Table of Contents

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Contents
These pages give an overview of the contents
of your owner's manual. The first page of each
section lists the topics covered in that section.
Motorcycle Safety ......................................... 1
precautions about loading, accessories,
and modifications, and the location of
Operating Controls..................................... 11
The location, function, and operation of
the throttle, brakes, clutch, and other
basic controls.
Before Riding .............................................. 21
The importance of wearing a helmet
and other protective gear, plus how to
make sure you and your motorcycle are
ready to ride.
Contents
31KPS740
Basic Operation & Riding ..........................27
How to start and stop the engine, shift
gears, and brake. Also, riding
precautions.
Servicing Your Honda.................................39
Why your motorcycle needs regular
maintenance, what you need to know
before servicing your Honda, a
maintenance schedule, and instructions
for specific maintenance items.
2019 CRF230F
MOM 16533 (1712)

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Summary of Contents for Honda CRF230F 2019

  • Page 1: Table Of Contents

    Motorcycle Safety ......... 1 Why your motorcycle needs regular Important safety information, maintenance, what you need to know precautions about loading, accessories, before servicing your Honda, a and modifications, and the location of maintenance schedule, and instructions safety labels. for specific maintenance items.
  • Page 2 What to do if you have a flat tire, your engine won’t start, etc. Technical Information ......145 ID numbers, technical specifications, and other technical facts. Consumer Information......163 Information on warranties and how to get Honda service manuals. Contents...
  • Page 3 2019 Honda CRF230F OWNER’S MANUAL FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal.
  • Page 4 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.
  • Page 5 A Few Words About Safety 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. •...
  • Page 6: Introduction

    It’s full of facts, instructions, safety information, and helpful When you own a Honda, you’re part of a tips. To make it easy to use, the manual worldwide family of satisfied customers – people contains, a detailed list of topics at the who appreciate Honda’s reputation for building...
  • Page 7 If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction. Please report any change of address or...
  • Page 8: Motorcycle Safety

    Motorcycle Safety This section presents some of the most Important Safety Information......2 important information and recommendations to Loading, Accessories & Modifications...5 help you ride your motorcycle safely. Please Loading ............5 take a few moments to read these pages. This Accessories & Modifications ......7 section also includes information about the Safety Labels...........9 location of safety labels on your motorcycle.
  • Page 9: Important Safety Information

    Important Safety Information Your motorcycle can provide many years of Never Carry a Passenger Your motorcycle is designed for one person service and pleasure – if you take responsibility only. There are no handholds, footrests, or seat for your own safety and understand the for a second person –...
  • Page 10 Important Safety Information Take Time to Learn and Practice Be Alert for Off-road Hazards Developing off-road riding skills is a gradual, The terrain can present a variety of challenges step-by-step process. Start by practicing at low when you ride off-road. Continually ‘‘read’’ the speeds in a safe area and slowly build your terrain for unexpected turns, drop-offs, rocks, skills.
  • Page 11 So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your motorcycle properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base.
  • Page 12: Loading, Accessories & Modifications

    Loading, Accessories & Modifications Your Honda was designed as a rider-only More specific information on load limits, motorcycle. It was not designed to carry a accessories, and modifications follows. passenger or cargo. A passenger or cargo could interfere with your ability to move around to...
  • Page 13 Loading, Accessories & Modifications Load Limits • Place weight as close to the center of the Following are the load limits for your motorcycle as possible. motorcycle: • Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebar, fork, Maximum weight capacity or front fender.
  • Page 14: Accessories & Modifications

    Before you consider making any modifications and use of non-Honda accessories. Check with or adding an accessory, be sure to read the your dealer for assistance and always follow following information.
  • Page 15 Loading, Accessories & Modifications 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. We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark arrester or...
  • Page 16: Safety Labels

    Safety Labels This page shows the locations of safety labels on your motorcycle. Some labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your dealer for a replacement. (For USA) (For USA) (For Canada)
  • Page 17 BLANK PAGE Motorcycle Safety...
  • Page 18: Operating Controls

    Operating Controls When you ride off-road, you need to operate Operation Component Locations ....12 the throttle, clutch, brakes, and other controls Operating Controls ........15 without stopping to look at them. Read this Fuel Valve ..........15 section carefully before you ride. It describes Choke Lever..........16 the location, function, and operation of all the Ignition Switch..........17...
  • Page 19: Operation Component Locations

    Operation Component Locations ignition switch clutch lever front brake lever throttle grip engine stop start button button Operating Controls...
  • Page 20 Operation Component Locations rear brake pedal Operating Controls...
  • Page 21 Operation Component Locations fuel valve choke lever shift lever Operating Controls...
  • Page 22: Operating Controls

    Operating Controls Fuel Valve Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. LEFT SIDE Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor.
  • Page 23: Choke Lever

    Operating Controls The reserve fuel supply is: The choke lever (1) is used for starting the 0.42 US gal (1.6 ) engine (page 29). The choke increases the percentage of fuel in the fuel/air mixture The tank should be refilled as soon as possible after delivered to the engine.
  • Page 24: Ignition Switch

    Operating Controls FRONT Ignition Switch The ignition switch (1) is used to prevent unauthorized use of the motorcycle. Before riding, insert the key and turn it to the ON position. Function Key Removal Position The engine cannot be The key can operated.
  • Page 25: Start Button

    Operating Controls Start Button Front Brake Lever The start button is used for starting the engine. The front brake lever is used to slow or stop Pushing the button in starts the engine. See your motorcycle. To operate, pull the lever. For Starting Procedure, page 29.
  • Page 26: Clutch Lever

