Honda CRF450L 2019 Owner's Manual & Off-Road Handbook
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Honda CRF450L 2019 Owner's Manual & Off-Road Handbook

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Contents
MOTORCYCLE SAFETY............................. 1
Important Safety Information ........................... 2
Important Safety Precautions ........................ 2
Accessories & Modifications ........................... 3
Accessories & Modifications ........................ 3
Off-Road Safety ............................................... 4
Off-Road Safety ............................................ 4
Safety Labels .................................................... 5
INSTRUMENTS & CONTROLS.................. 7
Operation Component Locations ...................... 8
Indicators & Displays ....................................... 9
Multi-function Display................................ 10
Speedometer ................................................ 12
Odometer/Tripmeter A & B ........................ 12
Fuel Mileage Meter ..................................... 12
Digital Clock Setting................................... 13
Changing the Fuel Mileage Unit ................. 14
Controls & Features ........................................ 15
Ignition Switch ............................................ 15
Start Button ................................................. 15
Engine Stop Switch ..................................... 15
Headlight Dimmer Switch........................... 15
Passing Light Control Switch...................... 15
Turn Signal Switch...................................... 15
Horn Button................................................. 15
BEFORE RIDING......................................... 17
Are You Ready to Ride? ................................ 18
Protective Apparel....................................... 18
Rider Training ............................................. 18
Pre-ride Inspection ...................................... 19
Load Limits & Guidelines .............................. 21
Loading........................................................ 21
Load Limits ................................................. 21
Loading Guidelines ..................................... 21
Contents
31MKE900
Basic Operating Instructions ...........................24
Safe Riding Precautions...............................24
Carbon Monoxide Hazard............................24
Starting & Stopping the Engine ......................25
Fast Idle Knob..............................................25
Preparation ...................................................25
Starting Procedure........................................25
How to Stop the Engine ...............................26
Shifting Gears .................................................27
Braking ............................................................28
Parking ............................................................29
Theft-prevention Tips ..................................29
Break-in Guidelines ........................................30
SERVICING YOUR HONDA ......................31
The Importance of Maintenance .....................32
Maintenance Safety .........................................33
Important Safety Precautions.......................33
Periodic Maintenance ......................................34
Maintenance Schedule ....................................35
(Off-Road Use Only) ......................................39
(Off-Road Use Only) ......................................43
After Competition Maintenance ..................44
Service Preparations
Seat ..................................................................46
Side Cover .......................................................47
Fuel Tank ........................................................48
Subframe .........................................................52
2019 CRF450L
Service Procedures
Fluids & Filters
Fuel System .................................................... 60
Fuel.............................................................. 60
Refueling Procedure .................................... 60
Fuel Line Inspection.................................... 61
Fuel Line Replacement................................ 61
Fuel Pump Filter Replacement .................... 63
Fuel Pressure Increasing.............................. 68
Engine Oil ....................................................... 69
Oil Recommendation................................... 69
Checking & Adding Oil .............................. 70
Changing Engine Oil & Filter ..................... 70
Coolant ........................................................... 72
Coolant Recommendation ........................... 72
Checking & Adding Coolant....................... 72
Cooling System Inspection.......................... 73
Coolant Replacement .................................. 73
Cooling System Bleed Air........................... 74
Air Cleaner ..................................................... 75
Cleaning....................................................... 75
Crankcase Breather ......................................... 77
Draining....................................................... 77
Engine
Throttle ........................................................... 78
Throttle Freeplay ......................................... 78
Throttle Inspection ...................................... 79
Throttle Cable Lubrication .......................... 79
Engine Idle Speed ........................................... 80
Idle Speed Adjustment ................................ 80
Clutch System ................................................. 81
Clutch Lever Freeplay ................................. 81
Other Inspections......................................... 82
Clutch Operation ......................................... 82
Clutch Cable Lubrication ............................ 82
Clutch Disc/Plate Removal ......................... 83
Clutch Disc/Plate Installation...................... 84
Spark Plug ...................................................... 86
Spark Plug Recommendation ...................... 86
MOM 16640 (1803)

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Summary of Contents for Honda CRF450L 2019

