Honda FIRE BLADE 1999 Owner's Manual
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Honda FIRE BLADE 1999 Owner's Manual

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06/03/06 13:39:47 3CMCJ600_001
CBR900RR
FIRE BLADE
OWNER'S MANUAL
MANUEL DU CONDUCTEUR
FAHRER-HANDBUCH
Honda Motor Co., Ltd. 1999

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Summary of Contents for Honda FIRE BLADE 1999

  • Page 1 06/03/06 13:39:47 3CMCJ600_001 CBR900RR FIRE BLADE OWNER’S MANUAL MANUEL DU CONDUCTEUR FAHRER-HANDBUCH Honda Motor Co., Ltd. 1999...
  • Page 2 06/03/06 13:39:53 3CMCJ600_002 IMPORTANT NOTICE OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. Never exceed the maximum weight capacity as shown on the loading and accessories label. ON-ROAD USE This motorcycle is designed to be used only on the road. READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: Indicates a strong possibility of severe personal injury or death if instructions are...
  • Page 3 OWNER’S MANUAL 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.
  • Page 4 BEFORE YOU RIDE THE MOTORCYCLE. When service is required, remember that your Honda dealer knows your motorcycle best. If you have the required mechanical ‘‘know-how’’ and tools, your dealer can supply you with an official Honda Service Manual to help you perform many maintenance and repair tasks.

  • Page 5: Operation

    06/03/06 13:40:15 3CMCJ600_005 OPERATION page page 1 MOTORCYCLE SAFETY Right Handlebar Controls Safe Riding Rules Left Handlebar Controls Protective Apparel 52 FEATURES Modifications (Not required for operation) Loading and Accessories Steering Lock 6 PARTS LOCATION Seat Instruments and Indicators Helmet Holder 24 MAJOR COMPONENTS Document Bag (Information you need to...
  • Page 6 06/03/06 13:40:18 3CMCJ600_006 MAINTENANCE page page 70 MAINTENANCE 115 CLEANING Maintenance Schedule Tool Kit 118 STORAGE GUIDE Serial Numbers Storage Colour Label Removal from Storage Maintenance Precautions Engine Oil 121 SPECIFICATIONS Spark Plugs Throttle Operation 125 RADIO TYPE APPROVALS OF Idle Speed IMMOBILIZER SYSTEM (HISS) Drive Chain...

  • Page 7: Motorcycle Safety

    06/03/06 13:40:27 3CMCJ600_007 MOTORCYCLE SAFETY Obey all national and local laws and regulations. Excessive speed is a factor in many Motorcycle riding requires special accidents. Obey the speed limits, and efforts on your part to ensure your saf ety. Know these requirements NEVER travel faster than conditions before you ride: warrant.

  • Page 8: Protective Apparel

    06/03/06 13:40:32 3CMCJ600_008 PROTECTIVE APPAREL MODIFICATIONS Most motorcycle accident fatalities are due to head injuries: ALWAYS wear an approved motorcycle helmet. You should Modification of the motorcycle, or also wear a face shield or goggles as well removal of original equipment, may as boots, gloves and protective clothing.

  • Page 9: Loading And Accessories

    And remember t hat t his 130 km/h Load weight equally on both sides to minimize imbalance. As weight is located (80mph) limit may be reduced by installation of non-Honda accessories, further from the motorcycle’s center of improper loading, worn tyres and gravity, handling is proportionally overall motorcycle condition, poor affected.
  • Page 10 Because the factory cannot test The Honda fairing is designed for this all other accessories, you are personally motorcycle only. Do not install it on any responsible for proper selection, installation, other motorcycle.
  • Page 11 06/03/06 13:40:48 3CMCJ600_011 Accessories which alter your riding position by moving hands or feet away from controls may increase reaction time in an emergency. 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.

  • Page 12: Parts Location

    06/03/06 13:40:52 3CMCJ600_012 PARTS LOCATION Tachometer Ignition switch Coolant temperature meter Multi-function Rearview mirror Rearview mirror display Indicators Front brake fluid reservoir Passing switch (Except U type) Engine stop switch Clutch lever Front brake lever Headlight switch (Except U type) Throttle grip Headlight dimmer switch...
  • Page 13 06/03/06 13:40:56 3CMCJ600_013 Storage compartment for U-shaped anti-theft lock Rear brake fluid reservoir Storage Tool box compartment Front compression damping adjuster Passenger footpeg Engine oil inspection Footpeg window Oil filler cap Rear brake pedal...
  • Page 14 06/03/06 13:40:59 3CMCJ600_014 Rear compression damping adjuster Helmet holder Document Battery compartment Fuse Front compression damping adjuster Passenger footpeg Footpeg Rear spring Coolant reserve tank preload adjuster Side stand Rear rebound damping adjuster Gearshift pedal...