    Operating Controls Clutch Lever Rear Brake Pedal The clutch lever is used to disengage the clutch The rear brake pedal is used to slow or stop whenever you shift gears. To operate, pull the your motorcycle. To operate, depress the pedal. clutch lever in all the way before shifting, then For information on braking techniques, see slowly release it after shifting.
  • Page 27 BLANK PAGE Operating Controls...
  • Page 28: Before Riding

    Before Riding Before each ride, you need to make sure you Are You Ready to Ride? .......22 and your Honda are both ready to ride. To help Protective Apparel ........22 get you prepared, this section discusses how to Is Your Motorcycle Ready to Ride?....24 evaluate your riding readiness, and how to Pre-ride Inspection ........24...
  • Page 29: Are You Ready To Ride

    Are You Ready to Ride? Before you ride your motorcycle for the first Protective Apparel time, we strongly recommend that you: • read this owner’s manual For your safety, we strongly recommend that • make sure you understand all the safety you always wear an approved motorcycle messages helmet, eye protection, boots, gloves, long...
  • Page 30 Are You Ready to Ride? (USA only). Always wear a face shield or goggles to protect your eyes and help your Not wearing a helmet increases the vision. chance of serious injury or death in a crash. Additional Riding Gear In addition to a helmet and eye protection, we Be sure you always wear a helmet, eye also recommend:...
  • Page 31: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Before each ride, it’s important to inspect your Pre-ride Inspection motorcycle and make sure any problem you find is corrected. A pre-ride inspection is a Check the following items before you get on must because off-road riding can be tough on a the motorcycle: motorcycle and you don’t want to have a breakdown far from help.
  • Page 32 Is Your Motorcycle Ready to Ride? Engine Oil Check the level and add oil if Cables Check the cable housings for needed (page 65). wear. Check the fittings for looseness. Replace or tighten as Fuel Check the level and add fuel needed.
  • Page 33 Is Your Motorcycle Ready to Ride? Check these items after you get on the Clutch Check for smooth operation and motorcycle: Lever adjust if needed (page 76). Throttle Check the freeplay and adjust if needed. Rotate the throttle to Remember, be sure to take care of any problem make sure it moves smoothly you find or have your dealer correct it before without sticking, and snaps shut...
  • Page 34: Basic Operation & Riding

    Tips & Practice Guide Braking............35 for the Off-Highway Motorcyclist booklet that Parking ............37 came with your Honda (USA only). Post-ride Inspection........38 To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page 153).
  • Page 35: Safe Riding Precautions

    Basic Operation & Riding Safe Riding Precautions Running the engine of your motorcycle Before riding your motorcycle for the first while in an enclosed or even partially time, please review the Important Safety enclosed area can cause a rapid Information beginning on page 2 and the build-up of toxic carbon monoxide gas.
  • Page 36: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Starting Procedure described below. To restart a warm engine, follow the procedure Your motorcycle can be started with the for High Air Temperature. transmission in gear by pulling in the clutch To start a cold engine, follow the procedure for lever before operating the starter.
  • Page 37 Starting & Stopping the Engine 2. With the throttle slightly open, press the start High Air Temperature button. 35°C (95°F) or above 3. Immediately after the engine starts, push the 1. Do not use the choke. 2. With the throttle slightly open, press the start choke lever down to the halfway position (B).
  • Page 38: Flooded Engine

    Starting & Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine: 1. Push the choke lever down all the way to OFF. 2. Open the throttle fully. 3.
  • Page 39: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine To stop the engine, shift into neutral, push the engine stop button in, and hold it in until the engine stops. Basic Operation & Riding...
  • Page 40: Shifting Gears

    Shifting Gears 3. Depress the shift lever from neutral down to first gear. 4. Release the front brake. Gradually open the throttle while you slowly release the clutch lever. If engine rpm (speed) is too low when you release the clutch lever, the engine will stall. If engine rpm is too high or you release the clutch lever too quickly, your motorcycle may lurch forward.
  • Page 41 Shifting Gears 6. To continue shifting up to each higher gear, NOTICE repeat step 5. Downshifting can help slow your motorcycle, 7. To shift down to a lower gear, close the especially on downhills. However, downshifting throttle, pull the clutch lever in, and depress when engine rpm is too high can cause engine the shift lever.
  • Page 42: Braking

    Braking To slow or stop, apply the front brake and rear Generally, reduce your speed or complete brake smoothly, while downshifting to match braking before beginning a turn. Avoid braking your speed. Gradually increase braking as you or closing the throttle quickly while turning. feel the brakes slowing your speed.
  • Page 43 Braking When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. When you brake to a stop, pull the clutch lever in before stopping completely to prevent stalling the engine. For support, put your left foot on the ground first, then your right foot when you have finished braking.
  • Page 44: Parking

    Parking Lower the side stand to support your motorcycle. Turn the ignition switch OFF and remove the key. If you’re finished riding for the day, also turn the fuel valve OFF. Always choose a level place to park. Basic Operation & Riding...
  • Page 45: Post-Ride Inspection

    Post-ride Inspection When you return home after riding, thoroughly clean your motorcycle and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way. After cleaning, carefully inspect your motorcycle for leaks or damage. Be sure to lubricate the drive chain (page 110) to prevent rusting.
  • Page 46: Servicing Your Honda

