Honda GLH125 SH Owner's Manual
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Honda GLH125 SH Owner's Manual

Honda GLH125 SH Owner's Manual

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11/05/07 10:01:23 32KVCC00_001
Honda GLH125 SH
OWNER'S MANUAL
Honda Motor Co., Ltd. 2011

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Summary of Contents for Honda GLH125 SH

  • Page 1 11/05/07 10:01:23 32KVCC00_001 Honda GLH125 SH OWNER’S MANUAL Honda Motor Co., Ltd. 2011...
  • Page 2 11/05/07 10:01:27 32KVCC00_002 IMPORTANT INFORMATION OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. Never exceed the maximum weight capacity. ON-ROAD USE This motorcycle is designed to be used only on the road. READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual.
  • 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 As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your motorcycle, other property, or the environment. Pleasant riding, and thank you for choosing a Honda !
  • Page 5 11/05/07 10:01:46 32KVCC00_005 The following codes in this manual indicate each country. Turkey (TU Type ) Ukraine Australia (U Type ) The illustrations herein are based on the type. The specifications may vary with each locale. This vehicle pictured in this owner’s manual may not match your actual vehicle.
  • Page 6 11/05/07 10:01:52 32KVCC00_006 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.
  • Page 7 11/05/07 10:01:57 32KVCC00_007 You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings –– such as Important Safety Reminders or Important Safety Precautions. Safety Section ––...
  • Page 8 11/05/07 10:02:13 32KVCC00_008 OPERATION page page MOTORCYCLE SAFETY ESSENTIAL INDIVIDUAL IMPOR T A NT SA F ET Y COMPONENTS INFORMATION IGNITION SWITCH PROTECTIVE APPAREL KEYS LOAD LIMITS AND GUIDELINES SHUTTER (TU, TU) IMAGE LABELS (U, U) RIGHT HANDLEBAR CONTROLS LEFT HANDLEBAR CONTROLS PARTS LOCATION INSTRUMENTS AND INDICATORS...

  • Page 9: Table Of Contents

    11/05/07 10:02:25 32KVCC00_009 page page FEATURES OPERATION (Not required for operation) PRE-RIDE INSPECTION STEERING LOCK STARTING THE ENGINE SEAT RUNNING-IN DOCUMENT COMPARTMENT RIDING LEFT SIDE COVER BRAKING RIGHT SIDE COVER PARKING HEADLIGHT AIM VERTICAL ANTI-THEFT TIPS ADJUSTMENT...
  • Page 10 11/05/07 10:02:48 32KVCC00_010 MAINTENANCE page page MAINTENANCE FUSE REPLACEMENT THE IMPORTANCE OF BRAKELIGHT SWITCH MAINTENANCE ADJUSTMENT MAINTENANCE SAFETY BULB REPLACEMENT SAFETY PRECAUTIONS MAINTENANCE SCHEDULE CLEANING TOOL KIT SERIAL NUMBERS STORAGE GUIDE COLOUR LABEL STORAGE CRANKCASE BREATHER REMOVAL FROM STORAGE ENGINE OIL SPARK PLUG TAKING CARE OF THE VALVE CLEARANCE...
  • Page 11 11/05/07 10:02:58 32KVCC00_011 MOTORCYCLE SAFETY IMPORTANT SAFETY INFORMATION Make Yourself Easy to See Your motorcycle can provide many years of Some drivers do not see motorcycles service and pleasure if you take because they are not looking for them. To responsibility for your own safety and make yourself more visible, wear bright understand the challenges that you can...
  • Page 12 Never exceed load limits, and only use accessories that have been approved by Honda for this motorcycle. See page more details. Not wearing a helmet increases the chance of serious injury or death in a crash.
  • Page 13 11/05/07 10:03:10 32KVCC00_013 Helmets and Eye Protection Additional Riding Gear Your helmet is your most important piece of In addition to a helmet and eye protection, riding gear because it offers the best we also recommend: protection against head injuries. A helmet Sturdy boots with non-slip soles to help should fit your head comfortably and protect your feet and ankles.
  • Page 14 Non-Honda accessories, im p r o p e r m od i f i c a t i on s , a n d p o or Follow all load limits and other loading maintenance can also reduce your safety guidelines in this manual.
  • Page 15 11/05/07 10:03:27 32KVCC00_015 Load Limits Loading Guidelines Following are the load limits for your Your motorcycle is primarily intended for motorcycle: transporting you and a passenger. You may wish to secure a jacket or other small items Maximum weight capacity: to the seat when you are not riding with a 150 kg (331 lb) passenger.
  • Page 16 11/05/07 10:03:31 32KVCC00_016 Follow these guidelines whenever you carry a passenger or cargo: Check that both tyres are properly inflated (page If you change your normal load, you may need to adjust the rear suspension (page To prevent loose items from creating a hazard, make sure that all cargo is securely tied down before you ride away.
  • Page 17 Modifying your motorcycle or using non- We strongly recommend that you use only Honda accessories can make your Honda Genuine Accessories that have been motorcycle unsafe. Before you consider specifically designed and tested for your making any modifications or adding an motorcycle.
  • Page 18 11/05/07 10:03:43 32KVCC00_018 Do not pull a trailer or sidecar with your Modifications motorcycle. This motorcycle was not We strongly advise you not to remove any designed for these attachments, and their original equipment or modif y your use can seriously impair your motorcycle’s motorcycle in any way that would change its handling.
  • Page 19 11/05/07 10:03:48 32KVCC00_019 IMAGE LABELS (U, U) There is a specific symbol on each label. The following pages describe the label The meanings of each symbol and label are meanings. Some labels warn you of as follows. potential hazards that could cause serious injury.
  • Page 20 11/05/07 10:03:57 32KVCC00_020 Read instructions contained in Owner’s Manual carefully. Read instructions contained in Shop Manual carefully. In the interest of safety, take the motorcycle to be serviced only by your dealer. DANGER (with RED background) You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
  • Page 21 11/05/07 10:04:07 32KVCC00_021 TYRE INFORMATION LABEL Cold tyre pressure: [Driver only] Front 200 kPa (2.00 kgf/cm , 29 psi) Rear 225 kPa (2.25 kgf/cm , 33 psi) [Driver and passenger] Front 200 kPa (2.00 kgf/cm , 29 psi) Rear 225 kPa (2.25 kgf/cm , 33 psi) Tyre size: Front 80/100 18M/C 47P...
  • Page 22 11/05/09 16:12:27 32KVCC00_022 SAFETY REMINDER LABEL For your protection, always wear helmet and protective gear. CARGO LIMIT LABEL Do not exceed 3.0 kg (6.6 lb)

