carefully and don’t remove the
labels.

If a label comes off or becomes hard to
read, contact your dealer for a replacement.

12

There 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.
In the interest of safety, take the motorcycle to be serviced only by your
dealer.

DANGER (with RED background)

You WILL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.

WARNING (with ORANGE background)

You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.

CAUTION (with YELLOW background)

You CAN be HURT if you don’t follow instructions.

13

14

BATTERY LABEL

DANGER

• Keep flames and sparks away from the batter y.
The battery produces explosive gas that can cause
an explosion.

• Wear eye protection and rubber gloves when
handling the battery to avoid risk of burns or loss
of eyesight if exposed to battery electrolyte.

• Do not allow children to handle the batter y, under
any circumstance. Ensure that anyone handling
the battery has a proper understanding of the
hazards and correct handling procedures
involved.

• Handle batter y electrolyte with extreme care, as it
contains dilute sulfuric acid. Exposure to eyes or
skin can cause burns or loss of eyesight.

• Read this manual carefully, and understand it
before handling the battery. Failure to do so can
cause personal injury and damage to the vehicle.

• Do not use the batter y if the level of electrolyte is
at or below the recommended level. Using the
battery with low electrolyte can cause it to
explode, causing serious injury.

USE CAUTION LABEL

Operator only. No passengers.
This vehicle is designed and manufactured for off­road use only. Operation on public streets, roads, or
highways is illegal.
Children should only use this vehicle under the
permanent supervision of an adult responsible of
their safety.
Operating this vehicle if you are under the age of 6
increases your chance of severe injury or death.
NEVER operate this vehicle if you are under age 6.
For your protection, always wear a helmet, eye
protection, and protective gear while riding.

DRIVE CHAIN LABEL

Keep chain adjusted and lubricated.

10 – 20 mm (0.4 – 0.8 in) Freeplay

15

16

REAR CUSHION LABEL

GAS FILLED
Do not open.
Do not heat.

CE MARK (ED type only)

Engine net power: 5.6 kW
Machine mass: 77 kg

FUEL LABEL (ED type only)

Unleaded petrol only

ETHANOL up to 10 % by volume

UKCA MARK (ED type only)

Some vehicles do not have
UKCA mark

USE CAUTION LABEL

BATTERY LABEL

DRIVE CHAIN LABEL

REAR CUSHION LABEL

UKCA MARK (ED type only)

17

CE MARK (ED type only)

FUEL LABEL (ED type only)

18

PARTS LOCATION

Ignition switch

Front brake lever

Throttle grip

Start button

Fuel fill cap

Engine stop switch

Fuel reserve indicator

PGM-FI malfunction
indicator lamp (MIL)

Ignition indicator lamp

19

Engine oil drain boltFootpeg

Clutch adjuster

Spark arrester

Kickstarter

Oil fill cap/dipstick

Spark plug

Rear brake pedal

20

Air cleaner

Drive chain

Main fuse
Sub fuse

Side stand

Footpeg

Shift lever

Crankcase breather plug

Battery

21

INDICATORS

(1)

(2)

(3)

The indicators are equipped to the locations
as shown in the illustrations. Their
functions are described in the tables.

(1) PGM-FI malfunction indicator lamp (MIL)
(2) Ignition Indicator

(3) Fuel reserve indicator

22

(Ref.No.) Description Function

(1) PGM-FI malfunction

indicator lamp (MIL)

(2) Ignition Indicator When the ignition switch is turned on, the ignition indicator comes on.

(3) Fuel reserve indicator When this indicator comes on while riding, fuel reser ved in the tank is about:

Lights when there is any abnormality in the PGM-FI (Programmed Fuel
Injection) system. The indicator should also light for a few seconds and then go
off when the ignition switch is turned to the (ON)position with the engine
stop switch in the
If the indicator does not come on when it should, have your dealer check for
problems.
If it comes on at any other time, reduce speed and take the motorcycle to your
dealer as soon as possible.

If the indicator does not come on when it should, have your dealer check for
problems.

0.7 (0.18 US gal, 0.15 Imp gal)
The indicator should also light for a few seconds and then go of f when the
ignition switch is turned to the (ON) with the engine stop switch in the
(RUN) position. If the indicator does not come on when it should, have your
dealer check for problems.

(RUN) position.

23

MAJOR COMPONENTS

(1)

(3)

(4)

(2)

(A)

(B)

(Information you need to operate this motorcycle)

BRAKES
Front Brake

Brakes are items of personal safety and
should always be maintained in proper
adjustment.
The distance the front brake lever or rear
brake pedal moves before the brake starts
to engage is called freeplay.
Measured at the tip of the front brake lever
(1), freeplay should be maintained at:

10 – 20 mm (0.4 – 0.8 in)

Adjust the freeplay of the brake lever with
the front wheel pointed straight ahead.

Adjusting the Front Brake Lever Freeplay:

1. Pull back the rubber dust cover (2).
Loosen the lock nut (3) and turn the
cable adjuster (4). Tighten the lock nut
and check the adjustment.

24

(1) Front brake lever

(2) Dust cover
(3) Lock nut
(4) Front brake cable

adjuster

(A) Decrease freeplay
(B) Increase freeplay

2. If the adjuster is threaded out near its

((BB)

((A

)

limit or the correct freeplay cannot be
obtained using the cable adjuster (4),
loosen the lock nut (3) and turn in the
cable adjuster (4) completely. Tighten
the lock nut (3) and install the rubber
dust cover.

3. Loosen the front brake cable guide bolt
(5).

4. Loosen the lock nut (6) at the lower end
of the cable. Turn the adjusting nut (7)
to obtain the specified freeplay. Tighten
the lock nut and check the adjustment.

If proper adjustment cannot be obtained by
this method, see your dealer.

(7)

(5) Cable guide bolt

(5)

(6)

(6) Lock nut
(7) Adjusting nut

)

)

A

(A) Decrease freeplay
(B) Increase freeplay

25

5. Apply the brake several times and check
for free wheel rotation after the brake
lever is released.
Tighten the front brake cable guide bolt.

After adjustment, push the brake arm (8) to
confirm that there is proper freeplay.

(8)

(8) Brake arm

After adjustment, confirm the freeplay of
the brake lever.

26

Other Checks:
Check the brake cable for kinks or signs of
wear that could cause sticking or failure.
Lubricate the brake cable with a
commercially available cable lubricant to
prevent premature wear and corrosion.
Make sure the brake arm, spring and
fasteners are in good condition.