    Maintenance Schedule are ‘‘certified’’ to EPA standards. for required servicing and step-by-step instructions for specific maintenance tasks. Before You Service Your Honda You’ll also find important safety precautions, The Importance of Maintenance ....41 information on oils, and tips for keeping your Maintenance Safety........43...
  • Page 47 Servicing Your Honda Service Preparations Engine Maintenance Component Locations ..... 53 Throttle............73 Tools ............. 56 Clutch System ..........76 Side Cover Removal........57 Engine Idle Speed .........79 Spark Plug .............80 Service Procedures Spark Arrester ..........82 Fluids & Filters Fuel ............... 59 Chassis Engine Oil.............
  • Page 48 More frequent service is needed if you subject Always follow the inspection and your motorcycle to severe use (see the maintenance recommendations and Competition Inspection checklist, page 50) or schedules in this owner’s manual. ride in unusually wet or dusty areas. Servicing Your Honda...
  • Page 49 The Importance of Maintenance Remember, proper maintenance is the owner’s responsibility. Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section. Servicing Your Honda...
  • Page 50 Always follow the procedures and precautions in this owner’s manual. Injury from moving parts. Do not run the engine unless instructed to do so. (cont’d) Servicing Your Honda...
  • Page 51 Maintenance Safety • Read the instructions before you begin, and • Remember that your Honda dealer knows make sure you have the tools and skills your motorcycle best and is fully equipped to required. maintain and repair it. To ensure the best •...
  • Page 52 If you do not feel capable of performing a given task or need assistance, remember that your The Maintenance Schedule also includes items Honda dealer knows your motorcycle best and that involve more extensive procedures and is fully equipped to maintain and repair it. If...
  • Page 53 I: inspect and clean, adjust, lubricate, or owner has the proper tools and service data and is mechanically qualified. Refer to the replace, if necessary official Honda Service Manual (page 164). C: clean **In the interest of safety, we recommend these A: adjust items be serviced only by your dealer.
  • Page 54 * Should be serviced by your dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 164). ** In the interest of safety, we recommend these items be serviced only by your dealer.
  • Page 55 * Should be serviced by your dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 164). ** In the interest of safety, we recommend these items be serviced only by your dealer.
  • Page 56 Months 600 (1,000) or 6 1,200 (2,000) or 12 1,800 (3,000) or 18 2,400 (4,000) or 24 3,000 (5,000) or 30 3,600 (6,000) or 36 4,200 (7,000) or 42 4,800 (8,000) or 48 5,400 (9,000) or 54 Servicing Your Honda...
  • Page 57 Refer to Page: all pre-ride inspection items engine oil contaminants change fuel line deterioration, damage, or leakage replace – valve clearance correct clearance adjust – engine idle speed correct idle speed adjust carburetor choke proper operation – – Servicing Your Honda...
  • Page 58 NOTE 1: Competition use may cause more rapid clutch disc wear. Refer to the official Honda Service Manual, or see your dealer for clutch disassembly and wear inspection. Servicing Your Honda...
  • Page 59 25.1 in (637 mm) / 41 pins drive chain: replace max. length/pin sprockets wear and secure installation replace or tighten seat security tighten – control cables smooth operation, kinks and correct lubricate or – routing replace engine mounting bolts tightness tighten – Servicing Your Honda...
  • Page 60: Maintenance Component Locations

    Maintenance Component Locations front brake fluid reservoir clutch lever front brake lever throttle grip fuel fill cap Servicing Your Honda...
  • Page 61 Maintenance Component Locations engine oil fill cap/dipstick spark plug air cleaner spark arrester rear brake pedal Servicing Your Honda...
  • Page 62 Maintenance Component Locations throttle stop screw battery (engine idle speed) main fuse choke lever crankcase breather tube engine oil drain bolt front brake caliper drive chain Servicing Your Honda...
  • Page 63: Tools

    Refer to Safety Precautions on page 43. The spoke wrench is delivered with your motorcycle for tightening or loosening the spokes (USA only). You will need to provide your own tools to perform any other owner maintenance. (1) spoke wrench Servicing Your Honda...
  • Page 64: Side Cover Removal

    2. Align the side cover prongs with the rubber grommets. Press the side cover into position. 3. Install the securing screw and tighten it. (1) right side cover (3) side cover prongs (2) screw (4) rubber grommets Servicing Your Honda...
  • Page 65 Press the side cover into position. 3. Install the securing screw, bolts, and collar and tighten them. (1) left side cover (5) bolt B (2) screw (6) side cover prongs (3) bolt A (7) rubber grommets (4) collar Servicing Your Honda...
  • Page 66: Fuel

    Fuel Recommendation of gasoline. If pinging or spark knock persists, consult your dealer. premium unleaded Type Use only unleaded fuel in your Honda. If you 91 (or higher) Pump Octane ride your Honda in a country where leaded fuel Number...
  • Page 67 • Stop the engine and keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. (1) fuel fill cap (3) steering stem nut (2) breather tube (4) bottom of the filler neck Servicing Your Honda...
  • Page 68 3. After refueling, turn the fuel fill cap clockwise until it is secure. 4. Insert the breather tube in the steering stem nut. If you replace the fuel fill cap, use only a Honda Genuine replacement part. Servicing Your Honda...
  • Page 69: Engine Oil

    Running the engine with insufficient oil can label cause serious damage to the engine and SAE 10W-30 transmission. viscosity (weight) JASO T 903 standard Pro Honda GN4 suggested oil 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil...
  • Page 70 API service label. a circular API ‘‘energy conserving’’ or ‘‘resource conserving’’ service label on the container. They may affect lubrication and clutch performance. NOT RECOMMENDED RECOMMENDED • Do not use non-detergent, vegetable, or castor based racing oils. (cont’d) Servicing Your Honda...
  • Page 71 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) oil code (2) oil classification Servicing Your Honda...
  • Page 72 8. Insert the oil fill cap/dipstick and screw it in (3) lower level mark tightly. 1. Park your motorcycle on a firm, level 9. Check for oil leaks. surface. 2. Clean around the oil fill cap/dipstick (1) and nearby surfaces. Servicing Your Honda...
  • Page 73 6. Pour the drained oil into a suitable container and dispose of it in an approved manner (page 129). NOTICE Improper disposal of drained fluids is harmful to the environment. (1) oil drain bolt (3) spring (2) O-ring (4) oil strainer screen Servicing Your Honda...
  • Page 74 11 lbf∙ft (15 N∙m, 1.5 kgf∙m) 12.Pour the recommended oil into the crankcase, approximately: 1.1 US qt (1.0 ) 13.Install the oil fill cap/dipstick securely. 14.Start the engine and let it idle for 3-5 minutes. Stop the engine. Wait 2-3 minutes. Servicing Your Honda...
  • Page 75: Air Cleaner