  • Page 1: Table Of Contents

    Break-in Guidelines ........30 Coolant Recommendation ......72 Fuel Mileage Meter ........12 Checking & Adding Coolant....... 72 Digital Clock Setting........13 SERVICING YOUR HONDA ......31 Cooling System Inspection......73 Backlight Brightness Adjustment....13 The Importance of Maintenance .....32 Coolant Replacement ........73 Changing the Speed and Mileage Unit..
  • Page 2 Contents Valve Clearance ..........87 Wheels ............126 Electrical Battery ............138 Cylinder Head Cover Removal ....87 Wheel Rims & Spokes.......126 Battery Storage .......... 138 Positioning At TDC On The Compression Axles & Wheel Bearings ......126 Stroke ............88 Tires & Tubes ..........127 Battery Charging ........
  • Page 3 2019 Honda CRF450L OWNER’S MANUAL & OFF-ROAD HANDBOOK...
  • Page 4 Throughout this manual, the following information is intended to help you avoid damage abbreviations are used to identify the respective When you own a Honda, you’re part of a to your motorcycle, other property, or the parts or system. worldwide family of satisfied customers – people environment.
  • Page 5 A Few Words About Safety Your safety, and the safety of others, is very important. 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 6 TECHNICAL INFORMATION....177 CONSUMER INFORMATION ....193 Transporting Your Motorcycle ..... 158 Vehicle Identification ........178 Authorized Manuals ........194 Storing Your Honda ........159 Serial Numbers ..........178 Warranty Coverage ........195 Preparation for Storage......159 Specifications ..........179 Warranty Service .......... 196 Removal from Storage ......

  • Page 7: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Information ......2 information and recommendations to help you ride Important Safety Precautions......2 your motorcycle safely. Please take a few moments Accessories & Modifications ......3 to read these pages. This section also includes Off-Road Safety ..........4 information about the location of safety labels on Safety Labels............5...

  • Page 8: Important Safety Information

    Also be sure to read Tips & Practice Guide Always Wear a Helmet. Keep your Honda in Safe Condition. It’s a proven fact: helmets and protective apparel for the Off-Highway Motorcyclist that came with It’s important to keep your motorcycle properly...

  • Page 9: Accessories & Modifications

    Accessories & Modifications We strongly advise that you do not add any accessories that were not specifically designed or approved for your motorcycle by Honda or make modifications to your motorcycle from its original design. Doing so can make it unsafe.

  • Page 10: Off-Road Safety

    Off-Road Safety Off-Road Safety Off-Road Safety Learn to ride in an uncongested off-road area free of obstacles before venturing onto unfamiliar terrain. • Always obey local off-road riding laws and regulations. • Obtain permission to ride on private property. Avoid posted areas and obey “NO Trespassing” signs.

  • Page 11: Safety Labels

    Safety Labels Safety and information labels on your motorcycle provide important safety information and may warn you of potential hazards that could cause serious injury. Read these labels carefully and don't remove them. If a label comes off or becomes hard to read, contact your dealer for replacement. Motorcycle Safety...
  • Page 12 Safety Labels Motorcycle Safety...

  • Page 13: Instruments & Controls

    Instruments & Controls This section shows the location of all indicators, Operation Component Locations .......8 and controls you would normally use before or Indicators & Displays ........9 while riding your motorcycle. Multi-function Display ........10 Speedometer..........12 The items listed on this page are described in this Odometer/Tripmeter A &...

  • Page 14: Operation Component Locations

    Operation Component Locations headlight dimmer switch ignition switch engine stop switch clutch lever front brake lever passing light control switch start button throttle grip turn signal switch horn button fast idle knob (engine idle speed) rear brake pedal shift lever side stand Instruments &...

  • Page 15: Indicators & Displays

    Indicators & Displays The indicators and display on your motorcycle Lamp Check Display Check Most of the indicator lights come on when you When the ignition switch is turned ON, the keep you informed, alert you to possible problems, and make your riding safer and more enjoyable. turn the ignition switch ON so you can check multi-function display (1) will temporarily Refer to the indicators and display frequently.

  • Page 16: Multi-Function Display

    Indicators & Displays SEL button Uses this button for the following purposes. Multi-function Display • To change the 12/24 hour • To adjust time The multi-function display includes the following • To adjust display illumination functions: • To select and reset the fuel mileage meter •...
  • Page 17 Indicators & Displays Normal MODE Setting MODE Press the SEL button to select the Odometer, TRIP A, TRIP B, Current fuel mileage, Average fuel Press and hold the SEL button, the display turn mileage (TRIP A/TRIP B) or Fuel consumption (TRIP A/TRIP B). into the setting mode.

  • Page 18: Speedometer

    Indicators & Displays To Reset the Tripmeter, Average Fuel Mileage and Speedometer Fuel Mileage Meter Fuel Consumption Press the SEL button (1) to select the TRIP A (2), The speedometer shows riding speed in miles or The fuel mileage meter includes the following average fuel mileage A (3), fuel consumption A kilometers per hour.

  • Page 19: Digital Clock Setting

    Indicators & Displays 6. Press SEL button until the desired hour is Digital Clock Setting Backlight Brightness Adjustment displayed. The digital clock shows the hour and minute. To To adjust the backlight brightness, proceed as adjust the time format and clock, proceed as follows: follows: 1.

  • Page 20: Changing The Speed And Mileage Unit

    Indicators & Displays Changing the Speed and Mileage Unit Changing the Fuel Mileage Unit To adjust the Speed and Mileage Unit proceed as If the “mph” for speed and “mile” for mileage are follows: selected, the fuel mileage unit cannot be select. To adjust the Fuel Mileage Unit proceed as 1.