Rear Brake

(1)

(

AA)

((B

)

Adjusting the Rear Brake Pedal Freeplay:

1. Place the motorcycle on its side stand.

2. Measure the distance the rear brake
pedal (1) moves before the brake starts
to take hold.

Freeplay should be:

10 – 20 mm (0.4 – 0.8 in)

3. If adjustment is necessary, turn the rear
brake adjusting nut (2).

(2)

)

(

)

B

(3)

(1) Rear brake pedal

(2) Rear brake

adjusting nut
(3) Brake arm pin
(A) Decrease freeplay
(B) Increase freeplay

27

Adjust by turning the rear brake adjusting

(3)

(2)

(4)

nut a half-turn at a time. Make sure the cut­out on the adjusting nut is seated on the
brake arm pin (3) after making final
freeplay adjustment.

4. Apply the brake several times and check
for free wheel rotation after the brake
pedal is released.

If proper adjustment cannot be obtained by
this method, see your dealer.

After adjustment, push the brake arm (4) to
confirm that there is a gap between the
adjusting nut (2) and the brake arm pin (3).

28

(2) Adjusting nut
(3) Brake arm pin

(4) Brake arm

After adjustment, confirm the freeplay of
the brake pedal.

Other Checks:
Make sure the brake rod, brake arm, spring
and fasteners are in good condition.

CLUTCH

(1)

(2)

Adjustment:

1. Loosen the adjuster lock nut (1).

2. Turn the clutch adjuster (2) clockwise
one turn; do not turn excessively.

3. Slowly turn the adjuster
counterclockwise until a slight
resistance is felt.

4. From this position, turn the adjuster
clockwise 1/8 turn, and tighten the lock
nut.

5. After adjustment, test ride the
motorcycle to be certain the clutch
operates properly.

The engine should start easily with the
kickstarter without the clutch slipping.
When shifting gears, the clutch operation
should be smooth and light, especially when
shifting into neutral.

If proper adjustment cannot be obtained or
the clutch does not work correctly, see your
dealer.

(1) Lock nut (2) Clutch adjuster

29

FUEL

(2)

(4)

(1)

(3)

Fuel Tank

The fuel tank capacity:

3.7

(0.98 US gal, 0.81 Imp gal)

To open the fuel fill cap (1), pull out the
breather tube (2) from the steering stem
nut (3). Then turn the fuel fill cap
counterclockwise.
Do not overfill the tank. There should be no
fuel in the filler neck (4).
After refuelling, turn the fuel fill cap
clockwise until it clicks. Insert the breather
tube into the steering stem nut.

Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.

• Stop the engine and keep heat,
sparks, and flames away.

• Refuel only outdoors.

• Do not spill the petrol. If you do, wipe
up the spills immediately.

30

(1) Fuel fill cap
(2) Breather tube

(3) Steering stem nut
(4) Filler neck

Use unleaded petrol with a research octane

NOTICE

number of 91 or higher.

If ‘‘spark knock’’ or ‘‘pinking’’ occurs at a
steady engine speed under normal load,
change brands of petrol. If spark knock or
pinking persists, consult your dealer.
Failure to do so is considered misuse, and
damage caused by misuse is not covered by
Honda’s Limited Warranty.

Occasionally you may experience light
spark knock while operating under heavy
loads. This is no cause for concern, it simply
means your engine is operating efficiently.

31

Petrol Containing Alcohol

If you decide to use a petrol containing
alcohol (gasohol), be sure it’s octane rating
is at least as high as that recommended by
Honda. Do not use petrol that contains
more than 10 % ethanol.

32

The use of petrol containing more than 10 %
ethanol may:

• Damage the painting of the fuel tank.

• Damage the rubber tubes of the fuel line.

• Cause corrosion of the fuel tank.

• Cause poor drivability.

Before buying fuel from an unfamiliar
station, try to find out if the fuel contains
alcohol. If it does, confirm the type and
percentage of alcohol used. If you notice
any undesirable operating symptoms while
using a petrol that contains alcohol, or one
that you think contains alcohol, switch to a
petrol that you know does not contain
alcohol.

ENGINE OIL

NOTICE

(2)

(1)

(3)

Engine Oil Level Check

Check the engine oil level each day before
operating the motorcycle.
The oil fill cap/dipstick (1) is at the rear of
the right crankcase cover and contains a
dipstick for measuring the oil level. Oil level
must be maintained between the upper (2)
and lower (3) level marks on the oil fill cap/
dipstick.

1. Hold the motorcycle upright on firm
level ground.

2. Star t the engine and let it idle for 3 – 5
minutes.

3. Stop the engine. After 2 – 3 minutes,
remove the oil fill cap/dipstick, wipe it
clean, and reinsert the oil fill cap/
dipstick without screwing it in. Remove
the oil fill cap/dipstick. The oil level
should be between the upper and lower
level marks on the oil fill cap/dipstick.

4. If required, add the specified oil (page

67) up to the upper level mark. Do not
overfill.

5. Reinstall the oil fill cap/dipstick. Check
for oil leaks.

Running the engine with insufficient oil can
cause serious engine damage.

(1) Oil fill cap/dipstick
(2) Upper level mark
(3) Lower level mark

33

WHEELS & TYRES

The tyres are the only point of contact
between your motorcycle and the road.
Safety under any riding conditions is
dependant upon this small point of contact.
Please understand that the tyres will have
less grip, as the tread wear decreases.

To safely operate your motorcycle, the
wheels and tyres must be the proper type
(off-road) and size, in good condition with
adequate tread, and correctly inflated.

It is important to properly replace parts
according to the replacement schedule.
We recommend that you leave this work to
the experts with the proper equipment and
experience.

Wheels that are deformed or damaged must
be replaced. And when the tyre is
punctured, it is essential to stop as soon as
possible, and inspect the tyre by removing
the tyre.

34

Please consult your dealer for tyre repair
and replacement.

Tyres age, even if they have not been used
or have only been used occasionally.
Cracking of the tread and sidewall rubber,
sometimes accompanied by carcass
deformation, is an evidence of ageing. Old
and aged tyres must be checked by experts
to determine the suitability for fur ther use.

Using tyres that are excessively worn or
improperly inflated can cause a crash in
which you can be seriously hurt or
killed.

Follow all instructions in this owner’s
manual regarding tyre inflation and
maintenance.

Air Pressure

Properly inflated tyres are most important
for safety, and will provide the best
combination of handling, tread life, and
riding comfort. Generally, underinflated
tyres wear unevenly, adversely affect
handling, and are more likely to fail from
being overheated. Underinflated tyres can
also cause wheel damage in rocky terrain.
Overinflated tyres make your motorcycle
ride harshly, are more prone to damage
from surface hazards, and wear unevenly.