    Improper or lack of proper air cleaner maintenance can cause poor performance and Your motorcycle’s air cleaner has very specific premature engine wear. performance requirements. Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality. Servicing Your Honda...
  • Page 76 3. Unhook the set spring (3), take care to avoid bending the set spring and set spring holder (4). 4. Remove the air cleaner (5). (1) screws (2) air cleaner housing cover (3) set spring (4) set spring holder (5) air cleaner (cont’d) Servicing Your Honda...
  • Page 77 8. Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil. (5) air cleaner (7) tabs (6) air cleaner holder (8) air cleaner holes Servicing Your Honda...
  • Page 78 Air Cleaner 9. Pour clean Pro Honda Foam Filter Oil or an 14.Install the air cleaner housing cover and equivalent (Canada: Honda Foam Filter Oil screws. or an equivalent) over the entire surface of 15.Install the right side cover (page 57).
  • Page 79: Crankcase Breather

    • Drain the deposits into a suitable container by pinching the crankcase breather tube (1). Service more frequently if your motorcycle is ridden in the rain or often at full throttle. LEFT SIDE (1) crankcase breather tube Servicing Your Honda...
  • Page 80: Throttle

    1. Pull the rubber dust cover (1) back. Inspection 2. Loosen the upper lock nut (2) on the throttle Check freeplay (1). Freeplay: 1/16–1/4 in (2–6 mm) cable mechanism. 3. Turn the upper adjuster (3). If necessary, adjust to the specified range. (cont’d) Servicing Your Honda...
  • Page 81 (4) lower lock nut (5) lower adjuster 1. Loosen the lower lock nut (4). 2. Turn the lower adjuster (5). 3. Tighten the lock nut. If you can’t get the freeplay within the specified range, contact your dealer. Servicing Your Honda...
  • Page 82 1. Check that the throttle assembly is positioned properly and the securing bolts are tight. 2. Check for smooth rotation of the throttle (1) from fully open to fully closed in all steering positions. If there is a problem, see your dealer. Servicing Your Honda...
  • Page 83: Clutch System

    1. Pull the rubber dust cover (2) back. If necessary, adjust to the specified range. 2. Loosen the upper lock nut (3). 3. Turn the upper clutch cable adjuster (4) to Improper freeplay adjustment can cause obtain the specified freeplay. premature clutch wear. Servicing Your Honda...
  • Page 84 4. Turn the lower adjusting nut to obtain the RIGHT SIDE specified freeplay. 5. Hold the lower adjusting nut and tighten the lower lock nut. Check the adjustment. (–) (5) lower adjusting nut (+) increase freeplay (6) lower lock nut (–) decrease freeplay (cont’d) Servicing Your Honda...
  • Page 85 • Lubricate the clutch cable with a kinked or worn, or the clutch discs may be commercially available cable lubricant to worn. See your dealer or refer to the official prevent premature wear and corrosion. Honda Service Manual (page 164). Servicing Your Honda...
  • Page 86: Engine Idle Speed

    2. Connect a tachometer, following the tachometer manufacturer’s instructions. 3. Adjust idle speed with the throttle stop screw (–) (1). Idle Speed: 1,400±100 rpm (1) throttle stop screw (+) increase rpm (–) decrease rpm Servicing Your Honda...
  • Page 87: Spark Plug

    Standard DPR8EA-9 (NGK) or X24EPR-U9 (DENSO) For cold climate DPR7EA-9 (NGK) or (below 5°C, 41°F) X22EPR-U9 (DENSO) (1) center electrode (3) spark plug gap (2) side electrode 1. Clean any dirt from around the spark plug base. Servicing Your Honda...
  • Page 88 6. With the plug washer attached, thread the spark plug in by hand (to prevent 8. Reinstall the spark plug cap. Take care to cross-threading). avoid pinching any cables or wires. Servicing Your Honda...
  • Page 89: Spark Arrester

    (1) bolts (3) gasket reaching the environment. (2) spark arrester (4) muffler 1. Allow the engine and muffler to cool. 2. Remove the bolts (1), the spark arrester (2), and the gasket (3) from the muffler (4). Servicing Your Honda...
  • Page 90 10 lbf∙ft (14 N∙m, 1.4 kgf∙m) avoid damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necessary. (5) spark arrester screen Servicing Your Honda...
  • Page 91: Suspension

    (1) mounting bolts 1. Check fork operation. Pull the front brake lever in, to lock the brake. Then pump up and down on the fork legs several times. The suspension should function smoothly. There should be no oil leakage. Servicing Your Honda...
  • Page 92 1. Place the motorcycle on a maintenance stand. Push hard against the side of the rear wheel and feel for any freeplay which indicates worn swingarm bearings (1). (1) swingarm bearing (2) shock absorber attachment points (cont’d) (3) suspension linkage attachment points Servicing Your Honda...
  • Page 93 (2) and rear suspension linkage attachment points (3) are secure. 3. Check for oil leaks in the shock absorber. If any rear suspension components appear worn or damaged, see your dealer for further inspection. Servicing Your Honda...
  • Page 94: Brakes