  • Page 21: Controls & Features

    Controls & Features Ignition Switch Start Button Headlight Dimmer Switch The ignition switch (1) is used for starting and The headlight dimmer switch (1) is used to change stopping the engine (page 26) and to lock the between the high and low beams of the headlight. steering for theft prevention (page 29).
  • Page 22 BLANK PAGE Instruments & Controls...

  • Page 23: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride? ........18 your motorcycle are both ready to ride. To help get Always carry this manual and tool kit ..18 you prepared, this section discusses how to Protective Apparel ........18 evaluate your riding readiness, what items you Rider Training..........18...

  • Page 24: Are You Ready To Ride

    Are You Ready to Ride? Are You Ready to Ride? Before you ride your motorcycle for the first time, Additional On-road Gear Protective Apparel we urge you to: In addition to a helmet and eye protection, we also • Read this owner’s manual recommend: For your safety, we strongly recommend that you •...

  • Page 25: Is Your Motorcycle Ready To Ride

    Always perform a pre-ride inspection properly. Remember, be sure to take care of any problem before every ride and correct any you find, or have your Honda dealer correct it problems. When riding at high or continuous speed on the before you ride.
  • Page 26 Is Your Motorcycle Ready to Ride? Off-Road Use Check the following before each ride: • Engine oil level ........... 70 • Fuel line for condition ......... 61 • Coolant for proper level ......72 • Cooling system and hoses for condition ..73 •...

  • Page 27: Load Limits & Guidelines

    Load Limits & Guidelines Your motorcycle was designed as a rider-only Load Limits motorcycle. It was not designed to carry a passenger or cargo. A passenger or cargo could Following are the load limits for your motorcycle: interfere with your ability to move around to maintain your balance and control of the Maximum weight capacity motorcycle.
  • Page 28 BLANK PAGE Memo...

  • Page 29: Basic Operating Instructions

    Basic Operating Instructions This section gives basic riding instructions, Safe Riding Precautions.......24 including how to start and stop your engine, and Carbon Monoxide Hazard......24 how to use the throttle, clutch, and brakes. Starting & Stopping the Engine .......25 Fast Idle Knob..........25 To protect your new engine and enjoy optimum Preparation ...........25 performance and service life, refer to Break-in...

  • Page 30: Basic Operating Instructions

    Basic Operating Instructions Basic Operating Instructions Safe Riding Precautions Carbon Monoxide Hazard Exhaust contains poisonous carbon monoxide, a Before riding your motorcycle for the first time, colorless, odorless gas. Breathing carbon please review the Important Safety Precautions monoxide can cause loss of consciousness and beginning on page 2 and the previous section, may lead to death.

  • Page 31: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure 3. With the throttle closed. Starting Procedure described below. Pull the clutch lever all the way in, and depress the start button (2). Always follow the proper starting procedure Your motorcycle can be started with the described as follows.

  • Page 32: Bank Angle Sensor Ignition Cut-Off System

    Starting & Stopping the Engine Warm Engine Starting Bank Angle Sensor Ignition Cut-off How to Stop the Engine 1. Shift the transmission into neutral. System 2. Pull the clutch lever and depress the start button. (Do not open the throttle.) Normal Engine Stop Your motorcycle’s banking (lean angle) sensor To stop the engine, shift into neutral and turn the...

  • Page 33: Shifting Gears

    Shifting Gears Remember to close the throttle and pull the clutch Recommended Shift Points lever in completely before shifting. Ride in the highest gear that lets the engine run and accelerate smoothly. This will give you good fuel economy and effective emissions control. When changing gears under normal conditions, use these NOTICE recommended shift points:...

  • Page 34: Braking

    Braking Your motorcycle is equipped with disc braking When possible, reduce your speed or complete systems which are hydraulically activated. braking before entering a turn. Avoid braking or Operating the brake lever applies the front disc closing the throttle quickly while turning. Either brake.

  • Page 35: Parking

    Parking 1. Look for a level parking area. If you can’t park Theft-prevention Tips on a paved surface, make sure the ground surface is firm, especially under the side stand. • Park your motorcycle in a locked garage If you must park on a hill, leave the whenever possible.

  • Page 36: Break-In Guidelines

    Break-in Guidelines Break-in Guidelines On-Road Use Help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first 300 miles (500 km). During this period, avoid full-throttle starts and rapid acceleration. Off-Road Use 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...

  • Page 37: Servicing Your Honda

    Spark Plug............86 unnecessary. If you want to check the ignition Valve Clearance ..........87 timing, refer to an official Honda Service Manual Piston/Piston Rings/Piston Pin......96 (page 194). An optional tool kit may be available. Check with your dealer’s parts department.

  • Page 38: The Importance Of Maintenance

    If your motorcycle overturns or is involved in a crash, be sure your dealer inspects all major parts, even if you are able to make some of the repairs yourself. Servicing Your Honda...