  • Page 23: Parts Location

    11/05/07 10:04:19 32KVCC00_023 PARTS LOCATION Speedometer Engine stop switch Headlight (U, U) dimmer switch Fuel gauge Rearview mirror Front brake fluid reservoir Choke lever (Type ) Passing light control switch Rearview mirror Clutch lever Front brake lever Turn signal switch Throttle grip Horn button Start button...
  • Page 24 11/05/07 10:04:23 32KVCC00_024 Engine oil fill cap/dipstick Battery Main fuse Rear carrier Rear suspension spring preload adjuster Rear brake pedal Passenger footpeg Footpeg...
  • Page 25 11/05/07 10:04:27 32KVCC00_025 Other fuses Fuel valve Tool kit Rear suspension spring preload adjuster Passenger footpeg Shift lever Footpeg Side stand Center stand...
  • Page 26 11/05/07 10:04:34 32KVCC00_026 INSTRUMENTS AND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages. (1) Speedometer (2) Gear range (3) Odometer (4) Gear position indicator (5) Fuel gauge (11) (6) High beam indicator (10) (7) Neutral indicator...
  • Page 27 11/05/07 10:04:48 32KVCC00_027 (Ref.No.) Description Function Speedometer Shows riding speed. Gear range Shows proper speed range for each gear. Odometer Shows accumulated mileage. Gear position indicator Indicates the engaging transmission gears. Fuel gauge Shows approximate fuel supply available (page High beam indicator Lights when the headlight is on high beam.
  • Page 28 11/05/07 10:04:56 32KVCC00_028 (Ref.No.) Description Function Right turn signal indicator Flashes when the right turn signal operates. (green) Left turn signal indicator Flashes when the left turn signal operates. (green) (10) Tripmeter Shows mileage per trip. (11) Tripmeter reset knob Resets tripmeter to zero (0).
  • Page 29 11/05/07 10:05:01 32KVCC00_029 Fuel Gauge When the fuel gauge needle ( ) enters the red band ( ), fuel will be low and you should refill the tank as soon as possible. The amount of fuel left in the tank with the vehicle set upright when the fuel gauge n e e d l e e n t e r s t h e r e d b a n d i s approximately:...
  • Page 30 11/05/07 10:05:10 32KVCC00_030 MAJOR COMPONENTS (Information you need to operate this motorcycle) SUSPENSION The spring preload adjuster ( ) has spring preload positions for different load or riding conditions. Adjust the spring preload by turning the spring preload adjuster with the pin spanner ( ) and extension bar ( ) provided in the tool kit (page Always adjust the spring preload adjuster...
  • Page 31 11/05/07 10:05:14 32KVCC00_031 BRAKES Front Brake (Type ) II This motorcycle has a hydraulic front disc brake. As the brake pads wear, brake fluid level drops. There are no adjustments to perform, but fluid level and pad wear must be inspected periodically.
  • Page 32 Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 3 or DOT 4 brake fluid from a sealed container, or an equivalent. (1) LOWER level mark...
  • Page 33 11/05/07 10:05:26 32KVCC00_033 (Type I) Brakes are items of personal safety and should always be maintained in proper adjustment. The distance the front brake lever ( ) moves before the brake starts to engage is called freeplay. Measured at the tip of the front brake lever, freeplay should be maintained at: 10 20 mm (0.4 0.8 in) Adjust the freeplay of the brake lever with...
  • Page 34 11/05/07 10:05:37 32KVCC00_034 Adjustment: Adjust brake lever freeplay with the front Major adjustment should be made using brake adjusting nut. Turning the nut the lower adjusting nut ( ) at the front clockwise will decrease freeplay and wheel. turning the nut counterclockwise will Minor adjustment can be made with the increase freeplay.
  • Page 35 11/05/07 10:05:48 32KVCC00_035 Apply the brake several times and check After adjustment, confirm the freeplay of for free wheel rotation after the brake the brake lever. lever is released. If proper adjustment cannot be obtained by After adjustment, push the brake arm ( ) this method, see your dealer.
  • Page 36 11/05/07 10:05:56 32KVCC00_036 Brake Adjustment: Rear Brake Pedal Height Adjustment: Place the motorcycle on its center stand. The stopper bolt ( ) is provided to allow Measure the distance the rear brake adjustment of the pedal height. To adjust pedal ( ) moves before the brake starts the pedal height, loosen the lock nut ( ) to take hold.
  • Page 37 11/05/07 10:06:06 32KVCC00_037 Adjust by turning the rear brake adjusting After adjustment, push the brake arm ( ) nut a half-turn at a time. Make sure the cut- to confirm that there is a gap between the out on the adjusting nut is seated on the rear brake adjusting nut ( ) and the brake brake arm pin ( ) after making final arm pin ( ).