  • Page 15: Instruments And Indicators

    06/03/06 13:41:05 3CMCJ600_015 INSTRUMENTS AND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages. (13) (1) Tachometer (2) Tachometer red zone (3) Fuel indicator (4) Immobilizer system (HISS) indicator Except MX, BR type 〈...
  • Page 16 06/03/06 13:41:09 3CMCJ600_016 (Ref.No.) Description Function (1) Tachometer Shows engine rpm. (2) Tachometer red zone Never allow the tachometer needle to enter the red zone, even after the engine has been broken in. Running the engine beyond recommended maximum engine speed (the beginning of the tachometer red zone) can damage the engine.
  • Page 17 06/03/06 13:41:12 3CMCJ600_017 (Ref. No.) Description Function (4) Immobilizer system This indicator lights for a few seconds when the (HISS) indicator ignition switch is turned ON and the engine stop switch is at (RUN). It will then go off if the properly-coded key has been inserted.
  • Page 18 06/03/06 13:41:15 3CMCJ600_018 (Ref. No.) Description Function (8) Right control button Except E type: This button is used to adjust the time. For E type: This button is used to adjust the time or to change the speed and mileage units for the speedometer/ odometer/tripmeter.
  • Page 19 06/03/06 13:41:18 3CMCJ600_019 (Ref. No.) Description Function (13) Multi-function display The display includes the following functions; Speedometer Shows riding speed (page 20). Odometer Shows accumulated mileage (page 20). Tripmeter A and B Shows mileage per trip (page 20). Digital clock Shows hour and minute (page 22).
  • Page 20 06/03/06 13:41:23 3CMCJ600_020 Multi-function Display Multi-function display ( ) includes the following functions: Speedometer Odometer Tripmeter Digital clock Information display (1) Multi-function display (2) Speedometer (3) Odometer (4) Tripmeter (5) Digital clock (6) Information display (7) Right control button (8) Left control button (9) Information indicator...
  • Page 21 06/03/06 13:41:29 3CMCJ600_021 Initial Display When the ignition switch is turned ON, the Multi-function display red information indicator lights, and both the multi-function display and coolant temperature meter will temporarily show all the modes and digital segments so you can make sure the liquid crystal display is functioning properly.
  • Page 22 06/03/06 13:41:33 3CMCJ600_022 Information Indicator and Information Display The red information indicator ( ) lights when there is any abnormality in the coolant temperature and/or engine oil pressure. As this happen, the coolant temperature indicator ( ) and/or low oil pressure indicator ( ) contained in the information display ( ) will also go on.
  • Page 23 06/03/06 13:41:38 3CMCJ600_023 Low Oil Pressure Information The low oil pressure indicator ( ) goes on and the red information indicator ( ) lights when engine oil pressure is below the normal operating range. Both indicator should go on when ignition switch is ON and engine is not running.
  • Page 24 (RUN). If the PGM-FI indicator goes on and red information indicator lights or flashes at any other time, reduce speed and take the motorcycle to your Honda dealer as soon as possible. (1) PGM-FI indicator (2) Information indicator...
  • Page 25 06/03/06 13:41:50 3CMCJ600_025 Overheating message Coolant Temperature Meter Coolant temperature meter ( ) shows When the coolant temperature reaches coolant temperature digitally. 122°C, the display begins to flash. At the same time, the coolant temperature Temperature display indicator ( ) goes on and the red information indicator ( ) lights.
  • Page 26 06/03/06 13:42:00 3CMCJ600_026 Speedometer/Odometer/Tripmeter Speedometer Shows riding speed. Odometer Shows accumulated mileage. Tripmeter Shows mileage par trip. There are two tripmeters, tripmeter A ( ) and tripmeter B ( ). Switch between the A and B displays by pressing the left control button ( ) repeatedly.
  • Page 27 06/03/06 13:42:05 3CMCJ600_027 Speed Unit Change (E type only) The speedometer displays both ‘‘km/h’’ and ‘‘mph’’. Push the right control button ( ) to select ‘‘km/h’’ or ‘‘mph’’. (7) Right control button...
  • Page 28 06/03/06 13:42:13 3CMCJ600_028 Digital clock Shows hour and minute. To adjust time, Set hour and minute. proceed as follows : The clock will alternate between the hour and minute adjust modes each Turn the ignition switch ON. time the left control button is pressed. Press the left control button while pressing the right control button.
  • Page 29 06/03/06 13:42:19 3CMCJ600_029 To set the hour, set the clock in the hour adjust mode and press the right control button until the desired hour and AM/PM are displayed. Wait approximately seconds; the display will stop flashing automatically. Adjustment will be cancelled when the ignition switch is turned OFF while the clock is in the adjust mode.