  • Page 39: Maintenance Safety

    To ensure the best quality and Important Safety Precautions reliability, use only new Honda Genuine Parts or their equivalents for repair and replacement. If you • Make sure the engine is off before you begin have the tools and skills required for additional any maintenance or repairs.

  • Page 40: Periodic Maintenance

    Check the freeplay of the clutch lever (page 81) and throttle grip (page 79). Drive Chain Check condition, adjust slack, and lubricate as needed (page 130). Fuses Make sure you have a full supply of spare fuses. Nuts & Bolts Check the major fasteners and tighten as needed. Servicing Your Honda...

  • Page 41: Maintenance Schedule

    Procedures for items in this schedule are provided in an official Honda Service Manual available for purchase from your dealer (page 194). Service intervals in the maintenance schedule are expressed in terms of races and riding hours.
  • Page 42 STEERING HEAD BEARINGS *Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 194). **In the interest of safety, we recommended these items be serviced only by your dealer.
  • Page 43 All items should be checked before each off-road event. See your dealer unless you are mechanically qualified and have the proper tools. Damage from Off-Road use is not covered by the Distributor’s Limited Warranty on your Honda. Perform the Pre-ride Inspection (page 19) at each scheduled maintenance period.

  • Page 44: Maintenance Record (On-Road Use Only)

    2,400 (4,000) or 16 3,000 (5,000) or 20 3,600 (6,000) or 24 4,200 (7,000) or 28 4,800 (8,000) or 32 5,400 (9,000) or 36 6,000 (10,000) or 40 6,600 (11,000) or 44 7,200 (12,000) or 48 7,800 (13,000) or 52 Servicing Your Honda...

  • Page 45: General Competition Maintenance (Off-Road Use Only)

    Use Honda Genuine Parts or their equivalents when servicing your motorcycle. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 46 Maintenance section. Use Pro Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda Foam Air Filter Sealer or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly (page 75).
  • Page 47 Make sure the engine mounting bolts and nuts are tightened Refer to an official Honda Service Manual (page 194). Use only to the proper torque specification. Pro Honda HP Fork Oil, SS-19 or an equivalent which contains special additives to assure maximum performance of your motorcycle's front suspension.
  • Page 48 A small amount of coolant offers added assurance and security. Remove the nuts, weeping from the bleed hole is normal. See an official Honda clean the threads of both the nuts and bolts, apply Pro Service Manual or consult your dealer for replacing the Honda Hondalock or an equivalent and tighten to the mechanical seal or oil seal.

  • Page 49: Before & After Competition Maintenance (Off-Road Use Only)

    • Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary. Do not perform maintenance while engine is running. Injury to your fingers or hands may result. Servicing Your Honda...

  • Page 50: After Competition Maintenance

    If you decide to wash your motorcycle or use Remove the drive chain, clean and lubricate it cleaners, refer to Appearance Care (page 141). (pages 131, 132). Be sure the chain is wiped clean and is dry before lubricating the chain. Servicing Your Honda...

  • Page 51: Maintenance Component Locations

    (both left and right) caliper front brake caliper adjuster Servicing Your Honda...

  • Page 52: Seat

    2. Install and tighten the seat mounting bolts (5) to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (1) seat front prong (4) seat support base slots (2) slot (5) seat mounting bolts (3) seat center prongs Servicing Your Honda...

  • Page 53: Side Cover

    The right and left side covers can be installed in the same manner. The right and left side covers can be removed in the same manner. (1) side cover (2) bolts (1) side cover 2. Install the seat (page 46). (2) bolts Servicing Your Honda...

  • Page 54: Fuel Tank

    (10) fuel tank bolts (11) washers (13) fuel feed hose 7. Lift the fuel tank (12) out of the frame to the left of the frame. Do not support the fuel tank by the fuel feed hose (13). Servicing Your Honda...
  • Page 55 (16) from the fuel pump (17). (17) (20) (21) (12) fuel tank (21) fuel joint (18) fuel quick connect fitting (22) connector housing (20) slide retainer (12) (16) (12) fuel tank (16) fuel quick connect fitting cover (17) fuel pump (cont’d) Servicing Your Honda...
  • Page 56 6. Install the fuel quick connect fitting cover (6). installing the quick connect fitting. Be sure the rubber cover (1) is properly installed between the fuel quick connect fitting cover and fuel pump. (3) slide retainer (1) rubber cover (6) fuel quick connect fitting cover Servicing Your Honda...
  • Page 57 (16) shroud (20) shroud C bolt (17) tab (21) shroud B bolt (10) (18) slot (22) shroud A bolt (19) side cover (4) fuel tank (11) fuel tank bolts (10) washers 12. Install the seat (page 46). Servicing Your Honda...