Make sure the valve stem caps are secure.
If necessary, install new caps.

Always check air pressure when your tyres
are ‘‘cold.’’ If you check air pressure when
your tyres are ‘‘warm’’ – even if your
motorcycle has only been ridden for a few
miles – the readings will be higher. If you let
air out of warm tyres to match the
recommended cold pressures, the tyres will
be underinflated.

The recommended ‘‘cold’’ tyre pressures
are:

Front 100 kPa

(1.00 kgf/cm

Rear 100 kPa

(1.00 kgf/cm

2

, 15 psi)

2

, 15 psi)

35

(1)

Inspection

Whenever you check the tyre pressures,
you should also examine the tyre treads and
sidewalls for wear, damage, and foreign
objects:

Look for:

• Bumps or bulges in the side of the tyre or
the tread. Replace the tyre if you find any
bumps or bulges.

• Cuts, splits or cracks in the tyre. Replace
the tyre if you can see fabric or cord.

• Excessive tread wear.

Also, if you hit a pothole or hard object, pull
to the side of the road as soon as you can
safely and carefully inspect the tyres for
damage.

36

Tre ad Wear

You must periodically confirm the tread
wear depth.

Replace tyres before tread depth at the
centre of the tyre reaches the following
limit:

Minimum tread depth
Front: 3.0 mm (0.12 in)
Rear: 3.0 mm (0.12 in)

(1) Tyre tread depth

Tube Repair and Replacement

If a tube is punctured or damaged, you
should replace it as soon as possible. A tube
that is repaired may not have the same
reliability as a new one, and it may fail while
you are riding.

If you need to make a temporary repair by
patching a tube or using an aerosol sealant,
ride cautiously at reduced speed and have
the tube replaced before you ride again. Any
time a tube is replaced, the tyre should be
carefully inspected as described on page 36.

37

Wheel & Tyre Replacement

The tyres that came on your motorcycle
were designed to match the performance
capabilities of your motorcycle and provide
the best combination of handling, braking,
durability and comfort.

Installing improper tyres on your
motorcycle can affect handling and
stability. This can cause a crash in
which you can be seriously hurt or
killed.

Always use the size and type of tyres
recommended in this owner’s manual.

38

Used tyres should not be installed if the
previous usage record is unknown.

The recommended tyres for your
motorcycle are:

Front: 70/100-14M/C 37J

Rear: 80/100-12 50J

Type: bias-ply, tube

The recommended wheels for your
motorcycle are:

Front: 14 × 1. 40

Rear: 12 × 1. 60

Whenever you replace a tyre, use one that is
equivalent to the original and be sure the
wheel is balanced after the new tyre is
installed.

Also remember to replace the inner tube
whenever you replace a tyre. The old tube
will probably be stretched, and if installed in
a new tyre, it could fail.

ESSENTIAL INDIVIDUAL COMPONENTS

(1)

ONOFF

OFF ON

IGNITION SWITCH

The ignition switch (1) is located in front of
handlebar.

The ignition switch is used to prevent
unauthorized use of the motorcycle. Before
riding, insert the key and turn it to the

(ON) position.

After parking the motorcycle, remove the
key.

Key Position Function Key Removal

(OFF) The engine cannot be operated. Key can be removed

(ON)

(1) Ignition switch

With the engine stop switch at (RUN) and the
transmission in neutral, the engine can be started.

Key cannot be removed

39

START BUTTON

(1)

The start button (1) is next to the throttle
grip.
When the start button is pressed, the
starter motor cranks the engine. See page
48 for the starting procedure.

(1) Start button

40

ENGINE STOP SWITCH

(1)

The engine stop switch (1) is next to the
throttle grip. When the switch is in the
(RUN) position, the engine will operate.
When the switch is in the (STOP)
position, the engine will not operate. This
switch is intended primarily as an
emergency switch and should normally
remain in the (RUN) position.

(1) Engine stop switch

41

FEATURES

(6)

(3)

(2)

(1)

(8)

(9)

(5)

(4)(5) (6)

(7)

(Not required for operation)

LEFT SIDE COVER

Removal:

1. Remove the bolt A (1), collar (2) and bolt
B (3) securing side cover (4).

2. Pull the prongs (5) out of the rubber
grommets (6).

Installation:

1. Attach the prongs to the rubber

2. Align the rib (8) of the side cover with

3. Install the collar, bolt A, and bolt B, and

grommets, aligning the side cover tab
(7) with lower edge of the left fuel tank
shroud.

the groove (9) of the battery
compartment. Press the side cover into
position.

tighten them.

(1) Bolt A
(2) Collar
(3) Bolt B

(4) Side cover
(5) Prongs
(6) Grommets

(7) Tab
(8) Rib
(9) Groove

42

LEFT FUEL TANK SHROUD

(5)

(3)

(1)

(2)

(4)

Removal:

1. Remove the left side cover (page 42).

2. Remove the clip (1) (page 45).

3. Remove the left fuel tank shroud (2) by
removing the bolt (3) and pulling the
prong (4) from the grommet (5).

Installation:
Installation is in the reverse order of
removal.

(1) Clip
(2) Left fuel tank shroud
(3) Bolt

(4) Prong
(5) Grommet

43

RIGHT SIDE COVER

(6)

(2)(3)(5)

(5)

(1) (4)

Removal:

1. Remove the bolt (1) and collar (2)
securing the right side cover (3).

2. Pull the right side cover prongs (4) out
of the rubber grommets (5).

Installation:

1. Attach the side cover on the rear frame,
aligning its tab (6) with the lower edge of
the right fuel tank shroud.

2. Align the side cover prongs with the
rubber grommets. Press the side cover
into position.

3. Install the collar and bolt, and tighten
them.

44

(1) Bolt
(2) Collar
(3) Side cover

(4) Prongs
(5) Grommets
(6) Tab

CLIP

Removal:

Pull up the centre pin to release the lock.
Pull out the clip from the hole.

Installation:

Insert the clip into the hole.
Press down the centre pin securely to
lock the clip.

45

OPERATION

PRE-RIDE INSPECTION

For your saf ety, it is ver y impor tant to take a
few moments before each ride to walk
around your motorcycle and check its
condition. If you detect any problem, be
sure you take care of it, or have it corrected
by your dealer.

Improperly maintaining this motorcycle
or failing to correct a problem before
riding can cause a crash in which you
can be seriously hurt or killed.

Always perform a pre-ride inspection
before every ride and correct any
problems.