  • Page 30: Major Components

    06/03/06 13:42:26 3CMCJ600_030 MAJOR COMPONENTS (Information you need to operate this motorcycle) Standard posision: To return to the standard posision, turn the If the Pre-ride Inspection (page ) is adjusters until the 4th groove from the top not performed, severe personal injury aligns with the top surface of the fork caps.
  • Page 31 06/03/06 13:42:32 3CMCJ600_031 Rebound damping: To reduce (SOFT) : Turn the adjuster counterclockwise toward SOFT for a light load and smooth road condition. To increase (HARD) : Turn the adjuster clockwise toward HARD for a firmer ride and rough road condition. To adjust the adjuster to the standard position, proceed as follows: Turn the damping adjuster ( ) clockwise...
  • Page 32 06/03/06 13:42:37 3CMCJ600_032 Compression damping: To reduce (SOFT) : Turn the adjuster counterclockwise toward SOFT for a light load and smooth road condition. To increase (HARD) : Turn the adjuster clockwise toward HARD for a firmer ride and rough road condition. To adjust the adjuster to the standard position, proceed as follows: Turn the damping adjuster ( ) clockwise...
  • Page 33 06/03/06 13:42:43 3CMCJ600_033 Rear Suspension Rebound damping: To reduce (SOFT) : Turn the adjuster counterclockwise toward SOFT for a light load and smooth road condition. To increase (HARD) : Turn the adjuster clockwise toward HARD for a firmer ride and rough road condition. To adjust the adjuster to the standard position, proceed as follows: Turn the damping adjuster ( ) clockwise...
  • Page 34 06/03/06 13:42:49 3CMCJ600_034 Compression damping: To reduce (SOFT) : Turn the adjuster counterclockwise toward SOFT for a light load and smooth road condition. To increase (HARD) : Turn the adjuster clockwise toward HARD for a firmer ride and rough road condition. To adjust the adjuster to the standard position, proceed as follows: Turn the damping adjuster ( ) clockwise...
  • Page 35 Puncture or exposure to flame may also result in an explosion, causing serious injury. Service or disposal should only be done by your Honda dealer or a qualified mechanic, equipped with the proper tools, safety equipment and the official Honda Shop Manual.
  • Page 36 (page ), there is probably air in the brake Handle brake fluid with care because system and it must be bled. See your Honda it can damage plastic and painted dealer for this service. surfaces.
  • Page 37 06/03/06 13:43:09 3CMCJ600_037 Check that the fluid level is above the Other Checks: LOWER level mark ( ) with the motorcycle Make sure there are no fluid leaks. Check in an upright position. for deterioration or cracks in the hoses and Brake fluid must be added to the reservoir fittings.
  • Page 38 06/03/06 13:43:17 3CMCJ600_038 Front Brake Lever: Rear Brake The distance between the tip of the brake Rear Brake Fluid Level: lever ( ) and the grip can be adjusted by turning the adjuster dial ( ) while pushing the lever forward. Brake f luid may cause irritation.
  • Page 39 06/03/06 13:43:23 3CMCJ600_039 Check that the fluid level is above the LOWER level mark ( ) with the motorcycle in an upright position. Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark ( ). Remove the bolt ( ).
  • Page 40 06/03/06 13:43:30 3CMCJ600_040 Loosen the lock nut ( ) and turn the CLUTCH Clutch adjustment may be required if the adjuster ( ). Tighten the lock nut ( ) motorcycle stalls when shifting into gear or and check the adjustment. tends to creep;...
  • Page 41 T he motorcycle should begin to move smoothly and accelerate gradually. If proper adjustment cannot be obtained or the clutch does not work correctly, see your Honda dealer. (4) Adjusting nut (A) Increase free play Other Checks: (5) Lock nut...
  • Page 42 06/03/06 13:43:43 3CMCJ600_042 COOLANT The factory provides a 50/50 solution of Coolant Recommendation antifreeze and distilled water in this The owner must properly maintain the motorcycle. T his coolant solution is coolant to prevent freezing, overheating, r e c o m m e n d e d f o r m o s t o p e r a t i n g and corrosion.
  • Page 43 ( ). Always add coolant to the reserve loss is excessive, check for leaks and see tank. Do not attempt to add coolant by your Honda dealer for repair. removing the radiator cap. (1) Reserve tank (3) LOWER level mark...
  • Page 44 06/03/06 13:43:57 3CMCJ600_044 FUEL For E, F, ED: Use unleaded or low-lead petrol with a Fuel Tank The fuel tank capacity including the reserve research octane number of 91 or higher. supply is: We recommend that you use unleaded petrol because it produces fewer engine and 18.0 (4.76 US gal , 3.96 Imp gal) To open the fuel fill cap ( ), insert the spark plug deposits and extends the life of...
  • Page 45 Refuel in a well-ventilated area with If spark knock or pinking persists, the engine stopped. Do not smoke or consult your Honda dealer. Failure to allow flames or sparks in the area do so is considered misuse, and dam- where petrol is stored or where the age caused by misuse is not covered fuel tank is refueled.
  • Page 46 Honda. There are two types of ‘‘gasohol’’: under the warranty. Honda cannot one containing ethanol, and the other con- endorse the use of fuels containing taining methanol.

  • Page 47: Engine Oil

    06/03/06 13:44:14 3CMCJ600_047 ENGINE OIL Reinstall the oil filler cap. Check for oil Engine Oil Level Check leaks. Check the engine oil level each day before riding the motorcycle. Running the engine with insufficient The level must be maintained between the oil pressure may cause serious engine upper ( ) and lower ( ) level marks in the damage.