  • Page 58: Subframe

    (3) starter relay from the seat rail, then remove the seat support (4) seat support base base (4) from the subframe (13). (12) (10) (10) (11) (13) (4) seat support base (12) hooks (10) bolts (13) subframe (11) collars Servicing Your Honda...
  • Page 59 (25) from the rear fender stay. Disconnect the license light/taillight/brake light connectors (26). Disconnect the turn signal light connectors (27). (24) (25) (27) (26) (24) wire harness band (25) connector covers (26) license light/taillight/brake light connectors (27) turn signal connectors (cont’d) Servicing Your Honda...
  • Page 60 Remove the regulator/rectifier mounting bolts (34) mounting A bolts (38) clip (40) (44). (35) collars A (13) (13) subframe (39) bolt (40) turn signal relay/bracket (43) (44) (43) fuse box assembly mounting bolt/washer (44) regulator/rectifier mounting bolts Servicing Your Honda...
  • Page 61 (17) air cleaner housing (49) air cleaner housing mounting A bolts (54) connecting tube (50) air cleaner housing mounting B bolts (3) subframe (51) collars (4) main frame (5) upper mounting bolts (6) lower mounting bolts (cont’d) Servicing Your Honda...
  • Page 62 (15) fuse box assembly mounting bolt/washer properly, then install it to the air cleaner (16) regulator/rectifier mounting bolts housing boss (13). (12) (10) (11) (13) (10) wire harness guide (12) canister air tube (11) flange nut (13) boss Servicing Your Honda...
  • Page 63 (3) subframe (18) turn signal relay/bracket (20) rear fender B (26) collars A (19) bolt (23) license light stay assembly (27) mounting B bolts (24) license light wire (28) collars B (25) mounting A bolts (29) clip (cont’d) Servicing Your Honda...
  • Page 64 (1) air cleaner housing (39) wire harness band (43) crankcase breather tube (43) (44) air injection air tube (45) IAT sensor connector (46) connecting tube band screw (42) (43) (42) (42) negative (-) battery cable (43) cable bands Servicing Your Honda...
  • Page 65 (47) seat support base 20. Install the muffler (page 133). (51) washers (48) collars 21. Install the fuel tank (page 50). (52) collars B (49) bolts (53) collars A 22. Install the battery (page 139). (54) ECM stay (55) bolts Servicing Your Honda...

  • Page 66: Fuel System

    Use of lower octane gasoline can cause persistent rotary joint to correct. “pinging” or “spark knock” (a louder rapping • If you replace the fuel cap, use a Honda noise) which, if severe, can lead to engine damage. Genuine replacement part or equivalent.

  • Page 67: Fuel Line Inspection

    4. Install the fuel quick connect fitting cover. 4. Place a shop towel (4) over the fuel quick 5. Install the fuel tank (page 50). connect fitting. (5) slide retainer (6) fuel joint (7) connector housing (4) shop towel (cont’d) Servicing Your Honda...
  • Page 68 • Do not reuse the kinked or damaged fuel hose. • Do not use gloves or a shop towel while installing the quick connect fitting. (6) fuel joint (9) disconnected connector (10) plastic bags (3) slide retainer Servicing Your Honda...

  • Page 69: Fuel Pump Filter Replacement

    6. Install the fuel tank (page 50). 7. Increase the fuel pressure (page 68). (1) fuel pump mounting nuts (2) fuel pump mounting cap nut (3) stopper cable guide (4) washer (5) collars (6) conical spring washers (7) fuel pump plate (cont’d) Servicing Your Honda...
  • Page 70 (15) tabs terminals and fuel pump wire terminals. (20) (13) (19) fuel pump stopper (20) damper rubber (11) (12) (11) fuel pump wire terminals (12) reserve sensor wire terminals (13) fuel pump base Servicing Your Honda...
  • Page 71 (6) while routing the fuel pump yellow (7) and green (8) wires through the holder grooves (9) as shown. (10) damper rubber (new) (24) (11) fuel pump stopper (21) fuel pump assembly (24) fuel pump filter (cont’d) Servicing Your Honda...
  • Page 72 Push the wire terminals until (23) dust seal (new) (26) dust seal lug they stop as shown. (24) tabs (27) index mark (31) fuel pump unit Be careful not to damage the wires. (32) fuel tank Servicing Your Honda...
  • Page 73 (35) fuel pump unit lug (36) Fuel tank side (33) (42) (33) fuel pump plate (36) conical spring washers (37) collars (38) washer (39) stopper cable guide (40) fuel pump mounting nuts (41) fuel pump mounting cap nut (42) identification mark Servicing Your Honda...

  • Page 74: Fuel Pressure Increasing

    The engine will start up by increasing the fuel pressure. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 194) for troubleshooting of the PGM-FI symptom. Servicing Your Honda...

  • Page 75: Engine Oil

    JASO T 903 standard suggested oil* Pro Honda GN4 4-stroke Oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label.