  • Page 38 11/05/07 10:06:14 32KVCC00_038 Pull back the rubber dust cover ( ). CLUTCH Clutch adjustment may be required if the Loosen the lock nut ( ) and turn the motorcycle stalls when shifting into gear or clutch cable adjuster. Tighten the lock tends to creep;...
  • Page 39 11/05/07 10:06:22 32KVCC00_039 Loosen the lock nut ( ) at the lower end Other Checks: of the cable. Turn the adjusting nut ( ) to Check the clutch cable for kinks or signs of obtain the specified freeplay. Tighten the wear that could cause sticking or failure.
  • Page 40 11/05/07 10:06:30 32KVCC00_040 FUEL Remember to check that the fuel valve is in Fuel Valve the ON position each time you refuel. If the The three way fuel valve ( ) is on the left valve is left in the RES position, you may side near the carburetor.
  • Page 41 11/05/07 10:06:39 32KVCC00_041 Fuel Tank The fuel tank capacity including the reserve supply is: 13.5 (3.57 US gal , 2.97 Imp gal) Petrol is highly flammable and explosive. You can be burned or To open the fuel fill cap ( ), open the tank seriously injured when handling fuel.
  • Page 42 The use of leaded petrol will cause change brands of petrol. If spark knock or premature damage to the catalytic pinking persists, consult your dealer. converters. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda’s Limited Warranty.
  • Page 43 Damage the painting of the fuel tank. is at least as high as that recommended by Damage the rubber tubes of the fuel line. Honda. Cause corrosion of the fuel tank. Cause poor drivability. There are two types of ‘‘gasohol’’: one con-...
  • Page 44 11/05/07 10:06:59 32KVCC00_044 ENGINE OIL Reinstall the oil fill cap/dipstick. Check Engine Oil Level Check for oil leaks. Check the engine oil level each day before riding the motorcycle. The level must be maintained between the Running the engine with insufficient oil upper ( ) and lower ( ) level marks on the pressure may cause serious engine damage.
  • Page 45 11/05/07 10:07:05 32KVCC00_045 TYRES Air Pressure To safely operate your motorcycle, the tyres Properly inflated tyres provide the best must be the proper type and size, in good combination of handling, tread life, and condition with adequate tread, and correctly riding comfort.
  • Page 46 11/05/07 10:07:14 32KVCC00_046 Always check air pressure when your tyres Inspection are ‘‘cold’’ when the motorcycle has been Whenever you check the tyre pressures, parked for at least three hours. If you check you should also examine the tyre treads and air pressure when your tyres are ‘‘warm’’...
  • Page 47 11/05/07 10:07:17 32KVCC00_047 Tread Wear Replace tyres immediately when the wear indicator ( ) appears at on the tyre. (1) Wear indicator (2) Wear indicator location mark...
  • Page 48 11/05/07 10:07:21 32KVCC00_048 Tube Repair and Replacement If a tube is punctured or damaged, you should replace it as soon as possible. A tube that is repaired may not have the same reliability as a new one, and it may fail while you are riding.
  • Page 49 11/05/07 10:07:29 32KVCC00_049 T he r ecommended t yres f or your Tyre Replacement The tyres that came on your motorcycle motorcycle are: were designed to match the performance Front: 80/100 18M/C 47P capabilities of your motorcycle and provide KENDA the best combination of handling, braking, K291F durability and comfort.
  • Page 50 11/05/07 10:07:35 32KVCC00_050 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH (OFF) (ON) The ignition switch ( ) is below the indicator panel. (LOCK) (1) Ignition switch Key Position Function Key Removal Steering is locked. Engine and lights cannot Key can be LOCK be operated.
  • Page 51 11/05/07 10:07:44 32KVCC00_051 KEYS You will need the key number if you ever This motorcycle has two keys ( ) and a key have to replace a key. Store the plate in a number plate ( ). safe place. To reproduce keys, bring all keys, key number plate and motorcycle to your dealer.
  • Page 52 11/05/07 10:07:52 32KVCC00_052 SHUTTER (TU, TU) This motorcycle has equipped the ignition CLOSE switch with the shutter, when separating from motorcycle, lets close a shutter for theft prevention. To close the shutter, ignition key is removed, align the projection ( ) of the shutter key ( ) with the slot ( ) of the shutter, and turn the shut ter key counterclockwise or move the knob ( )
  • Page 53 11/05/07 10:08:00 32KVCC00_053 RIGHT HANDLEBAR CONTROLS Start Button The start button ( ) is next to the throttle Engine Stop Switch (U, U) grip. The engine stop switch ( ) is next to the When the start button is pressed, the throttle grip.
  • Page 54 11/05/07 10:08:09 32KVCC00_054 LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch ( ) Push the dimmer switch to (HI) to select high beam or to (LO) to select low beam. Passing Light Control Switch ( ) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing.