  • Page 48: Tubeless Tyres

    06/03/06 13:44:28 3CMCJ600_048 TUBELESS TYRES This motorcycle is equipped with tubeless Tyre size tyres, valves, and wheel rims. Use only tyres marked ‘‘TUBELESS’’ and tubeless valves Front 120/70 ZR17 (58W) on rims marked ‘‘TUBELESS T YRE Rear 190/50 ZR17 (73W) APPLICABLE.’’...
  • Page 49 Check the rims for center of the tyre reaches the following dents or deformation. If there is any limit: damage, see your Honda dealer for repair, replacement, and balancing. Minimum tread depth Front : 1.5 mm (0.06 in) Rear : 2.0 mm (0.08 in)
  • Page 50 Excessive heat build-up may Honda dealer. Wheel balancing is cause the tube to burst resulting in r e q u i r e d a f t e r t y r e r e p a ir o r rapid tyre deflation that may result in replacement.

  • Page 51: Essential Individual Components Ignition Switch

    06/03/06 13:44:45 3CMCJ600_051 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (1) is below the indicator panel. (1) Ignition switch Key Position Function Key Removal LOCK Steering is locked. Engine and lights cannot be Key can be (steering lock) operated. removed Engine and lights cannot be operated.
  • Page 52 06/03/06 13:44:50 3CMCJ600_052 KEYS This motorcycle has two keys and a key number plate. Except MX, BR type For MX, BR type 〈 〉 〈 〉 (1) Keys (2) Key number plate...
  • Page 53 〈 〉 To reproduce keys, bring all keys, key immediately have it reproduced to ensure number plate and motorcycle to your Honda that a back-up is available. dealer. These keys contain electronic circuits that are activated by the immobilizer Up to four keys can be registered with the system (HISS).

  • Page 54: Immobilizer System (Hiss)

    Except MX, BR type 〉 If the system repeatedly does not recognize HISS is the abbreviation of Honda Ignition the coding of your key, contact your Honda Security System. dealer. The immobilizer system (HISS) protects your motorcycle from theft. A properly- The system may not recognize the key’s...

  • Page 55: Right Handlebar Controls

    06/03/06 13:45:07 3CMCJ600_055 RIGHT HANDLEBAR CONTROLS Starter Button Engine Stop Switch The starter button (2) is below the engine The engine stop switch ( ) is next to the stop switch (1). throttle grip. When the switch is in the When the starter button is pressed, the (RUN) position, the engine will operate.

  • Page 56: Left Handlebar Controls

    06/03/06 13:45:17 3CMCJ600_056 LEFT HANDLEBAR CONTROLS Turn Signal Switch 〈 Except U type 〉 Move to (L ) to signal a lef t t urn, (R) to signal a right turn. Press to turn signal off. Headlight Switch The headlight switch ( ) has three positions: and OFF, marked by a Horn Button...
  • Page 57 06/03/06 13:45:24 3CMCJ600_057 LEFT HANDLEBAR CONTROLS 〈 U type only 〉 Headlight Dimmer Switch Push the dimmer switch to (HI) to select high beam or to (LO) to select low beam. Turn Signal Switch Move to (L ) to signal a lef t t urn, (R) to signal a right turn.

  • Page 58: Steering Lock

    06/03/06 13:45:29 3CMCJ600_058 FEATURES To lock (Not required for operation) STEERING LOCK To lock the steering, turn the handlebars all the way to the left or right, turn the key ( ) to LOCK while pushing in. Remove the key. To unlock the steering, turn the key to OFF while pushing in.
  • Page 59 06/03/06 13:45:33 3CMCJ600_059 SEAT Front seat To remove the front seat (1), pull up the seat end and remove the two mounting bolts (2), and then pull the seat back and up. To install the front seat, insert the tab (3) into the recess under the frame and tighten the mount bolts securely.
  • Page 60 06/03/06 13:45:36 3CMCJ600_060 Rear seat To open the rear seat (4), insert the ignition key (5) into the seat lock (6) and turn it clockwise. To close the rear seat , push down on the rear of the seat. Be sure the seat is locked securely in position after installation.

  • Page 61: Helmet Holder

    06/03/06 13:45:40 3CMCJ600_061 HELMET HOLDER The helmet holder is on the back side of the rear seat. Open the rear seat ( ). (see page Hang the helmets on the holder hook ( ). Close the rear seat and lock it securely. The helmet holder is designed for helmet security while parked.

  • Page 62: Document Bag

    06/03/06 13:45:46 3CMCJ600_062 DOCUMENT BAG STORAGE COMPARTMENT The document bag (1) is in the document The storage compartment (4) is under the compartment (2) on the reverse side of the rear seat. rear seat (3). This compartment is for light weight items. This owner’s manual and other documents Do not carry more than 2.0 kg (4.5 lbs)
  • Page 63 06/03/06 13:45:49 3CMCJ600_063 STORAGE COMPARTMENT FOR U- SHAPED ANTI-THEFT LOCK The rear fender has a storage compartment to store a U-shaped anti-theft lock under the rear seat. After storing, be sure to fasten the lock with the rubber band ( ) securely. Some U-shaped locks may not be stored in the compartment due to their size or design.
  • Page 64 06/03/06 13:45:56 3CMCJ600_064 MIDDLE FAIRING The right and left middle fairings can be Installation: removed in the same manner. Installation can be done in the reverse order of removal. Removal: Pull the tab (1). Remove the bolt A (2). Remove the bolt B (3), then remove the bolt C (4).