  • Page 76: Checking & Adding Oil

    3. Support the motorcycle in an upright position on a level surface. 4. Remove the engine oil fill cap/dipstick (4) from the left crankcase cover. (1) engine oil fill cap/dipstick (2) upper level mark (3) lower level mark Servicing Your Honda...
  • Page 77 (15) on the filter body, near the seal. new O-ring, then install the O-ring on the drain Use a new Honda Genuine oil filter or a filter bolt and tighten the drain bolt to the specified of equal quality specified for your model.

  • Page 78: Coolant

    Checking & Adding Coolant Coolant Recommendation Refer to Important Safety Precautions on page 33. Use Pro Honda HP Coolant or an equivalent high 1. With the engine at normal operating quality ethylene glycol antifreeze containing temperature, check the coolant level in the corrosion protection inhibitors specifically reserve tank (1).

  • Page 79: Cooling System Inspection

    3. Check the radiator mount for looseness. A small amount of coolant weeping from the 4. Make sure the siphon hose (2) is connected and bleed hole is normal. See an official Honda not clogged. Service Manual or consult your dealer for (6) fins 5.

  • Page 80: Cooling System Bleed Air

    If the radiator cap is not installed properly, it will cause excessive coolant loss and may result in (3) reserve tank cap (4) UPPER level line overheating and engine damage. 5. Install the reserve tank cap. (1) radiator cap (2) filler neck Servicing Your Honda...

  • Page 81: Air Cleaner

    Your motorcycle' s air cleaner has very specific (5) air cleaner assembly the retainer (2) and remove the air cleaner lid performance requirements. Use a new Honda (3). 4. Remove the air cleaner element (6) from the air Genuine air cleaner specified for your model or an cleaner holder (7) by releasing the hole (8) of air cleaner of equal quality.
  • Page 82 Install the holder tab in the hole of the air cleaner element. 9. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda Foam Air Filter Sealer or equivalent to the air cleaner element contact area of the air cleaner housing.

  • Page 83: Crankcase Breather

    2. Reinstall the crankcase breather tube plugs. If the breather tube overflows, the air filter may become contaminated with engine oil causing poor engine performance. (1) crankcase breather tube plugs (2) crankcase breather tubes Servicing Your Honda...

  • Page 84: Throttle

    If you can’t get the freeplay within the specified Tighten the lock nut securely. range, contact your dealer. Make the adjustment with the lower adjuster. Servicing Your Honda...

  • Page 85: Throttle Inspection

    6. Install the dust cover in reverse order. If the throttle operation is not smooth, replace the (3) throttle throttle cable. Be sure the throttle returns freely from fully open to fully closed automatically, in all steering positions. Servicing Your Honda...

  • Page 86: Engine Idle Speed

    2. Connect a tachometer to the engine. 3. Shift the transmission into neutral. Start the engine. 4. Adjust idle speed with the fast idle knob (1). Idle speed: 1,800 ± 100 rpm (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 87: Clutch System

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 84). Servicing Your Honda...

  • Page 88: Other Inspections

    5. Connect the clutch cable end to the lever. with commercially available cable lubricant. 6. Install the clutch cable and turn the adjuster. 2. Check the clutch cable for deterioration, kinks, or damage. Servicing Your Honda...

  • Page 89: Clutch Disc/Plate Removal

    (1) and over cover (2). 5. Remove the clutch pressure plate (6). (9) thrust bearing If the operation is not smooth, refer to an official Honda Service Manual (page 194) for bearing (1) bolts (2) over cover disassembly or see your dealer.

  • Page 90: Clutch Disc/Plate/Spring Inspection

    B disc A (1) spring seat (6) lugs (2) judder spring (7) groove (3) clutch disc A (8) clutch disc C (4) clutch plates (9) tabs (5) clutch discs B (10) shallow slots (2) clutch plates Servicing Your Honda...
  • Page 91 (18). (17) (18) (14) (13) (13) clutch pressure plate (14) clutch spring bolts and springs (17) over cover (18) bolts 11. Pour recommended engine oil to the specified level (page 70). Servicing Your Honda...

  • Page 92: Spark Plug

    Press and hold the engine stop button and 11. Install the fuel tank and seat (pages 46, 50). disengage the clutch by pulling the lever in. Servicing Your Honda...

  • Page 93: Valve Clearance

    The valve clearance will change as engine temperature rises. (3) cylinder head cover socket bolts (4) cylinder head cover rubber seals (5) cylinder head cover (6) spark plug hole packing (1) breather tube (2) spark plug cap Servicing Your Honda...

  • Page 94: Positioning At Tdc On The Compression Stroke

    (2) primary drive gear bolt (3) “T” mark (4) index mark (5) decompressor weight 6. Check the timing marks (6) on the cam sprocket aligns with the camshaft holder mating surface (7) of the cylinder head. (8) rocker arms Servicing Your Honda...