  • Page 55: Features

    11/05/07 10:08:16 32KVCC00_055 FEATURES (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 (LOCK) while pushing in. Remove the key. T o unlock the steering, turn the key to (OFF).

  • Page 56: Seat

    11/05/07 10:08:24 32KVCC00_056 SEAT To remove the seat ( ), insert the ignition key into the seat lock ( ) and turn it clockwise. Pull the seat back and up. To install the seat, insert the front prong ( ) into the front stay ( ) and the rear prongs ( ) into the rear stays ( ) on the frame.

  • Page 57: Document Compartment

    11/05/07 10:08:29 32KVCC00_057 DOCUMENT COMPARTMENT The document compartment ( ) is located under the seat (page This owner’s manual and other documents should be stored in this compartment. When washing your motorcycle, be careful not to flood this area with water. (1) Document compartment...

  • Page 58: Left Side Cover

    11/05/07 10:08:39 32KVCC00_058 LEFT SIDE COVER The left side cover must be removed for fuse maintenance, and to access the tool kit. Removal: Insert the ignition key ( ) into the lock and turn it clockwise. Carefully pull the side cover ( ) out from the grommets ( ).

  • Page 59: Right Side Cover

    11/05/07 10:08:49 32KVCC00_059 RIGHT SIDE COVER The right side cover must be removed for battery and main fuse maintenance. Removal: Remove the screw ( ). Carefully pull the side cover ( ) out from the grommets ( ). Installation: Align the prongs with the rubber grommets.

  • Page 60: Headlight Aim Vertical

    11/05/07 10:08:58 32KVCC00_060 HEADLIGHT AIM VERTICAL (TU, TU) ADJUSTMENT Vertical adjustment can be made by moving the headlight case ( ) as necessary. (TU, TU) To move the headlight case, loosen the bolt ( ). Tighten the bolt after adjustment. Obey local laws and regulations.
  • Page 61 11/05/07 10:09:09 32KVCC00_061 OPERATION PRE-RIDE INSPECTION Fuel level Fill fuel tank when necessary For your safety, it is very important to take (page a few moments before each ride to walk Throttle Check for smooth opening and around your motorcycle and check its full closing in all steering positions (page condition.
  • Page 62 11/05/07 10:09:15 32KVCC00_062 Lights and horn Check that lights, indicators and horn function properly. (U, U) Engine stop switch Check for proper function (page Side stand ignition cut-off system Check for proper function (page Wheels and tyres Check condition, air pressure and adjust if necessary (pages...
  • Page 63 11/05/07 10:09:24 32KVCC00_063 Y our motorcycle’s exhaust contains STARTING THE ENGINE Always follow the proper starting procedure poisonous carbon monoxide gas. High described below. levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. This motorcycle is equipped with a side Do not run the engine with the garage door stand ignition cut-off system.
  • Page 64 11/05/07 10:09:35 32KVCC00_064 Starting Procedure To restart a warm engine, follow the procedure for ‘‘High Air Temperature.’’ Extended use of the choke may impair piston and cylinder wall lubrication and Normal Air Temperature damage the engine. 10° 35°C (50° 95°F) Pull the choke lever ( ) back all the way to Fully ON ( ), if the engine is cold.
  • Page 65 11/05/07 10:09:41 32KVCC00_065 High Air Temperature Low Air Temperature 35°C (95°F) or above 10°C (50°F) or below Do not use the choke. Follow steps 1 2 under ‘‘Normal Air With the throttle 1/8 1/4 open, press Temperature.’’ the start button. When engine speed begins to pick up, operate the choke lever to keep fast idle.
  • Page 66 11/05/07 10:09:45 32KVCC00_066 Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine, turn the ignition switch to (ON) and move the choke lever to Fully OFF ( ). Open the throttle fully and press the start button for 5 seconds.
  • Page 67 11/05/07 10:09:48 32KVCC00_067 RUNNING-IN Help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first 500 km (300 miles). During this period, avoid full-throttle starts and rapid acceleration.
  • Page 68 11/05/07 10:09:55 32KVCC00_068 RIDING Slowly release the clutch lever and at the Review Motorcycle Safety (pages same time gradually increase engine before you ride. s p e e d b y o p e n i n g t h e t h r o t t l e . Coordination of the throttle and clutch Make sure you understand the function of lever will assure a smooth positive start.
  • Page 69 11/05/07 10:10:00 32KVCC00_069 Raise the shift lever to shift to a higher Do not downshift when traveling at a gear and depress the shift lever to shift to speed that would force the engine to a lower gear. Each stroke of the shift overrev in the next lower gear;...
  • Page 70 11/05/07 10:10:09 32KVCC00_070 Important Safety Reminders: BRAKING (Type ) Independent operation of only the brake Your motorcycle is equipped with a lever or brake pedal reduces stopping hydraulically-activated disc brake in front performance. and a mechanically-activated drum brake at Extreme application of the brake controls the rear.
  • Page 71 11/05/07 10:10:16 32KVCC00_071 When descending a long, steep grade, PARKING use engine compression braking by down- After stopping the motorcycle, shift the shifting, with intermittent use of both transmission into neutral, turn the fuel brakes. valve OFF, turn the handlebar fully to the Continuous brake application can left, turn the ignition switch (OFF) and...
  • Page 72 11/05/07 10:10:22 32KVCC00_072 (TU, TU) ANTI-THEFT TIPS Make sure flammable materials such as dry Always lock the steering and never leave grass or leaves do not come in contact with the key in the ignition switch. This the exhaust system when parking your sounds simple but people do forget.
  • Page 73 11/05/07 10:10:29 32KVCC00_073 MAINTENANCE If your motorcycle overturns or becomes THE IMPORTANCE OF MAINTENANCE involved in a crash, be sure your dealer A well-maintained motorcycle is essential inspects all major parts, even if you are able for safe, economical and trouble-free riding. to make some repairs.
  • Page 74 Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service.
  • Page 75 To ensure the best quality and reliability, Injury from moving parts. Do not run the engine unless instructed use only new Honda Genuine Parts or their to do so. equivalents for repair and replacement. Read the instructions before you begin, and make sure you have the tools and skills required.