  • Page 65: Lower Fairing

    06/03/06 13:46:01 3CMCJ600_065 LOWER FAIRING Removal: Remove the middle fairing. ( page Remove the bolts A (1). Remove the bolts B (2). Installation: Installation can be done in the reverse order of removal. Run the tubes through the clip of the lower fairing.

  • Page 66: Inner Panel

    06/03/06 13:46:06 3CMCJ600_066 INNER PANEL The right and left inner panels can be removed in the same manner. Removal: Remove the middle fairing (page 58). Remove the clips (1). Remove the bolt A (2). Remove the bolt B (3). Remove the inner panel (4) while lifting front of the fuel tank (5).
  • Page 67 06/03/06 13:46:10 3CMCJ600_067 H E A D L I G H T A I M V E R T I C A L ADJUSTMENT Vertical adjustment can be made by turning the adjuster ( ) in or out as necessary. Obey local laws and regulations.
  • Page 68 − (page ). Check for leaks Correct any discrepancy before you ride. Coolant level add coolant if required. − Contact your Honda dealer for assistance if Check for leaks (pages 36 37). you cannot correct the problem. − Front and rear brakes check operation;...

  • Page 69: Starting The Engine

    06/03/06 13:46:29 3CMCJ600_069 STARTING THE ENGINE Always follow the proper starting procedure described below. Never run the engine in an enclosed area. The exhaust contains poisonous This motorcycle is equipped with a side carbon monoxide gas that can cause stand ignition cut-off system. The engine loss of consciousness and lead to cannot be started if the side stand is down, death.
  • Page 70 06/03/06 13:46:34 3CMCJ600_070 Starting Procedure This motorcycle has an automatic choke. The red information indicator and low Follow the procedure indicated below. oil pressure indicator should go off a few seconds after the engine starts. If Any Air Temperature both indicators stays on, stop the Press the starter button with the throttle engine immediately and check engine completely closed.
  • Page 71 06/03/06 13:46:37 3CMCJ600_071 Flooded engine RUNNING-IN If the engine fails to start after repeated Help assure your motorcycle’s future attempts, it may be flooded engine. reliability and performance by paying extra L ea ve t he e ngine st op sw it ch se t t o attention to how you ride during the first (RUN).
  • Page 72 06/03/06 13:46:42 3CMCJ600_072 RIDING After the engine has been warmed up, the motorcycle is ready for riding. While the engine is idling, pull in the clutch lever and depress the gearshift Review Motorcycle Safety (pages − ) before you ride. pedal to shift into 1st (low) gear.
  • Page 73 06/03/06 13:46:44 3CMCJ600_073 Coordinate the throttle and brakes for smooth deceleration. Both front and rear brakes should be used at the same time and should not be applied strongly enough to lock the wheel, or braking effectiveness will be reduced and control of the motorcycle be difficult.
  • Page 74 06/03/06 13:46:50 3CMCJ600_074 BRAKING For normal braking, gradually apply both the f ront and rear brakes while When riding in wet or rainy condi- downshifting to suit your road speed. tions, or on loose surfaces, the ability For maximum deceleration, close the to maneuver and stop will be reduced.

  • Page 75: Anti-Theft Tips

    06/03/06 13:46:58 3CMCJ600_075 PARKING ANTI-THEFT TIPS After stopping the motorcycle, shift the Always lock the steering and never leave transmission into neutral, turn the the key in the ignition switch. This handlebar fully to the left, turn the sounds simple but people do forget. ignition switch OFF and remove the key.

  • Page 76: Maintenance

    Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the MAINTENANCE SCHEDULE. Consult your Honda dealer for recommendations applicable to your individual needs and use.

  • Page 77: Maintenance Schedule

    The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating condition. Maintenance work should be performed in accordance with standards and specifications of Honda by properly trained and equipped technicians. Your Honda dealer meets all of these requirements.
  • Page 78 06/03/06 13:47:26 3CMCJ600_078 FREQUENCY WHICHEVER → ODOMETER READING [NOTE (1)] COMES FIRST × 1,000 km Refer 1,000 mi ↓ × ITEMS NOTE MONTH pages DRIVE CHAIN EVERY 1,000 km (600 mi) I, L DRIVE CHAIN SLIDER BRAKE FLUID NOTE BRAKE PAD WEAR BRAKE SYSTEM 30, 102 BRAKE LIGHT SWITCH...
  • Page 79 06/03/06 13:47:32 3CMCJ600_079 Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the Official Honda Shop Manual. In the interest of safety, we recommend these items be serviced only by your Honda dealer.
  • Page 80 06/03/06 13:47:36 3CMCJ600_080 TOOL KIT The tool kit (1) is under the rear seat. Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. Pin spanner Spark plug wrench 12 mm box end wrench ×...

  • Page 81: Serial Numbers

    06/03/06 13:47:43 3CMCJ600_081 SERIAL NUMBERS The frame and engine serial numbers are The frame number (1) is stamped on the required when registering your motorcycle. right side of the steering head. They may also be required by your dealer when ordering replacement parts. The engine number (2) is stamped on top of Record the numbers here f or your the crankcase.