  • Page 95: Valve Clearance Inspection

    Camshaft Removal (this page) and select the correct shim for each (1) feeler gauge (3) camshaft cam lobes valve. (2) intake rocker arms Valve Clearance: IN: 0.004 ± 0.001 in (0.11 ± 0.03 mm) (cont’d) Servicing Your Honda...
  • Page 96 (8) set rings (9) left camshaft bearing (10) camshaft NOTICE (11) cam chain Do not let the set rings fall into the crankcase. If the set rings are remained on the camshaft holder, remove the set rings carefully. Servicing Your Honda...

  • Page 97: Shim Selection

    Do not let the shims fall into the crankcase. If a calculated dimension is out of specifications, Do not clean the intake rocker arms using a have your motorcycle inspected by your dealer. commercially available compound cleaner. 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda...

  • Page 98: Camshaft Installation

    (5) decompressor weight (10) If the operation is not smooth, refer to an official Honda Service Manual (page 194) for decompressor disassembly or see your dealer. (1) rocker arms (3) valve spring retainers (2) shims...
  • Page 99 NOTICE (12) (17) camshaft holder (19) camshaft holder bolts (long) (20) camshaft holder bolts (short) (18) “ ” mark (11) timing mark Do not let the set rings fall into the crankcase. (12) camshaft holder mating surface Servicing Your Honda...

  • Page 100: Crankshaft Hole Cap Installation

    (27). (1) O-ring (new) (2) crankshaft hole cap (27) 3. Install the right crankcase over cover (page 85). (26) (26) sealing washer (new) (27) cam chain tensioner lifter cover bolt Servicing Your Honda...

  • Page 101: Cylinder Head Cover Installation

    7 lbf·ft (10 N·m, 1.0 kgf·m) (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (4) cylinder head cover groove (2) cylinder head cover (7) cylinder head cover socket bolts Servicing Your Honda...

  • Page 102: Piston/Piston Rings/Piston Pin

    Do not hang the throttle body and support it with a ignition coil bolts (4). suitable strap. (10) (1) ignition coil A connector (3) ignition coil (2) ignition coil B connector (4) ignition coil bolts (7) insulator band screw (8) throttle body (9) insulator (10) vacuum tube Servicing Your Honda...
  • Page 103 (15) cylinder head hanger plate bolts (16) left cylinder head hanger plate (17) right cylinder head hanger plate (28) (27) cam chain guide (28) cylinder (22) (22) cylinder bolt (23) cylinder head bolts and washers (24) cylinder head Servicing Your Honda...

  • Page 104: Cylinder Removal

    Do not let the cam chain fall into the crankcase. Do not let the dowel pins fall into the crankcase. (1) shop towels (3) piston pin (2) piston pin clips (4) piston (3) dowel pins (4) cylinder gasket Servicing Your Honda...

  • Page 105: Piston/Piston Pin/Piston Ring Inspection

    Piston Ring Installation rotate freely, without sticking. Space the ring end gaps 120 degrees apart between top ring, We recommend you consult an official Honda 1. Remove the carbon deposits from the piston second ring and spacer. Space each ring end Service Manual or your dealer for correct Service head and piston ring grooves.

  • Page 106: Piston Installation

    Be careful not to damage or shock the piston pin. Use new pin clips. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8). Servicing Your Honda...

  • Page 107: Cylinder Installation

    Do not let the cam chain fall into the crankcase. 0.2 – 0.4 in (5 – 10 mm) 0.2 – 0.4 in (2) dowel pins (3) cylinder gasket (new) (5 – 10 mm) (1) cylinder mating surface (4) cylinder bore (6) cam chain (5) piston rings Servicing Your Honda...

  • Page 108: Cylinder Head Installation

    (6) cylinder head (11) oil catch tank 37 lbf·ft (50 N·m, 5.1 kgf·m) (9) oil catch tank stay (12) mounting bolt (10) collar NOTICE Do not let the washers fall into the crankcase. Servicing Your Honda...
  • Page 109 (26) cylinder head (27) bolts (13) left cylinder head hanger plate (14) right cylinder head hanger plate (15) cylinder head hanger plate bolts (22) (21) (16) cylinder head hanger bolts (21) right radiator lower mounting bolt (22) washer (cont’d) Servicing Your Honda...
  • Page 110 – abnormal engine noise – secondary air leaks – exhaust gas leaks – coolant leaks – oil leaks (29) (31) (28) ignition coil (29) ignition coil bolts (30) ignition coil A connector (31) ignition coil B connector Servicing Your Honda...

  • Page 111: Suspension

    • Replace the damper oil every 8 races or 30.0 hours of running. See page 115 for damper fork oil replacement. • Use Pro Honda HP Fork Oil, SS-19 or an equivalent which contains special additives to assure maximum performance of your...