46

• Engine oil level – add engine oil if
required (page 33). Check for leaks.

• Fuel level – fill fuel tank when necessary
(page 30). Check for leaks.

• Front and rear brakes – check operation
and if necessary, adjust freeplay (pages 24
– 28).

• Tyres – check condition and pressure
(page 34 – 38).

• Spokes – check and tighten if necessary
(page 84).

• Drive chain – check condition and slack
(page 79). Adjust and lubricate if
necessary.

• Chain slider – check slider wear (page

80).

• Throttle – check for smooth opening and
full closing in all steering positions.
Adjust freeplay if necessary (pages 74 –

76).

• Indicators – check for normal operation of
the indicators (page 22).

• Spark plug and high tension terminal –
check for looseness.

• Engine stop switch – check for proper
function (page 41).

• Nuts, bolts, fasteners – check the front
and rear wheels to see that the axle nuts
are tightened securely. Check security of
all other nuts, bolts, and fasteners.

47

STARTING THE ENGINE

Always follow the proper starting procedure
described below.

Your motorcycle’s exhaust contains
poisonous carbon monoxide gas. High
levels of carbon monoxide can collect
rapidly in enclosed areas such as a garage.
Do not run the engine with the garage door
closed. Even with the door open, run the
engine only long enough to move your
motorcycle out of the garage.

Do not use the electric starter for more than
5 seconds at a time. Release the start button
for approximately 10 seconds before
pressing it again.

48

Preparation

Before starting, insert the key and turn the
ignition switch (ON).
Make sure that the transmission is in
neutral, and the engine stop switch is at
(RUN) and the PGM-FI malfunction
indicator lamp (MIL) is off.

Starting Procedure

NOTICE

about 3 mm (0.1 in),
without freeplay

This motorcycle has a fuel-injected engine.
Follow the procedure indicated below.

Any Air Temperature

1. (Using the star t button)

With the throttle completely closed,
press the start button.
(Using the kickstarter)
Lightly depress the kickstarter until
resistance is felt.
Then, let kickstarter return to the top of
its stroke.
With the throttle completely closed,
operate the kickstarter star ting from the
top of the stroke, kick through to the
bottom with a rapid, continuous motion.

2. If you cannot start the engine, open the
throttle slightly (about 3 mm (0.1 in),
without freeplay).

Allowing the kickstarter to snap back freely
against the pedal stop can damage the
engine case.

49

Flooded Engine

(Using the start button)
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel.
To clear a flooded engine, open the throttle
fully and press the start button for 5
seconds. Follow the normal starting
procedure.

(Using the kickstarter)
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel.
To clear a flooded engine, turn the engine
stop switch to (STOP). Open the throttle
fully and crank the engine several times
with the kickstarter. Turn the engine stop
switch to (RUN) and follow the normal
starting procedure.

50

Ignition Cut Off

Your motorcycle is designed to
automatically stop the engine and fuel pump
if the motorcycle is over-turned (a banking
sensor cuts off the ignition system).

RUNNING-IN

Help assure your motorcycle’s future
reliability and performance by paying extra
attention to how you ride during the first
operating day or 25 km (15 miles).
During this period, avoid full-throttle starts
and rapid acceleration.

51

RIDING

Review Motorcycle Safety (pages 1 – 18)
before you ride.

Make sure the side stand is fully retracted
before riding the motorcycle. If the stand is
extended, it may interfere with control
during a left turn.

Make sure you understand the function of
the side stand mechanism. (See MAIN­TENANCE SCHEDULE on page 59 and
explanation for SIDE STAND on page 96).

1. After the engine has warmed up, the
motorcycle is ready for riding.

2. Close the throttle and raise the shift
lever to shift into 1st (low) gear.

52

3. Increase engine speed by gradually
opening the throttle.

4. When your speed increases, close the
throttle and shift to 2nd gear by raising
the shift lever.

5. This sequence is repeated to shift to 3rd
and 4th (top) gears.

6. Raise the shift lever to shift to a higher
gear and depress the shift lever to shift
to a lower gear. Each stroke of the shift
lever engages the next gear in sequence.
The shift lever automatically returns to
the horizontal position when released.

Shifting pattern

• Do not downshift when travelling at a
speed that would force the engine to
overrev in the next lower gear; the rear
wheel may lose traction, resulting in a
possible loss of vehicle control.

• Do not shift gears without closing the
throttle. The engine and drive train could
be damaged by overspeed and shock.

• Do not tow the motorcycle or coast for
long distances while the engine is off. The
transmission will not be properly
lubricated and damage may result.

• Do not run the engine at high rpm with
the transmission in neutral. Serious
engine damage may result.

53

BRAKING

For normal braking, gradually apply both
the front and rear brakes while
downshifting to suit your road speed.
For maximum deceleration, close the
throttle and apply the front and rear brakes
firmly.

Important Safety Reminders:

• Independent operation of only the brake
lever or brake pedal reduces stopping
performance.

• Extreme application of the brake controls
may cause wheel lock, reducing control of
the motorcycle.

• When possible, reduce speed or brake
before entering a turn; closing the
throttle or braking in mid-turn may cause
wheel slip. Wheel slip will reduce control
of the motorcycle.

54

• When riding in wet or rainy conditions, or
on loose surfaces, the ability to maneuver
and stop will be reduced. All of your
actions should be smooth under these
conditions. Rapid acceleration, braking or
turning may cause loss of control. For
your safety, exercise extreme caution
when braking, accelerating or turning.

• When descending a long, steep grade,
use engine compression braking by
downshifting, with intermittent use of
both brakes.
Continuous brake application can
overheat the brakes and reduce their
effectiveness.

PARK ING

Touching the brakes after long hours or
heavy usage, can cause burn injuries. Also,
depending on the section, the engine can be
hot, and cause burn injuries.

1. After stopping the motorcycle, shift the
transmission into neutral and turn the
ignition switch (OFF).

2. Use the side stand to support the
motorcycle while parked.

Park the motorcycle on firm, level ground
to prevent it from falling over.
If you must park on a slight incline, aim the
front of the motorcycle uphill to reduce the
possibility of rolling off the side stand or
overturning.

3. Remove the key.

ANTI-THEFT TIPS

1. Be sure the registration information for
your motorcycle is accurate and current.

2. Park your motorcycle in a locked garage
whenever possible.

3. Use an additional anti-theft device of
good quality.

4. Put your name, address and phone
number in this Owner’s Manual and
keep it on your motorcycle at all times.
Many times stolen motorcycles are
identified by information in the Owner’s
Manuals which are still with them.