    See your dealer to have the air bled from the system. Never use adjusters other than those designed for this motorcycle. Install a new adjuster from the lever side with the lock nut under the head of the adjuster. (cont’d) Servicing Your Honda...
  • Page 95 If brake lever freeplay is not within this It should be above the LWR mark (1). If the range, see your dealer. level is at or below the LWR mark, check the brake pads for wear (page 90). Servicing Your Honda...
  • Page 96 • Make sure there are no fluid leaks. for leaks. • Check for deterioration or cracks in the hoses and fittings. The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an equivalent. NOTICE Brake fluid can damage plastic and painted surfaces.
  • Page 97 More About: Brake Fluid Brake fluid should be added and replaced by your dealer. The recommended brake fluid is Honda DOT 4 Brake Fluid, or any brake fluid of equal quality and performance. Use fresh brake fluid from a sealed container.
  • Page 98 Repeat engage. Freeplay: 13/16–1 3/16 in (20–30 mm) this procedure several times. 3. Check the freeplay. If you can’t adjust the If necessary, adjust to the specified range. freeplay properly, see your dealer. (cont’d) Servicing Your Honda...
  • Page 99 RIGHT REAR (2) rear brake adjusting nut (4) brake arm (3) brake arm pin After adjustment, confirm the freeplay of the (1) arrow (3) reference mark brake pedal. (2) brake arm (4) brake panel Servicing Your Honda...
  • Page 100 • Make sure the brake rod, brake arm, spring, and fasteners are in good condition. 1. Loosen the lock nut (1) and turn the stopper bolt (2). 2. Tighten the lock nut. 3. Check the freeplay (page 91). Servicing Your Honda...
  • Page 101: Wheels

    Excessively loose spokes may result in instability at high speeds and the possible loss of control. Neglecting this maintenance may also cause rim or spoke damage. It’s also important that the rim locks are secure to prevent tire slippage. Servicing Your Honda...
  • Page 102 3. Rotate the wheel slowly to see if it appears to ‘‘wobble.’’ If it does, the rim is out of round or not ‘‘true.’’ If the wobble is noticeable, see your dealer for inspection. (1) wheel rim (2) spoke (3) rim lock Servicing Your Honda...
  • Page 103 The result will be loss of brake fluid. If this occurs, the brake system will require service. See your dealer for this service. (1) axle holder nuts (2) axle holder (3) front axle shaft Servicing Your Honda...
  • Page 104 3. Tighten the front axle shaft to the specified verify proper assembly. Improper assembly torque: 54 lbf∙ft (73.5 N∙m, 7.5 kgf∙m) may lead to loss of braking capacity. Servicing Your Honda...
  • Page 105 Remove the wheel and side collar. (3) brake arm (6) chain adjusters Take care to prevent getting grease, oil, or dirt on the brake shoe surfaces. This can cause poor brake performance or rapid brake shoe wear after reassembly. Servicing Your Honda...
  • Page 106 If a torque wrench was not used to install the (7) lug (8) slot wheel, see your dealer as soon as possible to (9) brake panel verify proper assembly. Improper assembly may lead to loss of braking capacity. Servicing Your Honda...
  • Page 107: Tires & Tubes

    Make sure the valve stem caps are secure. If necessary, install new caps. The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, Servicing Your Honda...
  • Page 108 The correct ‘‘cold’’ tire pressures are: 15 psi (100 kPa, 1.0 kgf/cm Front 15 psi (100 kPa, 1.0 kgf/cm Rear If you decide to adjust tire pressures for a particular riding condition, make changes a little at a time. (1) tread depth Servicing Your Honda...
  • Page 109 Replacing a tube requires removing and inside the tire or the tire is slipping on the reinstalling the wheel. Any time a tube is rim. See your dealer. replaced, carefully inspect the tire as described on page 101. Servicing Your Honda...
  • Page 110 This can cause a crash in • We recommend that tires be replaced by your which you can be seriously hurt or dealer. killed. Always use the size and type of tires recommended in this owner’s manual. Servicing Your Honda...
  • Page 111: Side Stand

    LEFT SIDE 2. Check the side stand assembly for freedom of movement. If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with clean engine oil. (1) side stand spring Servicing Your Honda...
  • Page 112: Drive Chain

    1. Check slack in the lower drive chain (1) run drive chain to perform the recommended midway between the sprockets. Drive chain service in the Maintenance Schedule. slack should allow the following vertical movement by hand: 13/16–1 3/16 in (20–30 mm) (cont’d) Servicing Your Honda...
  • Page 113 • damaged or missing O-rings Replace the drive chain (page 111) if it has damaged rollers, loose pins, or kinks that cannot be freed. Lubricate the drive chain (page 110) if it appears dry or shows signs of Servicing Your Honda...
  • Page 114 Excessive slack cutting and staking. Do not use an ordinary indicates the chain is worn beyond its service master link with this chain. limit. (cont’d) Servicing Your Honda...
  • Page 115 If necessary, have Use of a new chain with worn sprockets will your dealer replace a worn sprocket. cause rapid chain wear. Worn Sprocket Damaged Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth GOOD Servicing Your Honda...
  • Page 116 If a torque wrench is not used for this (1) rear axle shaft (2) rear axle nut installation, see your dealer as soon as possible (3) chain adjusters to verify proper assembly. (4) index marks (5) stopper pins Servicing Your Honda...
  • Page 117 Drive Chain Recommended lubricant: Pro Honda HP Chain Lubrication Lube or equivalent. Commercial chain lubricants not designed for motorcycle drive chains may contain solvents which could damage the O-rings. Lubricate every 300 miles (500 km) or sooner if chain appears dry.
  • Page 118 Use of a solvent may also damage the O-rings. 2. Inspect the drive chain for possible wear or damage. Replace the drive chain if it has damaged rollers, loose fitting links, or otherwise appears unserviceable. Replacement chain: DID 520VD Servicing Your Honda...
  • Page 119: Battery