  • Page 76: Maintenance Schedule

    Refer to the Official Honda Shop Manual. In the interest of safety, we recommend these items be serviced only by your dealer. Honda recommends that your dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: At higher odometer readings, repeat at the frequency interval established here.
  • Page 77 11/05/07 10:11:01 32KVCC00_077 FREQUENCY (NOTE 1) PRE-RIDE ANNUAL REGULAR Refer ITEMS NOTE CHECK 1,000 km CHECK REPLACE (page 1,000 mi page FUEL LINE (NOTE 4) 2 years FUEL LEVEL FUEL STRAINER SCREEN T HR OT T L E OPERATION CHOKE OPERATION AIR CLEANER (NOTE 2) EVERY 16,000 km (10,000 mi) R...
  • Page 78 11/05/07 10:11:12 32KVCC00_078 FREQUENCY (NOTE 1) PRE-RIDE ANNUAL REGULAR Refer ITEMS NOTE CHECK 1,000 km CHECK REPLACE (page 1,000 mi page DRIVE CHAIN EVERY 1,000 km (600 mi) I, L BRAKE FLUID (NOTE 4) 2 years (DISC BRAKE ONLY) BRAKE SHOES WEAR (DRUM BRAKE ONLY) BRAKE SHOES/PADS WEAR...
  • Page 79 11/05/07 10:11:24 32KVCC00_079 TOOL KIT The tool kit ( ) is in the tool box ( ) behind the left side cover (page Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. 8 mm Open end wrench 12 mm Open end wrench 17 mm Open end wrench...
  • Page 80 11/05/07 10:11:33 32KVCC00_080 SERIAL NUMBERS The frame and engine serial numbers are The frame number ( ) 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.
  • Page 81 11/05/07 10:11:39 32KVCC00_081 COLOUR LABEL The colour label ( ) is attached to the frame behind the left side cover (page It is helpful when ordering replacement parts. Record the colour and code here for your reference. COLOUR CODE (1) Colour label...
  • Page 82 11/05/07 10:11:45 32KVCC00_082 CRANKCASE BREATHER Refer to the Safety Precautions on page Remove the crankcase breather tube ( ) from the air cleaner housing and drain deposits into a suitable container. Reinstall the crankcase breather tube. Service more frequently when riding in rain or at full throttle.
  • Page 83 They may affect on the circular API lubrication and clutch performance. service label Viscosity SAE 10W-30 JASO T 903 standard NOT RECOMMENDED Suggested Oil Honda ‘‘4-STROKE MOTORCYCLE Do not use non-detergent, vegetable, or OIL’’ or equivalent. castor based racing oils.
  • Page 84 11/05/07 10:12:07 32KVCC00_084 JASO T 903 standard Viscosity: Viscosity grade of engine oil should be The JASO T 903 standard is an index for based on average atmospheric temperature engine oils for 4-stroke motorcycle engines. in your riding area. The following provides a There are two classes: MA and MB.
  • Page 85 11/05/07 10:12:14 32KVCC00_085 Changing the oil requires a torque wrench. Engine Oil Engine oil quality is the chief factor If you do not have it and the necessary skill, affecting engine service life. Change the we recommend that you have your dealer engine oil as specified in the maintenance perform this service.
  • Page 86 11/05/07 10:12:23 32KVCC00_086 Place a drain pan under the crankcase. Check that the sealing washer on the To drain the oil, remove the oil fill cap/ drain bolt is in good condition and install dipstick, oil drain bolt ( ), and sealing the bolt.
  • Page 87 11/05/07 10:12:34 32KVCC00_087 Disconnect the spark plug cap ( ) from SPARK PLUG Refer to the Safety Precautions on page the spark plug. Clean any dirt from around the spark plug Recommended plugs: base. Standard: Remove the spark plug using a spark plug CPR7EA 9 (NGK) wrench ( ) furnished in the tool kit (page For extended high speed riding:...
  • Page 88 11/05/07 10:12:47 32KVCC00_088 Visually inspect the spark plug electrodes Make sure the plug washer is in good for wear. The center electrode should condition. have square edges and the side electrode With the plug washer attached, thread should not be eroded. the spark plug in by hand to prevent Discard the spark plug if there is cross-threading.