  • Page 82: Colour Label

    06/03/06 13:47:47 3CMCJ600_082 COLOUR LABEL The colour label (1) is attached to the storage compartment below the rear seat (See page It is helpful when ordering replacement parts. Record the colour and code here for your reference. COLOUR CODE (1) Colour label...

  • Page 83: Maintenance Precautions

    Do not ride the motorcycle if damage impairs safe operation. Have your Honda dealer inspect the major co m po n e nt s , i n c lu d in g f r a m e, suspension and steering parts, for misalignment and damage that you may not be able to detect.
  • Page 84 06/03/06 13:47:57 3CMCJ600_084 ENGINE OIL (Refer to the maintenance precautions on page Engine Oil Good engine oil has many desirable qualities. Use only high detergent, quality motor oil certified on the container to meet or exceed requirements for API Service Classification SE, SF or SG.
  • Page 85 If a torque wrench is not used for this installation, see Remove the middle fairing (page ) and your Honda dealer as soon as possible to the lower fairing (page verify proper assembly. To drain the oil, remove the oil filler cap and oil drain plug ( ) and sealing washer ( ).
  • Page 86 Apply a thin coat of engine oil to the new wrench and let the remaining oil drain out. oil filter rubber seal ( ). Use only the Honda genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong Honda filter...
  • Page 87 06/03/06 13:48:19 3CMCJ600_087 Check that the sealing washer on the drain plug is in good condition and install When running in very dusty conditions, the plug. Replace the sealing washer oil changes should be performed more every other time the oil is changed, or f requent ly t han specif ied in the each time if necessary.

  • Page 88: Spark Plugs

    06/03/06 13:48:28 3CMCJ600_088 SPARK PLUGS (Refer to the maintenance precautions on Remove the middle fairing (page 58) and page the lower fairing (page 59). Recommended plugs: Disconnect the radiator fan connector (1). Standard: Disconnect the thermo switch connector IUH27D (DENSO) (2).
  • Page 89 06/03/06 13:48:34 3CMCJ600_089 Move the radiator (6) out of the way and Disconnect the ignition coil connectors remove the grommet (7) from the hook (9). (8). Disconnect the ignition coils (10) from Pull the radiator toward the front. the spark plugs. Be careful not to damage the radiator fins.
  • Page 90 06/03/06 13:48:39 3CMCJ600_090 Clean any dirt from around the spark plug Inspect the electrodes and center bases. Remove the spark plugs using the porcelain for deposits, erosion or carbon plug wrench ( ) furnished in the tool kit. fouling. If the erosion or deposit is heavy, replace the plug.
  • Page 91 06/03/06 13:48:47 3CMCJ600_091 Make sure the plug washer is in good Connect the ignition coil connectors to condition. the ignition coils as before removal. With the plug washer attached, thread Connect the connector with blue tube the spark plug in by hand to prevent (13) to the second ignition coil as cross-threading.

  • Page 92: Throttle Operation

    06/03/06 13:48:53 3CMCJ600_092 THROTTLE OPERATION (Refer to the maintenance precautions on page Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. Measure the throttle grip free play at the throttle grip flange.

  • Page 93: Idle Speed

    06/03/06 13:48:59 3CMCJ600_093 Idle Speed: IDLE SPEED (In neutral) (Refer to the maintenance precautions on 1,200 ± 100 min (rpm) page The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-and-go riding is sufficient. Warm up the engine, shift to neutral, and place the motorcycle on its side stand.

  • Page 94: Drive Chain

    06/03/06 13:49:06 3CMCJ600_094 Roll the motorcycle forward. Stop. Check DRIVE CHAIN (Refer to the maintenance precautions on drive chain slack. Repeat this procedure page several times. Drive chain slack should The service life of the drive chain is remain constant. If the chain is slack only dependent upon proper lubrication and in certain sections, some links are kinked adjustment.
  • Page 95 06/03/06 13:49:10 3CMCJ600_095 Roll the motorcycle forward. Stop and place it on its side stand. Inspect the drive Worn Sprocket chain and sprockets for any of the Teeth Teeth following conditions: REPLACE REPLACE DRIVE CHAIN *Damaged Rollers *Loose Pins *Dry or Rusted Links *Kinked or Binding Links *Excessive Wear *Improper Adjustment...
  • Page 96 06/03/06 13:49:17 3CMCJ600_096 Adjustment: If the drive chain requires adjustment, the Drive chain slack should be checked and procedure is as follows: adjusted, if necessary, every 1,000 km (600 Place the motorcycle on its side stand miles). When operated at sustained high with the transmission in neutral and the speeds or under conditions of frequent ignition switch off.
  • Page 97 Recheck drive chain slack. If a torque wrench was not used for installation, see your Honda dealer as soon as possible to verify proper as- sembly.
  • Page 98 RK GB50HFOZ5 This motorcycle has a staked master link drive chain which requires a special tool for cutting and staking. Do not use an ordinary master link with this chain. See your Honda dealer. (1) Index mark (2) Red zone...
  • Page 99 06/03/06 13:49:34 3CMCJ600_099 Lubrication and cleaning: Lubricate every 1,000 km (600 miles) or sooner if chain appears dry. The O-rings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents. Clean the side surfaces of the chain with a dry cloth. Do not brush the rubber O-rings.