    If you have electrical accessories on your compounds. Wash hands after handling. motorcycle or do not ride frequently, we recommend that you charge the battery frequently (see Battery Charging, page 116). Servicing Your Honda...
  • Page 120 Wear protective clothing and a face shield, or have a skilled mechanic do You will get the best storage results from the battery maintenance. removing the battery and slow charging it every 30 days (see Battery Charging, page 116). Servicing Your Honda...
  • Page 121 1. Make sure the ignition switch is OFF. compartment. 2. Remove the left side cover (page 58). 3. Remove the battery holder (1). LEFT SIDE (1) battery holder (2) negative (–) terminal lead (3) positive (+) terminal lead (4) battery Servicing Your Honda...
  • Page 122 8. Clean the battery box after removing the battery for storage. Dry the battery box and, if paint is missing, re-paint the area. 9. Slow charge the battery (see following section) once every 30 days. Servicing Your Honda...
  • Page 123 Battery We recommend using a charger (1) designed Battery Charging specifically for your Honda, which can be purchased from your dealer. These units can be Refer to Safety Precautions on page 43. left connected for long periods without risking damage to the battery. However, do not...
  • Page 124: Appearance Care

    Refer to Safety Precautions on page 43. General Recommendations Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning • To clean your motorcycle, you may use: ─ water also identifies you as an owner who values your ─...
  • Page 125 4. After washing, rinse your motorcycle • carburetor thoroughly with plenty of clean water to NOTICE remove any residue. Detergent residue can corrode alloy parts. High pressure water (or air) can damage certain parts of your motorcycle. Servicing Your Honda...
  • Page 126 8. As a precaution, ride at a slow speed and contact your dealer. apply the brakes several times. This will help dry the brakes and restore normal braking performance. Servicing Your Honda...
  • Page 127 Dry with a soft, clean cloth. Do not use polishing compounds or wax containing polishing compounds. These can damage or discolor the paint. To keep your Honda looking new, clean and polish it frequently. Servicing Your Honda...
  • Page 128: Tips

    Here’s helpful advice on how to prepare for an Preparing for a Ride ........122 off-road adventure, how to transport and store Transporting Your Honda ......124 your Honda, and how to be an environmentally Storing Your Honda ........126 responsible motorcycle owner. You & the Environment ......129...
  • Page 129: Preparing For A Ride

    Preparing for a Ride A safe and enjoyable ride begins with good What to Take to the Riding Area planning and preparation. Always ride with at least one other person in case you have trouble, Along with your motorcycle and riding gear, and let someone know where you’re going and you should take along some tools and supplies when you expect to return.
  • Page 130 Preparing for a Ride For safety, all refueling should be done at a gas If you decide to take some tools, spare parts, or station on the way to the riding area or at your other supplies on the trail, be sure you can carry base camp.
  • Page 131: Transporting Your Honda

    Transporting Your Honda If you use a truck or motorcycle trailer to transport your Honda, we recommend that you follow these guidelines: • Use a loading ramp. • Make sure the fuel valve is off. • Secure the motorcycle in an upright position, using motorcycle tie-down straps.
  • Page 132 Transporting Your Honda Check that the tie-down straps do not contact any control cables or electrical wiring. Tighten both straps until the front suspension is compressed about half-way. Too much pressure is unnecessary and could damage the fork seals. Use another tie-down strap to keep the rear of the motorcycle from moving.
  • Page 133: Storing Your Honda

    If you won’t be riding for an extended period, For more information about storage, refer to the such as during the winter, thoroughly inspect Honda Winter Storage Guide, available from your motorcycle and correct any problem your dealer (USA only).
  • Page 134 Storing Your Honda 4. Drain the carburetor into an approved Preparation for Storage gasoline container and dispose of it in an approved manner (page 129). If storage will 1. Change the engine oil (page 66). last longer than one month, carburetor 2.
  • Page 135 Storing Your Honda 5. Remove the battery and charge it fully. Store Removal from Storage it in an area protected from freezing temperatures and direct sunlight. Slow 1. Uncover and clean your motorcycle. charge the battery (page 116) once a month.
  • Page 136: You & The Environment

    You & the Environment Owning and riding a motorcycle can be • Choose Sensible Cleaners. Use a enjoyable, but you must do your part to protect biodegradable detergent when you wash your nature. When you show respect for the land, motorcycle.
  • Page 137 You & the Environment • Recycle Wastes. It’s illegal and thoughtless to put used engine oil in the trash, down a drain, or on the ground. Used oil, gasoline, and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water, lakes, rivers, and oceans.
  • Page 138: Taking Care Of The Unexpected

    Taking Care of the Unexpected With all the challenges you can encounter General Guidelines........132 off-road, there’s a chance that sometime If Your Engine Quits or Won’t Start...133 something may go wrong. This section gives If You Have a Flat Tire .......137 practical advice to help you deal with a wide If a Fuse Blows ...........138 range of problems.
  • Page 139: General Guidelines

    Taking Care of the Unexpected If a problem is relatively minor and you have General Guidelines the tools, supplies, and skills to make a permanent repair, you may be able to fix it on If something goes wrong during a ride, the first the trail and continue riding.
  • Page 140: If Your Engine Quits Or Won't Start