  • Page 89 11/05/07 10:12:57 32KVCC00_089 Remove the crankshaft hole cap ( ) and VALVE CLEARANCE Refer to the Safety Precautions on page timing hole cap ( ). Remove the bolts ( ) and cylinder head Excessive valve clearance will cause noise cover bolts ( ). and eventual engine damage.
  • Page 90 11/05/07 10:13:02 32KVCC00_090 Rotate the generator flywheel counter- clockwise until the T mark ( ) on the flywheel lines up with the index mark ( ) on the crankcase. In this position, the piston may either be on the compression or exhaust stroke.
  • Page 91 11/05/07 10:13:10 32KVCC00_091 Check the clearance of both valves by If a torque wrench is not used for this inserting a feeler gauge ( ) between the installation, see your dealer as soon as adjusting screw ( ) and the valve stem. possible to verify proper assembly.
  • Page 92 11/05/07 10:13:15 32KVCC00_092 THROTTLE OPERATION Refer to the Safety 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.
  • Page 93 11/05/07 10:13:23 32KVCC00_093 IDLE SPEED Refer to the Safety Precautions on page The engine must be at normal operating temperature for accurate idle speed adjustment. 10 minutes of stop-and-go riding is sufficient. Do not attempt to compensate for faults in other systems by adjusting idle speed.
  • Page 94 11/05/07 10:13:34 32KVCC00_094 Rotate the rear wheel. Stop. Check the DRIVE CHAIN Refer to the Safety Precautions on page drive chain slack. Repeat this procedure several times. Drive chain slack should The service life of the drive chain ( ) is remain constant.
  • Page 95 11/05/07 10:13:41 32KVCC00_095 Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth GOOD If the drive chain or sprockets are excessively worn or damaged, they should be replaced.
  • Page 96 11/05/07 10:13:50 32KVCC00_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 center stand miles). When operated at sustained high on a firm, level surface with the speeds or under conditions of frequent transmission in neutral and the ignition...
  • Page 97 11/05/07 10:13:59 32KVCC00_097 Check the rear axle alignment by making Tighten the drive chain adjusting nuts sure the drive chain adjuster index marks lightly, then tighten the drive chain lock ( ) align with the front edge of the drive nuts by holding the drive chain adjusting chain adjusters ( ).
  • Page 98 11/05/07 10:14:04 32KVCC00_098 Lubrication: Lubricate every 1,000 km (600 miles) or sooner if chain appears dry. Use SAE 80 or 90 gear oil or a commercially prepared drive chain lubricant s in preference to motor oil or other lubricants. Saturate each chain link joint so that the lubricant penetrates between the link plates, pins, bushings, and rollers.
  • Page 99 11/05/07 10:14:15 32KVCC00_099 Removal and Cleaning: Never use a new drive chain on badly When the drive chain becomes dirty, it worn sprockets. Both chain and sprockets should be removed and cleaned prior to must be in good condition, or the new lubrication.
  • Page 100 11/05/07 10:14:19 32KVCC00_100 Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. The master link is the most critical part affecting the security of the drive chain.
  • Page 101 11/05/07 10:14:25 32KVCC00_101 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page Check the fork assembly by locking the front brake and pumping the fork up and down vigorously. Suspension action should be smooth and there must be no oil leakage.
  • Page 102 11/05/07 10:14:33 32KVCC00_102 SIDE STAND Refer to the Safety Precautions on page Perform the following maintenance in accordance with the maintenance schedule. Functional Check: Check the side stand spring ( ) for damage or loss of tension and the side stand assembly for freedom of movement.
  • Page 103 11/05/07 10:14:46 32KVCC00_103 WHEEL REMOVAL Refer to the Safety Precautions on page Front Wheel Removal (Type ) II Place the motorcycle on its center stand. Raise the front wheel off the ground by placing a support block under the engine. Remove the speedometer cable ( ) by removing the screw ( ).