  • Page 100: Drive Chain Slider

    Check the chain slider (1) for wear. The chain slider must be replaced if it is worn to bottom of the wear indicator mark ( ). For replacement, see your Honda dealer. (1) Chain slider (2) Wear indicator mark...
  • Page 101 06/03/06 13:49:44 3CMCJ600_101 F R O N T A N D R E A R S U S P E N S I O N INSPECTION (Refer to the maintenance precautions on page Check the fork assembly by locking the front brake and pumping the fork up and down vigorously.

  • Page 102: Side Stand

    Lower the side stand. The engine should stop as you put the side stand down. (1) Side stand spring If the side stand system does not operate as described, see your Honda dealer for service.

  • Page 103: Wheel Removal

    This motorcycle is equipped with a side occurs, servicing of the brake system will stand only. Therefore, if front or rear be necessary. See your Honda dealer for wheel removal is required, it will be this service. necessary to raise the center of the motorcycle with a jack or other firm support.
  • Page 104 06/03/06 13:50:01 3CMCJ600_104 Loosen the right and left axle pinch bolts (3), and remove the axle bolt (5). Withdraw the front axle (4) and remove the front wheel. (3) Axle pinch bolts (5) Axle bolt (4) Front axle...
  • Page 105 (2). If a torque wrench was not used for Tighten the axle pinch bolt on the left installation, see your Honda dealer as fork leg to the specified torque: soon as possible to verify proper as- 22 N·m (2.2 kgf·m , 16 lbf·ft) sembly.
  • Page 106 If this wheel forward. occurs, servicing of the brake system will be necessary. See your Honda dealer for this service. (1) Rear axle nut (2) Lock nuts (4) Drive chain...
  • Page 107 If a torque wrench was not used for Make sure that the slot (8) on the installation, see your Honda dealer as swingarm (9) is located in the lug (10) in soon as possible to verify proper as- the brake caliper.

  • Page 108: Brake Pad Wear

    (page Front Brake Check the grooves ( ) in each pad. If either pad is worn to the bottom of the grooves, replace both pads as a set. See your Honda dealer for this service. (1) Wear indicator grooves...
  • Page 109 06/03/06 13:50:31 3CMCJ600_109 REAR BRAKE Rear Brake 〈 〉 Check the cutout ( ) in each pad. If either pad is worn to the cutout, replace both pads as a set. See your Honda dealer for this service. (2) Cutouts...
  • Page 110 (causing hard starting The battery contains sulf uric acid or other electrical troubles), contact your (electrolyte). Contact with skin or Honda dealer. eyes may cause severe burns. Wear protective clothing and a face shield. Removing the battery cap strip can −...
  • Page 111 06/03/06 13:50:45 3CMCJ600_111 Battery removal: Remove the front seat (page 53). Release the rings and remove the rubber band (1). Disconnect the negative ( ) terminal − lead ( ) from the battery first, then disconnect the positive ( ) terminal lead ＋...

  • Page 112: Fuse Replacement

    See your fire may result, causing a dangerous Honda dealer for repair. loss of lights or engine power. Turn the ignition switch OFF before checking or replacing the fuses to Blown fuse prevent accidental short-circuiting.
  • Page 113 06/03/06 13:50:56 3CMCJ600_113 Fuse box: The fuse box is located under the front seat. The specified fuses are: 10A , 20A Remove the front seat (page 53). Open the fuse box cover (1). Pull out the old fuse and install a new fuse. The spare fuse (2) are located in the fuse box.
  • Page 114 06/03/06 13:51:02 3CMCJ600_114 Main fuse A: The main fuse A (1) is located under the front seat. The specified fuse is: Remove the front seat (page 53). Disconnect the wire connector (2) of the starter magnetic switch. Pull out the old fuse and install a new fuse. The spare fuse (3) is located the starter magnetic switch holder.

  • Page 115: Stoplight Switch Adjustment

    06/03/06 13:51:08 3CMCJ600_115 STOPLIGHT SWITCH ADJUSTMENT (Refer to the maintenance precautions on page Check the operation of the stoplight switch ( ) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut ( ).