NAME: ______________________________

ADDRESS: ___________________________

_____________________________________

_____________________________________

PHONE NO: __________________________

55

MAINTENANCE

MAINTENANCE

THE IMPORTANCE OF
MAINTENANCE

A well-maintained motorcycle is essential
for safe, economical, and trouble-free riding.
It will also help reduce air pollution. Careful
pre-ride inspections and good maintenance
are especially important because your
motorcycle is designed to be ridden over
rough off-road terrain.

To help you properly care for your
motorcycle, this section of the manual
provides a Maintenance Schedule.

The service intervals in this schedule are
based on average riding conditions.

More frequent service is needed if you
subject your motorcycle to severe use (such
as competition) or ride in unusually wet or
dusty areas.

56

Frequent servicing of the air cleaner is
especially important to help you avoid a
possible costly engine repair.

If your motorcycle overturns or becomes
involved in a crash, be sure your dealer
inspects all major parts, even if you are able
to make some repairs.

Improperly maintaining this motorcycle
or failing to correct a problem before
you ride can cause a crash in which you
can be seriously hurt or killed.

Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.

MAINTENANCE SAFETY

This section includes instructions on some
important maintenance tasks. You can
perform some of these tasks with the tools
provided – if you have basic mechanical
skills.

Other tasks that are more difficult and
require special tools are best performed by
professionals. Wheel removal should
normally be handled only by a Honda
technician or other qualified mechanic;
instructions are included in this manual
only to assist in emergency service.

Some of the most important safety
precautions follow. However, we cannot
warn you of ever y conceivable hazard that
can arise in performing maintenance. Only
you can decide whether or not you should
perform a given task.

Failure to properly follow maintenance
instructions and precautions can cause
you to be seriously hurt or killed.

Always follow the procedures and
precautions in this owner’s manual.

57

SAFETY PRECAUTIONS

• Make sure the engine is of f before you
begin any maintenance or repairs. This
will help eliminate several potential
hazards:

✽ Carbon monoxide poisoning from

engine exhaust.

Be sure there is adequate ventilation
whenever you operate the engine.

✽ Burns from hot parts.

Allow the engine, muffler, brakes and
other high-temperature parts to cool
before servicing as you can get burned.

✽ Injury from moving parts.

Do not run the engine unless
instructed to do so.

• Read the instructions before you begin,
and make sure you have the tools and
skills required.

• To help prevent the motorcycle from
falling over, park it on a firm, level
surface, using the side stand or a
maintenance stand to provide support.

58

• To reduce the possibility of a fire or
explosion, be careful when working
around petrol. Use only nonflammable
solvent, not petrol, to clean parts. Keep
cigarettes, sparks and flames away from
all fuel-related parts.

Remember that your dealer knows your
motorcycle best and is fully equipped to
maintain and repair it.

To ensure the best quality and reliability,
use only new Honda Genuine Parts or their
equivalents for repair and replacement.

Changing parts can affect your health and
safety. We recommend that you consult
your dealer if you do not have the proper
skill and tools to change parts on your own.

MAINTENANCE SCHEDULE

Perform the Pre-ride Inspection (page 46) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating
condition. Maintenance work should be per formed in accordance with standards and specifications of Honda by
properly trained and equipped technicians. Your dealer meets all of these requirements.

✽ Should be ser viced by your dealer, unless the owner has proper tools and ser vice data and is mechanically

qualified. Refer to the Of ficial Honda Shop Manual.

✽✽ In the interest of safety, we recommend these items be serviced only by your dealer.

NOTE: (1) Service more frequently when ridden in wet or dusty conditions.

59

FREQUENCY

WHICHEVER INITIAL
COMES

MAINT.

REGULAR MAINT. INTERVAL

FIRST km 150 1,000 2,000 3,000 4,000 REFER

 mi 100 600 1,200 1,800 2,400

ITEMS

✽

FUEL LINE I I –

✽✽

FUEL FILTER Every 8,000 km (4,800 mi): R –

✽

THROTTLE OPERATION I I 74

NOTE MONTH 1 6 12 18 24

AIR CLEANER NOTE (1) C C C C 64
CRANKCASE BREATHER I I I I 66
SPARK PLUG IIII72

✽✽

VALVE CLEARANCE I I I I I –
ENGINE OIL R R R R R 67

✽✽

ENGINE OIL STRAINER
SCREEN

✽✽

ENGINE OIL CENTRIFUGAL
FILTER

✽✽

ENGINE IDLE SPEED I I I I I –

CC –

CC –

60

TO

PAGE

FREQUENCY

WHICHEVER INITIAL
COMES

MAINT.

REGULAR MAINT. INTERVAL

FIRST km 150 1,000 2,000 3,000 4,000 REFER

 mi 100 600 1,200 1,800 2,400

ITEMS

NOTE MONTH 1 6 12 18 24

DRIVE CHAIN NOTE (1) I, L Every 500 km (300 mi) or

every 3 months: I,L
DRIVE CHAIN SLIDER I I I I 80
BRAKE SHOES WEAR I I I I 88
BRAKE SYSTEM I I I I I 24, 27, 88
CLUTCH SYSTEM I I I I I 29
SIDE STAND I I 96

✽

SUSPENSION I I 94, 95

✽

SPARK ARRESTER Every 1,600 km (1,000 mi) or

✽

NUTS, BOLTS, FASTENERS I I I –

✽✽

WHEELS/TYRES I I I I I 34, 84

✽✽

STEERING HEAD BEARINGS I I I –

every 100 operating hours: C

TO

PAGE

79

77

61

TOOL KIT

(1)

(2)

(3)

The spark plug wrench (1) and its handle
(2) are stored in the tool bag (3).

(1) Spark plug wrench
(2) Handle
(3) Tool bag

62

SERIAL NUMBERS

(1)

(2)

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

FRAME NO.__________________________

The frame number (1) is stamped on the left
side of the steering head.

The engine number (2) is stamped on the
left side of the engine.

ENGINE NO. _________________________

(1) Frame number

(2) Engine number

63

AIR CLEANER

(1)

(2)

(5)

(4)

(3)

Refer to the Safety Precautions on page 58.

The air cleaner element should be serviced
at regular intervals (page 60). If your
motorcycle is operated in dusty areas, more
frequent servicing will be required. Your
dealer can help you to determine the
correct ser vice inter val for your par ticular
riding conditions.

1. Remove the bolts (1), air cleaner
housing cover (2) and air cleaner
element (3).

2. Wash the air cleaner element in clean,
nonflammable or high flash point solvent
and let it dry thoroughly.

Never use petrol or low flash point solvents
for cleaning the air cleaner element. A fire
or explosion could result.