  • Page 104 11/05/07 10:14:56 32KVCC00_104 (Type I) Place the motorcycle on its center stand. Raise the front wheel off the ground by placing a support block under the engine. Remove the speedometer cable ( ) by removing the screw ( ). Remove the front brake adjusting nut ( ) and remove the front brake cable ( ) from the brake arm ( ).
  • Page 105 11/05/07 10:15:09 32KVCC00_105 If a torque wrench is not used for Front Wheel Installation (Type ) II installation, see your dealer as soon as Install the side collar into the right side possible to verif y proper assembly. wheel hub. Improper assembly may lead to loss of Position the wheel between the fork legs braking capacity.
  • Page 106 11/05/07 10:15:20 32KVCC00_106 If a torque wrench is not used for (Type I) Install the side collar into the right side installation, see your dealer as soon as wheel hub. possible to verif y proper assembly. Position the wheel between the fork legs Improper assembly may lead to loss of and insert the front axle shaft from the braking capacity.
  • Page 107 11/05/07 10:15:31 32KVCC00_107 Disconnect the brake stopper arm ( ) Rear Wheel Removal Place the motorcycle on its center stand. from the brake panel by removing the Remove the rear brake adjusting nut ( ). cotter pin ( ), stopper arm nut ( ), Disconnect the brake rod ( ) from the washer and rubber grommet.
  • Page 108 11/05/07 10:15:40 32KVCC00_108 If a torque wrench is not used for Rear Wheel Installation Install the side collars into the left and installation, see your dealer as soon as right side wheel hub. possible to verif y proper assembly. Tighten the rear axle nut and brake Improper assembly may lead to loss of stopper arm nut to specified torque.
  • Page 109 11/05/07 10:15:47 32KVCC00_109 BRAKE PAD WEAR (Type ) II Refer to the Safety Precautions on page FRONT BRAKE Brake pad wear depends upon the severity of usage, the type of riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect t he pa ds a t e ach r egular maintenance interval (page Front Brake...
  • Page 110 See your dealer for this service. When the brake service is necessary, see your dealer. Use only Honda Genuine Parts or its equivalent. (1) Arrow (3) Reference mark...
  • Page 111 11/05/07 10:16:04 32KVCC00_111 BATTERY Refer to the Safety Precautions on page An improperly disposed of battery can be It is not necessary to check the battery harmful to the environment and human electrolyte level or add distilled water as the health.
  • Page 112 11/05/07 10:16:14 32KVCC00_112 Removal: Make sure the ignition switch is OFF. Remove the right side cover (page Remove the fuse holder ( ) from the battery holder ( ). Disconnect the negative ( ) terminal lead ( ) from the battery first, then disconnect the positive ( ) terminal lead ( ).
  • Page 113 11/05/07 10:16:20 32KVCC00_113 FUSE REPLACEMENT Refer to the Safety Precautions on page Blown fuse When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your dealer for repair. Never use a fuse with a different rating from that specified.
  • Page 114 11/05/07 10:16:30 32KVCC00_114 Fuse Holder: The fuse holders ( ) are located behind the left side cover. The specified fuses are: 10A, 15A Remove the left side cover (page Remove the fuse holder from the fuse holder cover ( ). Open the fuse holder and lift out the old fuse ( ) with the clips ( ).
  • Page 115 11/05/07 10:16:42 32KVCC00_115 Main Fuse: The main fuse ( ) is located behind the right side cover. The specified fuse is: Remove the right side cover (page Remove the fuse holder ( ) from the battery holder ( ). Open the fuse holder and lift out the main fuse with the clips ( ).
  • Page 116 11/05/07 10:16:49 32KVCC00_116 If you do not have a replacement fuse with REMOVAL the proper rating for the circuit, install one with a lower rating. Pull up Replacing a fuse with one that has a higher rating greatly increases the chances of damaging the electrical system.