  • Page 116: Bulb Replacement

    06/03/06 13:51:14 3CMCJ600_116 BULB REPLACEMENT (Refer to the maintenance precautions on Be sure to turn the ignition switch OFF page when replacing the bulb. Do not use bulbs other than those specified. After installing a new bulb, check that the The light bulb becomes very hot while light operates properly.
  • Page 117 06/03/06 13:51:19 3CMCJ600_117 Headlight Bulb Pull off the socket (1) without turning. Remove the dust cover (2). Remove the bulb (4) while pressing down on the pin (3). Pull out the bulb (4) without turning. Install a new bulb in the reverse order of removal.
  • Page 118 06/03/06 13:51:23 3CMCJ600_118 Position Light Bulb (Except U type) Remove the inner panel (page 60). Pull the position light socket (1) and remove it. Pull out the bulb (2) without turning. Install a new bulb in the reverse order of removal.
  • Page 119 06/03/06 13:51:27 3CMCJ600_119 Stop/Taillight Bulb Open the rear seat (page 54). Turn the socket (1) 90° counterclockwise, then pull it out toward you. Pull out the bulb (2) without turning. Install a new bulb in the reverse order of removal. (1) Socket (2) Bulb...
  • Page 120 06/03/06 13:51:31 3CMCJ600_120 Front/Rear Turn Signal Bulb Remove the turn signal lens (1) from the turn signal by removing the screw (2). Slightly press in on the bulb (3) and turn in 90° counterclockwise. Remove the bulb. Install a new bulb in the reverse order of removal.
  • Page 121 06/03/06 13:51:42 3CMCJ600_121 CLEANING Clean your motorcycle regularly to protect After cleaning, rinse the motorcycle the surface finishes and inspect for damage, thoroughly with plenty of clean water. wear, and oil, coolant or brake fluid leakage. Strong detergent residue can corrode alloy parts.
  • Page 122 06/03/06 13:51:49 3CMCJ600_122 Dry the motorcycle, start the engine, and Painted Aluminum Wheel Maintenance let it run for several minutes. Aluminum may corrode from contact with dirt, mud, or road salt. Clean the wheels af ter riding through any of these substances.
  • Page 123 06/03/06 13:51:54 3CMCJ600_123 Aluminum Muffler Maintenance Aluminun corrodes when it comes in Avoid using steel wool, polishing contact with dust, mud and road salt. compounds, or wax on an aluminum To remove stains, use Scotch Brite Hand muffler. Steel wool may damage or 7447 (maroon) or equivalent.

  • Page 124: Storage Guide

    06/03/06 13:51:59 3CMCJ600_124 STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from Petrol is extremely flammable and is non-use of the motorcycle. In addition, explosive under certain conditions. necessary repairs should be made BEFORE Perform this operation in a well- storing the motorcycle;...
  • Page 125 06/03/06 13:52:05 3CMCJ600_125 To prevent rusting in the cylinders, Remove the battery. Store in an area perform the following: protected from freezing temperatures Remove the ignition coil connectors and direct sunlight. and ignition coils from the spark plugs. Slow charge the battery once a month. Using tape or string, secure the Wash and dry the motorcycle.

  • Page 126: Removal From Storage

    06/03/06 13:52:10 3CMCJ600_126 REMOVAL FROM STORAGE Uncover and clean the motorcycle. Change the engine oil if more than 4 months have passed since the start of storage. Charge the battery as required. Install the battery. Drain any excess aerosol rust-inhibiting oil from the fuel tank.

  • Page 127: Specifications & Dimensions

    06/03/06 13:52:21 3CMCJ600_127 SPECIFICATIONS DIMENSIONS Overall length 2,065 mm (81.3 in) Overall width 680 mm (26.8 in) Overall height 1,125 mm (44.3 in) Wheelbase 1,400 mm (55.1 in) … Except MX 1,395 mm (54.9 in) … MX WEIGHT Dry weight 170 kg (375 lbs) …...
  • Page 128 06/03/06 13:52:26 3CMCJ600_128 ENGINE Bore and stroke 74.0 × 54.0 mm (2.91 × 2.13 in) Compression ratio 11.3 : 1 Displacement 929 cm (56.7 cu-in) Spark plug Standard IUH27D (DENSO) For cold climate IUH24D (DENSO) (Below 5°C, 41°F) Idle speed 1,200 ±...

  • Page 129: Chassis And Suspension

    06/03/06 13:52:34 3CMCJ600_129 CHASSIS AND SUSPENSION Caster 23°45’ Trail 97 mm (3.8 in) Tyre size, front 120/70 ZR17 (58W) Tyre size, rear 190/50 ZR17 (73W) POWER TRANSMISSION Primary reduction 1.521 Gear ratio, 1st 2.692 1.933 1.600 1.400 1.286 1.190 Final reduction 2.625 …...
  • Page 130 06/03/06 13:52:43 3CMCJ600_130 ELECTRICAL Battery 12V 8.6AH − Generator 0.421 kW/5,000 min (rpm) LIGHTS Headlight 12V 55W − Tail/brake light 12V 21/5W − Turn signal light Front 12V 21W − Rear 12V 21W − Position light 12V 5W − …Except U FUSE Main fuse A Main fuse B...
  • Page 131 06/03/06 13:53:03 3CMCJ600_131 R A D I O T Y P E A P P R O V A L S O F IMMOBILIZER SYSTEM (HISS) The radio type approval label of immobilizer (Except MX, BR) system (HISS) ( ) is attached in front of the ignition switch( ).

  • Page 132: Catalytic Converter

    The catalytic converter acts on HC, CO, and the catalyst metals, making the catalytic NOx. A replacement unit must be an converter ineffective. original Honda part or its equivalent. Keep the engine tuned-up. The catalytic converter must operate at a high temperature for the chemical reactions Have your motorcycle diagnosed and to take place.

  • Page 133: Noise Control System (Australia Only)

    06/03/06 13:53:09 3CMCJ600_133 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners are warned that the law may prohibit : (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...

This manual is also suitable for:

Cbr900rr 1999

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