    Taking Care of the Unexpected • If the problem is relatively minor and you If you have a problem starting the engine – or have the tools, supplies, and skills to make a experience poor engine performance – the temporary repair, be sure to have permanent following information may help you.
  • Page 141 Taking Care of the Unexpected SYMPTOM: Starter motor doesn’t operate. POSSIBLE CAUSE WHAT TO DO ignition switch OFF Turn the ignition switch ON. transmission not in neutral Shift into neutral. blown fuse Replace with a new fuse of the same rating (page 138). battery lead loose Tighten the battery lead.
  • Page 142 Taking Care of the Unexpected SYMPTOM: Starter motor works, but the engine won’t start. POSSIBLE CAUSE WHAT TO DO out of fuel Fill the fuel tank. flooded engine See Flooded Engine (page 31). loose or unconnected spark Install the spark plug cap securely. If the engine still won’t plug cap start, see your dealer.
  • Page 143 Taking Care of the Unexpected SYMPTOM: Engine starts, but runs poorly. (cont’d) POSSIBLE CAUSE WHAT TO DO sooty exhaust (rich fuel See your dealer. mixture) detonates or pings under load If applicable, switch to the recommended octane gasoline (page 59) or change your brand of gasoline. If the problem persists, see your dealer.
  • Page 144: If You Have A Flat Tire

    Taking Care of the Unexpected If the leak is more serious, or a temporary If You Have a Flat Tire repair doesn’t hold, the tube must be replaced. The tire will also need to be replaced if it is How you handle a flat tire on the trail depends damaged (page 103).
  • Page 145: If A Fuse Blows

    Taking Care of the Unexpected If a Fuse Blows Riding your motorcycle with a All of the electrical circuits on your motorcycle temporary tire repair can be risky. have a fuse to protect them from damage If the temporary repair fails, you can caused by excess current flow (short circuit or crash and be seriously injured or killed.
  • Page 146 Taking Care of the Unexpected The fuse is located behind the left side cover. LEFT SIDE Recommended Fuse main fuse 7.5 A 1. To prevent an accidental short circuit, turn the ignition switch OFF before checking or replacing the fuse. 2.
  • Page 147: If You Crash

    Taking Care of the Unexpected If there is minor damage, or you are unsure If You Crash about possible damage but decide to try riding the motorcycle back to your base, ride slowly Personal safety is your first priority after a and cautiously.
  • Page 148: If You Lose Your Key

    If you don’t know your key number, call the dealer where you purchased your Honda. They may have it listed in their records. If they don’t, transport your motorcycle to them or the nearest dealer.
  • Page 149: If A Component Fails

    Taking Care of the Unexpected • If any component of the front brake system is If a Component Fails damaged, you may be able to ride carefully back to your base using the rear brake for The drive chain, brake lever or pedal, control slowing or stopping.
  • Page 150: If Your Battery Is Low (Or Dead)

    Taking Care of the Unexpected If Your Battery Is Low (or Dead) Jump starting is not recommended, especially if you use an automobile battery. The greater amperage of an automobile battery when the car engine is running can damage your motorcycle’s electrical system.
  • Page 151 BLANK PAGE Taking Care of the Unexpected...
  • Page 152: Technical Information

    Technical Information This section contains dimensions, capacities, Vehicle Identification........146 and other technical data, plus information on Specifications ..........148 government requirements and how to break-in Break-in Guidelines ........153 your motorcycle. High Altitude Carburetor Adjustment..154 Emission Control Systems ......155 Oxygenated Fuels........160 Technical Information...
  • Page 153: Vehicle Identification

    Vehicle Identification RIGHT SIDE Serial Numbers The VIN and engine serial number are required when you register your motorcycle. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of the manual.
  • Page 154 Vehicle Identification The engine number (2) is stamped on the left LEFT SIDE side of the engine. (2) engine number Technical Information...
  • Page 155: Specifications

    Specifications Dimensions Fuel & Lubricants 81.1 in (2,059 mm) 1.85 US gal (7.0 ) Overall length Fuel tank capacity including reserve 31.5 in (801 mm) Overall width 0.42 US gal (1.6 ) 45.9 in (1,167 mm) Fuel tank reserve Overall height premium unleaded 54.0 in (1,372 mm) Fuel...
  • Page 156 Specifications Fuel & Lubricants Fuel & Lubricants API Service Pro Honda (USA only) Engine oil Air cleaner oil Classification SG or or Honda Foam Filter recommendation higher except oils Oil or an equivalent labeled as energy conserving or resource Capacities conserving on the operator only;...
  • Page 157 Specifications Engine Specifications Power Transmission Intake: 0.004 in 3.090 Valve clearance Primary reduction (0.10 mm) (cold) 2.769 Gear ratio, 1st Exhaust: 0.004 in 1.941 (0.10 mm) 1.450 DPR8EA-9 (NGK) or Spark plug 1.148 X24EPR-U9 (DENSO) (standard) 0.960 DPR7EA-9 (NGK) or Spark plug 0.812 X22EPR-U9 (DENSO)
  • Page 158 Specifications Power Transmission Chassis & Suspension 13/16–1 3/16 in 45 ’ ° Drive chain Caster (20–30 mm) freeplay 4.4 in (111 mm) Trail 25.0 in (635 mm) New chain length 80/100-21 51R NHS Tire size, front distance between a 100/100-18 59R NHS Tire size, rear span of 41 pins bias-ply, tube...
  • Page 159 Specifications Electrical Torque Specifications YTX5L–BS 11 lbf∙ft Battery Oil drain bolt 12 V–4 Ah (10HR) (15 N∙m, 1.5 kgf∙m) 0.06 kW/5,000 rpm 10 lbf∙ft Generator Spark arrester (14 N∙m, 1.4 kgf∙m) mount bolts 54 lbf∙ft Front wheel axle Fuse (73.5 N∙m, 7.5 kgf∙m) 7.5 A Main 9 lbf∙ft...
  • Page 160: Break-In Guidelines

    Break-in Guidelines Help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. Technical Information...
  • Page 161: High Altitude Carburetor Adjustment

    High Altitude Carburetor Adjustment At high altitude, the standard carburetor Even with carburetor modification, engine air-fuel mixture will be too rich. Performance horsepower will decrease about 3.5% for each will decrease, and fuel consumption will 1,000-foot (300-meter) increase in altitude. The increase.
  • Page 162: Emission Control Systems