  • Page 117: Brakelight Switch Adjustment

    11/05/07 10:16:55 32KVCC00_117 BRAKELIGHT SWITCH ADJUSTMENT Refer to the Safety Precautions on page Check the operation of the brakelight switch ( ) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut ( ).
  • Page 118 11/05/07 10:17:04 32KVCC00_118 BULB REPLACEMENT Refer to the Safety Precautions on page Be sure to turn the ignition switch (OFF) when replacing the bulb. The light bulb becomes very hot while the Do not use bulbs other than those light is ON, and remains hot for a while specified.
  • Page 119 11/05/07 10:17:15 32KVCC00_119 Pull out the socket ( ) without turning. Headlight Bulb (TU, TU) Remove the seat rubber ( ). Remove the bolts ( ) from the front cowl Remove the headlight bulb ( ) while ( ). pressing down on the pin ( ). Disconnect the connector ( ).
  • Page 120 11/05/07 10:17:26 32KVCC00_120 (U, U) Slightly press the headlight bulb ( ) and Remove the screws ( ) from the turn it counterclockwise. headlight case. Install a new bulb in the reverse order of Gently pull the lower end of the headlight removal.
  • Page 121 11/05/07 10:17:38 32KVCC00_121 (U, U) Position Light Bulb (TU, TU) Remove the headlight ( ) (page Remove the front cowl and disconnect Pull the position light socket ( ) and the connector (page remove it. Pull the position light socket ( ) and Pull out the bulb ( ) without turning.
  • Page 122 11/05/07 10:17:44 32KVCC00_122 Brake/Tail Light Bulb Remove the taillight lens ( ) by removing the screws ( ). Slightly press the bulb ( ) and turn it counterclockwise. Install a new bulb in the reverse order of removal. (3) Bulb (1) Taillight lens (2) Screws...
  • Page 123 11/05/07 10:17:53 32KVCC00_123 Front/Rear Turn Signal Bulb Remove the screw A ( ). Remove the reflector ( ) and turn signal lens ( ) by removing the screws B ( ). Slightly press the bulb ( ) and turn it counterclockwise.
  • Page 124 11/05/07 10:18:00 32KVCC00_124 License Light Bulb Remove the screws ( ). Remove the license light cover ( ). Pull out the bulb ( ) without turning. Install a new bulb in the reverse order of removal. (1) Screws (2) License light cover (3) Bulb...
  • Page 125 11/05/07 10:18:10 32KVCC00_125 CLEANING Clean your motorcycle regularly to protect Washing the Motorcycle the surface finishes and inspect for damage, Rinse the motorcycle thoroughly with wear, and oil or brake fluid leakage. cool water to remove loose dirt. Clean the motorcycle with a sponge or Avoid cleaning products that are not soft cloth using cool water.
  • Page 126 11/05/07 10:18:22 32KVCC00_126 After cleaning, rinse the motorcycle Finishing Touches thoroughly with plenty of clean water. After washing your motorcycle, consider Strong detergent residue can corrode using a comme r cia lly-a v a ilable spr a y alloy parts. cleaner/polish or quality liquid or paste wax Dry the motorcycle, start the engine, and to finish the job.
  • Page 127 11/05/07 10:18:32 32KVCC00_127 Clean the Seat Painted Aluminum Wheel Maintenance Due to the top coat design, the seat surface Aluminum may corrode from contact with tends to catch and trap dirt or dust in its dirt, mud, or road salt. Clean the wheels texture.
  • Page 128 11/05/07 10:18:40 32KVCC00_128 STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non-use of the motorcycle. In addition, Petrol is highly flammable and necessary repairs should be made BEFORE explosive.
  • Page 129 11/05/07 10:18:47 32KVCC00_129 To prevent rusting in the cylinder, Remove the battery. Store in an area perform the following: protected from freezing temperatures Remove the spark plug cap from the and direct sunlight. spark plug. Using tape or string, secure Slow charge the battery once a month.
  • Page 130 11/05/07 10:18:53 32KVCC00_130 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 131 11/05/07 10:18:58 32KVCC00_131 TAKING CARE OF THE UNEXPECTED IF YOU CRASH Personal safety is your first priority after a If there is minor damage, or you are unsure crash. If you or anyone else has been about possible damage, ride slowly and injured, take time to assess the severity of cautiously.
  • Page 132 11/05/07 10:19:10 32KVCC00_132 SPECIFICATIONS DIMENSIONS Overall length 2,048 mm (80.6 in) Overall width 766 mm (30.2 in) …Type 752 mm (29.6 in) …Type I Overall height 1,084 mm (42.7 in) …TU, TU 1,067 mm (42.0 in) … U 1,048 mm (41.3 in) …U Wheelbase 1,299 mm (51.1 in)
  • Page 133 11/05/07 10:19:16 32KVCC00_133 ENGINE Bore and stroke 52.4 57.8 mm (2.06 2.28 in) Compression ratio 9.2 : 1 Displacement 124.7 cm (7.61 cu-in) Spark plug Standard CPR7EA 9 (NGK) For extended high speed riding CPR8EA 9 (NGK) Spark plug gap 0.80 0.90 mm (0.031 0.035 in) Idle speed 1,400...
  • Page 134 11/05/07 10:19:26 32KVCC00_134 CHASSIS AND SUSPENSION Caster 26°30’ Trail 100.0 mm (3.94 in) Tyre size, Front 80/100 18M/C 47P KENDA K291F Tyre size, Rear 90/90 18M/C 51P KENDA K328X Tyre type bias-ply, tube POWER TRANSMISSION Primary reduction 3.350 Gear ratio, 1st 3.076 1.875 1.409...
  • Page 135 11/05/07 10:19:39 32KVCC00_135 ELECTRICAL Battery YTX7L BS 12V 6Ah (10HR) Generator 0.22 kW/5,000 min (rpm) LIGHTS Headlight 12V 35/35W Brake/Tail light 12V 21/5W Turn signal light Front 12V 10W Rear 12V 10W Position light 12V 5W …U, U 12V 5W …TU, TU License light 12V 5W...

  • Page 136: Catalytic Converter

    The catalytic converters act on HC, CO, and amount of leaded petrol can contaminate NOx. Replacement parts must be original the catalyst metals, making the catalytic Honda parts or their equivalents. converters ineffective. The catalytic converters must operate at a Keep the engine in good running high temperature for the chemical reactions condition.

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