64

(1) Bolts
(2) Air cleaner housing cover
(3) Air cleaner element
(4) Hole
(5) Boss

3. Soak the air cleaner element in 4-stroke
motorcycle engine oil (10W-30 MA) until
saturated, then squeeze out the excess
oil.

4. Install the air cleaner element, aligning
its hole (4) with the boss (5) on the air
cleaner housing.

5. Install the air cleaner housing cover and
tighten the bolts to the specified torque:

1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

65

CRANKCASE BREATHER

(1)

Refer to the Safety Precautions on page 58.

Service more frequently if your motorcycle
is ridden in the rain or often at full throttle.

If the drain plug overflows, the air filter may
become contaminated with engine oil
causing poor engine performance.

1. Place a suitable container under the
crankcase breather

2. Remove the crankcase breather

plug.

plug and

drain deposits.

3. Reinstall the crankcase breather

66

plug.

(1) Crankcase breather plug

ENGINE OIL

Refer to the Safety Precautions on page 58.

Oil Recommendation

A P I
classification

Viscosity SAE 10W-30

SJ or higher except oils
labeled as energy
conserving or resource
conserving on the
circular API service
label

• Your motorcycle does not need oil
additives. Use the recommended oil.

• Do not use oils with graphite or
molybdenum additives. They may
adversely affect clutch operation.

• Do not use API SJ or higher oils
displaying a circular API ‘‘energy
conserving’’ or ‘‘resource conserving’’
service label on the container. They may
affect lubrication and clutch
performance.

JASO T 903
standard

Suggested Oil

Honda ‘‘4-STROKE MOTORCYCLE OIL’’
or equivalent.

MA

NOT RECOMMENDED RECOMMENDED

• Do not use non-detergent, vegetable, or
castor based racing oils.

67

Viscosity:

Viscosity grade of engine oil should be
based on average atmospheric temperature
in your riding area. The following provides a
guide to the selection of the proper grade or
viscosity of oil to be used at various
atmospheric temperatures.

68

JASO T 903 standard
The JASO T 903 standard is an index for
engine oils for 4-stroke motorcycle engines.
There are two classes: MA and MB.
Oil conforming to the standard is labeled on
the oil container. For example, the following
label shows the MA classification.

(1)

(2)

(1) Oil code
(2) Oil classification

69

Engine Oil

Engine oil quality is the chief factor
affecting engine ser vice life. Change the
engine oil as specified in the maintenance
schedule (page 60).
When running in ver y dusty conditions, oil
changes should be performed more
frequently than specified in the
maintenance schedule.

Please dispose of used engine oil in a
manner that is compatible with the
environment. We suggest you take it in a
sealed container to your local recycling
centre or service station for reclamation. Do
not throw it in the trash or pour it on the
ground or down a drain.

Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle 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.

70

Changing the oil requires a torque wrench.
If you do not have it and the necessary skill,
we recommend that you have your dealer
perform this service.

If a torque wrench is not used for this
installation, see your dealer as soon as
possible to verify proper assembly.

Change the engine oil with the engine at
normal operating temperature and the
motorcycle on its side stand to assure
complete and rapid draining.

1. Remove the oil fill cap/dipstick from the

NOTICE

right crankcase cover.

2. Place a drain pan under the crankcase.

3. To drain the oil, remove the oil drain bolt
(1) and sealing washer (2).

4. Install the oil drain bolt with a new
sealing washer.
Oil drain bolt torque:

24 N·m (2.4 kgf·m, 18 lbf·ft)

5. Fill the crankcase with the
recommended grade oil; approximately:

1.0 (1.1 US qt, 0.9 Imp qt)

6. Reinstall the oil fill cap/dipstick.

7. Star t the engine and let it idle for 3 – 5
minutes.

8. 2 – 3 minutes after stopping the engine,
check that the oil level is at the upper
level mark on the oil fill cap/dipstick with
the motorcycle upright on firm, level
ground. Make sure there are no oil leaks.

Running the engine with insufficient oil can
cause serious engine damage.

(2)

(1)

(1) Oil drain bolt
(2) Sealing washer

71

SPARK PLUG

NOTICE

Refer to the Safety Precautions on page 58.

Recommended plug:
Standard:

CPR6EA-9S (NGK)

For most riding conditions this spark plug
heat range number is satisfactory.

72

Never use a spark plug with an improper
heat range. Severe engine damage could
result.

1. Disconnect the spark plug cap.

2. Clean any dir t from around the spark
plug base.

3. Remove the spark plug using a spark
plug wrench provided in the tool kit.

4. Visually inspect the spark plug
electrodes for wear. The centre
electrode should have square edges and
the side electrode should not be eroded.

5. Discard the spark plug if there is
apparent wear or if the insulator is
cracked or chipped.

6. Check the spark plug gap (1) using a

NOTICE

wire-type feeler gauge. If adjustment is
necessary, bend the side electrode (2)
carefully.
The gap should be:

0.8 – 0.9 mm (0.03 – 0.04 in)

(2)

(1)

7. Make sure the plug washer is in good
condition.

8. With the plug washer attached, thread
the spark plug in by hand to prevent
cross-threading.

9. Tighten the spark plug:

• If the old plug is good:

1/6 turn after it seats.

• If installing a new plug, tighten it twice

to prevent loosening:
a) First, tighten the plug:

1/4 turn after it seats.
b) Then, loosen the plug.
c) Next, tighten the plug again:

1/6 turn after it seats.

An improperly tightened spark plug can
damage the engine. If a plug is too loose, a
piston may be damaged. If a plug is too
tight, the threads may be damaged.

(1) Spark plug gap (2) Side electrode

10. Reinstall the spark plug cap. Take care
to avoid pinching any cables or wires.

73

THROTTLE OPERATION

(1)

Refer to the Safety Precautions on page 58.

Cable Inspection:

1. Check for smooth rotation of the throttle
grip from the fully open to the fully
closed position at both full steering
positions.

2. Inspect the condition of the throttle
cables (1) from the throttle grip down to
the throttle body. If the cable is kinked,
chafed or improperly routed, it should
be replaced and/or rerouted.

3. Lubricate the cable with a commercially
available cable lubricant to prevent
premature wear and corrosion.

(1) Throttle cables

74

Freeplay Adjustment:

(1)

(2)

(3)

(A)

(B)

1. Adjust freeplay with the throttle cable
adjuster (1). Measured in grip rotation,
the standard throttle grip freeplay is:

2 – 6 mm (0.1 – 0.2 in)

2. To adjust the freeplay, slide the throttle
cable boot (2), then loosen the lock nut
(3) and turn the cable adjuster.

3. After adjustment, check again for
smooth rotation of the throttle grip from
the fully closed to the fully open position
with the steering to the full right and left
as well as straight ahead.