    Emission Control Systems Exhaust Emission Requirements (For Canada) The U.S. Environmental Protection Agency (EPA), and Environment and Climate Control Canada (ECCC) require that your motorcycle comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided.
  • Page 163 Crankcase Emission Control System Honda Motor Co., Ltd. utilizes various systems The engine is equipped with a closed crankcase to reduce carbon monoxide, oxides of nitrogen system to prevent discharging crankcase and hydrocarbons.
  • Page 164 Emission Control Systems Noise Emission Control System AMONG THOSE ACTS PRESUMED TO TAMPERING WITH THE NOISE CONTROL CONSTITUTE TAMPERING ARE THE SYSTEM IS PROHIBITED: U. S. federal law ACTS LISTED BELOW: prohibits, or Canadian provincial laws may • Removal of, or puncturing the muffler, prohibit the following acts or the causing baffles, header pipes, or any other component thereof: (1) The removal or rendering...
  • Page 165 Honda Motorcycle Dealer: vehicle is to be used for competition only. 1. Hard starting or stalling after starting 2.
  • Page 166 Emission Control Systems Fuel Permeation Emission Control System This vehicle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), and Environment and Climate Control Canada (ECCC). The fuel tank, fuel hoses, and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control technologies.
  • Page 167: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended ETHANOL (ethyl or grain alcohol) up to 10% with alcohol or an ether compound. These by Volume gasolines are collectively referred to as You may use gasoline containing up to 10% oxygenated fuels. To meet clean air standards, ethanol by volume.
  • Page 168 Oxygenated Fuels If you notice any undesirable operating NOTICE symptoms, try another service station or switch Oxygenated fuels can damage paint and to another brand of gasoline. plastic. Damage caused by spilled fuel is not Fuel system damage or performance problems covered under warranty.
  • Page 169 BLANK PAGE Technical Information...
  • Page 170: Consumer Information

    Consumer Information This section contains information on your Authorized Manuals ........164 warranty and how to get an official Honda Warranty Coverage ........165 service manual. Warranty Service.........166 Contacting Honda ........167 Your Honda Dealer ........168 Consumer Information...
  • Page 171: Authorized Manuals

    Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized manuals.) Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems on Honda motorcycles, scooters, ATVs, SxSs, and PWCs.
  • Page 172: Warranty Coverage

    However, you should have the proper tools and Please read the Warranties Booklet given to service information and be mechanically you by your Honda dealer at the time of qualified. Failures that occur due directly to purchase. Be sure to keep your Honda owner’s improper maintenance or lack of maintenance card with your Warranties Booklet.
  • Page 173: Warranty Service

    If the problem If you believe you have a problem with your has already been reviewed with the Service Honda, call the service department of your Manager, Parts Manager, Sales Manager, etc., dealer. Make an appointment for an inspection contact the Owner of the dealership or his and diagnosis.
  • Page 174: Contacting Honda

    If you wish to comment on your experiences • name, address, and telephone number with your Honda or with your dealer, please • product model, year, and VIN send your comments to the following address: • date of purchase •...
  • Page 175: Your Honda Dealer

    Accessories (USA only), and Honda dependability of your Honda. accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department.
  • Page 176: Index

    Index break-in guidelines ........153 button, engine stop ..........18 accessories ............7 start ............18 air cleaner ............. 68 air pressure, tires ......... 100 altering your motorcycle ........ 8 arrester, spark ..........82 capacity, fuel ..........60 authorized manuals ........164 carburetor, high altitude adjustment ......
  • Page 177 Index consumer information ......... 163 starting ............. 29 controls, operating ........11 stop button ..........18 cover removal, side ........57 stopping ............ 32 crankcase breather ........72 won’t start ..........133 customer service ......... 167 environment, protecting ......129 drive chain ..........
  • Page 178 ............160 gasoline ............59 gears, shifting ..........33 key, lost ............141 high altitude adjustment ......154 lever, Honda service manual ........ 164 clutch ............19 Honda, contacting ........167 front brake ..........18 shift ............19 Index...
  • Page 179 Index limit, weight ............ 6 loading ............5 parking ............37 pedal, rear brake ........... 19 pinging, engine ..........59 maintenance, plug, spark ............ 80 component locations ......... 53 post-ride inspection ........38 record ............49 pre-ride inspection ........24 safety ............
  • Page 180 Index shifting gears ..........33 shoe, brake ........... 92 side cover, removal ........57 rear wheel removal ........98 side stand ..........19 reserve capacity, fuel tank ......60 spark arrester ..........82 rider training ...........3 spark knock ..........59 riding, spark plug .............
  • Page 181 Index throttle, valve, fuel ............. 15 freeplay ............. 73 vehicle identification no. (VIN) ....146 operation ........... 18 tires, air pressure ..........100 flat ............137 warranty, replacing ..........103 coverage ..........165 tools .............. 56 extended ..........165 towing ............34 service ............
  • Page 182: Quick Reference

    Frequent causes of costly chassis repair are: collection of information you need to know • Chain -- A loosely adjusted chain or a chain about your Honda. You’ll also find space to stretched because of lack of lubrication may record important notes.
  • Page 183 Quick Reference Record important information here: Engine No. Owner’s: Name Address City/State Phone Dealer’s: Name Address City/State Phone Service Mgr. Quick Reference...
  • Page 184 API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label, SAE 10W-30, JASO T 903 standard MA, Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil after draining: 1.1 US qt (1.0 )
  • Page 185 Quick Reference These symbols are used in Operating Controls section: SYMBOL COMPONENT SEE PAGE choke lever ON – ignition switch OFF – ignition switch START button engine stop button Quick Reference...

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