If proper throttle freeplay cannot achieved,
contact your dealer.

(1) Cable adjuster
(2) Cable boot
(3) Lock nut

(A) Decrease freeplay
(B) Increase freeplay

75

Throttle Limiter Activation:

(1)

(1)

(2)

You can reduce throttle grip movement.

1. Remove the M6 × 6 screw (1) from the
throttle housing.

2. Replace the M6 × 6 screw with throttle
stopper screw (2) provided and tighten it
fully.

When the M6 × 6 screw is installed, the
throttle can be fully opened.
When the throttle stopper screw is installed,
the throttle opening is restricted to
approximately 50% and the maximum
engine speed is limited.

Do not remove the screw except when
activating or deactivating the limiter.
Use only provided screws. Do not use any
other screw.
Never operate the motorcycle without
either the M6 × 6 screw or throttle stopper
screw installed as debris can enter the
housing and cause the throttle to bind.

76

(1) M6 × 6 screw
(2) Throttle stopper screw

SPARK ARRESTER

(3)(9) (2) (1)

(10)

Refer to the Safety Precautions on page 58.

The exhaust system spark arrester must be
purged of accumulated carbon periodically
(see Maintenance Schedule for servicing
period, page 61).

The exhaust system becomes very hot
during operation and remains hot for a
period of time after stopping the engine.
Allow the exhaust system to cool before
performing this operation.

1. Remove the right side cover (page 44).

2. Remove the muf fler protector screw (1),
collar (2) and muffler protector (3).

(1) Muffler protector screw
(2) Collar
(3) Muffler protector

(9) Slots
(10)Tabs

77

3. Remove the bolts (4), the spark ar rester

(5)

(4) (7)(6)

(8)

(5), and the gasket (6) from the muffler
(7).

4. Use a brush to remove carbon deposits
from the spark arrester screen (8). Be
careful to avoid damaging the spark
arrester screen. The spark arrester must
be free of breaks and holes. Replace, if
necessary.

5. Install the spark arrester and the new
gasket in the muffler and tighten the
bolts to the specified torque:

10 N·m (1.0 kgf·m, 7 lbf·ft)

6. Install the muffler protector, aligning
slots (9) with the tabs (10) on the
muffler. Install the muffler protector
screw and collar and tighten the screw to
the specified torque:

9 N·m (0.9 kgf·m, 6.6 lbf·ft)

7. Install the right side cover (page 44).

78

(4) Bolts
(5) Spark arrester

(8) spark arrester screen

(6) Gasket
(7) Muffler

DRIVE CHAIN

NOTICE

(1)

Refer to the Safety Precautions on page 58.

The service life of the drive chain (1) is
dependent upon proper lubrication and
adjustment. Poor maintenance can cause
premature wear or damage to the drive
chain and sprockets.
The drive chain should be checked and
lubricated as part of the Pre-ride Inspection
(page 46). Under severe usage, or when the
motorcycle is ridden in unusually dusty or
muddy areas, more frequent maintenance
will be necessary.

Inspection:

1. Turn the engine off, place the
motorcycle on its side stand and shift the
transmission into neutral.

2. Check slack in the lower drive chain run
midway between the sprockets.
Drive chain slack should be adjusted to
allow the following vertical movement
by hand:

10 – 20 mm (0.4 – 0.8 in)

3. Roll the motorcycle forward. Stop.
Check the drive chain slack. Repeat this
procedure several times. Drive chain
slack should remain constant. If the
chain is slack only in certain sections,
some links are kinked and binding.
Binding and kinking can frequently be
eliminated by lubrication.

Excessive chain slack may allow the drive
chain to damage the engine cases.

(1) Drive chain

79

4. Check the chain slider (2) for wear.

((33)

((33)

If the ridge (3) in the centre of the slider
is worn, have your dealer replace the
chain slider.

(2)

5. Measure a section of the drive chain to
determine whether the chain is worn
beyond its service limit. Remove the
drive chain and measure the distance
between a span of pins from pin centre to
pin centre. If the distance exceeds the
service limit, the chain is worn out and
should be replaced.

(2) Chain slider
(3) Ridge

80

)

)

New Chain:

1,080 mm (42.5 in)

Service Limit:

1,101 mm (43.3 in)

Measure a span of: 86 pins.

6. Inspect the sprocket teeth for possible

Damaged Sprocket
Teeth

REPLACE

Wor n S p r ocket

Teeth

REPLACE

Normal Sprocket Teeth

GOOD

wear or damage.

Adjustment:
If the drive chain requires adjustment, the
procedure is as follows:

1. Place a suppor t block under the engine
to raise the rear wheel off the ground.

2. Loosen the rear axle nut (1).

3. Loosen the lock nuts (2) on both right
and left chain adjusters.

(4)

(5)

If the drive chain or sprockets are
excessively worn or damaged, they should
be replaced. Never use a new chain with
worn sprockets; rapid chain wear will result.

(1) Rear axle nut
(2) Lock nut
(3) Adjusting nut

(3)

(1)(2)

(4) Chain adjuster
(5) Graduated scale

81

4. Turn the adjusting nut (3) on both the
right and left chain adjusters an equal
number of turns to increase or decrease
chain slack.
Align the front edge of chain adjusters
(4) with the graduated scales (5) on both
sides of the swingarm.

If the drive chain slack is excessive when
the rear axle is moved to the furthest limit
of adjustment, the drive chain is worn and
must be replaced.

5. Tighten the rear axle nut to:

64 N·m (6.5 kgf·m, 47 lbf·ft)

6. Tighten the adjusting nuts lightly, then
tighten the lock nuts by holding the
adjusting nuts with a spanner.

7. Recheck drive chain slack.

8. Rear brake pedal freeplay is affected
when repositioning the rear wheel to
adjust drive chain slack. Check rear
brake pedal freeplay and adjust as
necessary (page 27).

82

If a torque wrench is not used for this
installation, see your dealer as soon as
possible to verify proper assembly.

Lubrication:
Lubricate every 500 km (300 miles) or
sooner if chain appears dry.

Recommended lubricant:

Drive chain lubricant
If not available, use SAE 80 or 90 gear oil.

Saturate each chain link joint so that the
lubricant penetrates between the link plates,
pins, bushings, and rollers.

Removal and Cleaning:

(1)

When the drive chain becomes dirty, it
should be removed and cleaned prior to
lubrication.

1. With the engine off, carefully remove
the master link retaining clip (1) with a
pair of pliers. Do not bend or twist the
clip. Remove the master link. Remove
the drive chain from the motorcycle.

2. Clean the drive chain in high flash-point
solvent and allow it to dry. Inspect the
drive chain for possible wear or damage.
Replace any chain that has damaged
rollers, loose fitting links, or otherwise
appears unserviceable.

Replacement chain:

DID 420D-86RB

Never use petrol or low flash point solvents
for cleaning the drive chain. A fire or
explosion could result.

3. Inspect the sprocket teeth for possible
wear or damage.

4. Lubricate the drive chain (page 82).

5. Pass the chain over the sprockets and
join the ends of the chain with the
master link. For ease of assembly, hold
the chain ends against adjacent rear
sprocket teeth while inserting the
master link.
The master link is the most critical part
affecting the security of the drive chain.
Master links are reusable, if they remain
in excellent condition, but it is
recommended that a new master link
retaining clip be installed whenever the
drive chain is reassembled.
Install the master link retaining clip so
that the closed end of the clip will face
the direction of forward wheel rotation.

(1) Retaining clip

83

(1)

(2)

WHEEL RIMS AND SPOKES

Refer to the Safety Precautions on page 58.

1. Inspect the wheel rims (1) and spokes
(2) for damage.

2. Tighten any loose spokes.

3. Check wheel rim runout. If runout is
noticeable, see your dealer for
inspection.

Maintenance of spoke tension and wheel
trueness are critical to safe motorcycle
operation. During the first 150 km (100
miles), spokes will loosen more rapidly due
to initial seating of parts. Excessively loose
spokes may result in high speed instability
and possible loss of control.

(1) Wheel rim
(2) Spoke

84

WHEEL REMOVAL

(2)

(1)

(3)

(6)

(5)

(4)

(2)

Refer to the Safety Precautions on page 58.

Front Wheel Removal

1. Raise the front wheel off the ground by
placing a support block under the engine.

2. Loosen the cable guide bolt (1).

3. Disconnect the front brake cable (2)
from the brake arm (3).

4. Remove the front axle nut (4) and front
axle. The front wheel can now be
removed.

Installation:

1. Reverse the removal procedure. Make
sure that the lug (5) on the fork leg is
located in the slot (6) in the brake panel.
Be sure to tighten the front axle nut to:

59 N·m (6.0 kgf·m, 44 lbf·ft)

2. Check front brake adjustment.

3. After installing the wheel, apply the
brake several times and then check if
the wheel rotates freely. Recheck the
wheel if the brake drags or if the wheel
does not rotate freely.

If a torque wrench is not used for
installation, see your dealer as soon as
possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.

(1) Cable guide bolt
(2) Front brake cable
(3) Brake arm

(4) Front axle nut
(5) Lug
(6) Slot

85

Rear Wheel Removal

(4)

(4)

(1) (2)

(3) (5)

(7)

(5)

(6)

1. Raise the rear wheel off the ground by
placing a support block under the
engine.

2. Unscrew the rear brake adjuster (1).

3. Press and release the rear brake pedal
and disconnect the brake rod (2) from
the brake arm (3).

4. Loosen the lock nut (4) and adjusting
nut (5) on the chain adjuster on both
sides.

5. Unscrew the axle nut (6) and pull out the
axle (7). Push the wheel forward and
derail the drive chain from the rear
sprocket. Remove the wheel.

(1) Brake adjuster
(2) Brake rod
(3) Brake arm
(4) Lock nut

(5) Adjusting nut
(6) Axle nut
(7) Axle

86

(1)

(2)

Installation:

1. Reverse the removal procedure. Make
sure that the lug (1) on the swingarm is
located in the slot (2) in the brake panel.
Tighten the axle nut to:

64 N·m (6.5 kgf·m, 47 lbf·ft)

2. Adjust the drive chain (pages 81 – 82).

3. Adjust the brake (page 27).

4. Apply the brake several times and check
for free wheel rotation after the brake
pedal is released.

If a torque wrench is not used for
installation, see your dealer as soon as
possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.

(1)Lug (2)Slot

87

BRAKE SHOES WEAR

(1)

(3)

(4)

(2)

(1)

(2)

(3) (4)

Refer to the Safety Precautions on page 58.

The front and rear brakes are equipped with
brake wear indicators.
When the brake is applied, an arrow (1)
attached to the brake arm (2) moves toward
a reference mark (3) on the brake panel (4).
If the arrow aligns with the reference mark
on full application of the brake, the brake
shoes must be replaced.
See your dealer for this service.

When the brake service is necessary, see
your dealer. Use only Honda Genuine Parts
or its equivalent.

<FRONT BRAKE>

<REAR BRAKE>

88

(1) Arrow
(2) Brake arm

(3) Reference mark
(4) Brake panel

BATTERY

NOTICE

NOTICE

Refer to the Safety Precautions on page 58.

It is not necessary to check the batter y
electrolyte level or add distilled water as the
battery is a maintenance-free (sealed) type.
If your battery seems weak and/or is
leaking electrolyte (causing hard starting or
other electrical troubles), contact your
dealer.

Your battery is a maintenance-free type and
can be permanently damaged if the cap strip
is removed.

This symbol on the battery means
that this product must not be
treated as household waste.

An improperly disposed of battery can be
harmful to the environment and human
health.
Always confirm local regulations for batter y
disposal.

The battery gives off explosive
hydrogen gas during normal operation.

A spark or flame can cause the battery
to explode with enough force to kill or
seriously hurt you.

Wear protective clothing and a face
shield, or have a skilled mechanic do
the battery maintenance.

89

The battery (1) is in the battery

(1)

(4)

(5)

(2)

(3)

compartment behind the left side cover.

Removal:

1. Make sure the ignition switch is
(OFF).

2. Remove the left side cover (page 42).

3. Remove the battery holder (2) by
removing the bolt (3).

4. Disconnect the negative (–) terminal
lead (4) from the battery first, then
disconnect the positive (+) terminal lead
(5).

5. Pull out the battery from the battery
box.

Installation:

1. Reinstall in the reverse order of removal.
Be sure to connect the positive (+)
terminal first, then the negative (–)
terminal.

2. Check all bolts and other fasteners are
secure.

90

(1) Battery
(2) Battery holder
(3) Bolt
(4) Negative (–) terminal lead
(5) Positive (+) terminal lead