  • Page 112: Front Suspension Removal

    (3) handlebar lower holder nuts, washers and mounting (1) compression damping adjuster rubbers (2) rebound damping adjuster (4) handlebar 3. Loosen the fork bridge upper pinch bolts (5). 4. Loosen the fork bolts assembly (6), but do not remove them yet. Servicing Your Honda...
  • Page 113 • Do not operate the brake lever after the front (26) fork protectors wheel is removed. To do so will cause difficulty in fitting the brake disc between the brake pads. (9) disc cover (10) disc cover socket bolts (cont’d) Servicing Your Honda...

  • Page 114: Recommended Fork Oil

    The outer tube (1) can drop on the axle holder (4) suggested oil Pro Honda HP Fork Oil, SS-19 and damage the fork dust seal (5). To avoid damage, hold both the outer tube and slider when removing the fork damper.

  • Page 115: Fork Oil Refilling

    • Lock nut wrench 07WMA-KZ30100 Recommended Oil: Improper disposal of drained oil is harmful to the environment. Pro Honda HP Fork Oil, SS-19 Recommended Standard Amount: Amount of fork oil left in the fork 12.0 US oz (355 cm (within damper and spring)

  • Page 116: Front Suspension Installation

    5. Align the groove (7) in the outer tube with the top surface of the upper fork bridge (8). Align (2) fork damper assembly (3) lock nut wrench (4) fork bolt assembly (7) groove (8) upper fork bridge Servicing Your Honda...
  • Page 117 (14) with the lower ends of the stay A (15) and stay B (16), and assemble them. Install and tighten them to the left fork protector using the brake hose/speed sensor wire clamp bolts (17). (cont’d) Servicing Your Honda...
  • Page 118 15. Route the speed sensor wire (24) properly and holder nuts install the speed sensor (25) to the left fork bracket. Install and tighten the speed sensor mounting bolt (26). Install the speed sensor wire guide plate (27) and tighten the guide plate screw (28). Servicing Your Honda...

  • Page 119: Fork Damper Disassembly

    (3) is fully exposed and install the piston base (4) or mechanic’s stopper tool between the axle holder (1) and fork center bolt lock nut. • Piston base 07958-2500001 (35) (34) compression damping adjuster (35) rebound damping adjuster (cont’d) Servicing Your Honda...
  • Page 120 (9) and back-up ring/seat stopper (10) from the fork assembly. (6) fork damper assembly (7) fork assembly (8) fork spring (9) spring seat collar (10) back-up ring/seat stopper (1) axle holder (3) fork center bolt lock nut (2) fork center bolt (4) piston base Servicing Your Honda...

  • Page 121: Damper Oil Change

    Pour the recommended fork oil into the fork damper assembly (4). Recommended Oil: Pro Honda HP Fork Oil, SS-19 (2) fork damper piston rod (3) fork bolt assembly Recommended Amount: 8.4 US oz (248 cm (1) fork center bolt lock nut 5.
  • Page 122 (1) fork center bolt lock nut (2) fork damper piston rod (7) (8) 13. Check the fork damper piston rod sliding (3) fork bolt assembly (7) O-rings (new) surface and threads for damage. (6) fork bolt bushings (8) piston ring (new) Servicing Your Honda...
  • Page 123 (2) fork damper piston rod (4) fork damper assembly Pour the drained oil into a suitable container and dispose of it in an approved manner (page 160). NOTICE Improper disposal of drained fluids is harmful to the environment. (cont’d) Servicing Your Honda...

  • Page 124: Fork Damper Installation

    (4) fork damper assembly (10) oil hole Amount of fork oil left in the fork (12) air pressure release screws (without damper and spring) unit: cm (13) O-rings (new) minute °C/°F 30/86 20/68 10/50 0/32 Servicing Your Honda...
  • Page 125 Measure the thread length again. Standard: 0.35 – 0.43 in (9 – 11 mm) • Piston base 07958-2500001 (3) slider bushing (6) spring seat collar (4) seat stopper (7) fork damper (5) back-up ring (cont’d) Servicing Your Honda...
  • Page 126 Align 51 lbf·ft (69 N·m, 7.0 kgf·m) (17) (16) (15) (14) (17) (14) push rod (16) O-ring (new) (15) piston rod (17) fork center bolt (17) fork center bolt Servicing Your Honda...

  • Page 127: Rear Suspension Inspection

    If there is, have the in 1/12 turn increments. bearings replaced by your dealer. • If you have a problem finding an acceptable adjustment, return to the standard position and begin again. Servicing Your Honda...

  • Page 128: Brakes

    (page 125), there is probably air in the brake system. Refer to an official Honda Service Manual or see your dealer to have the air bled from the system. (–)

  • Page 129: Fluid Level Inspection

    If the travel for the rear brake pedal feels leaks. excessive, there is probably air in the brake system and it must be bled. Refer to an official Honda If the pulling distance for the front brake lever Service Manual or see your dealer for brake feels excessive, there is probably air in the brake bleeding.
  • Page 130 Do not mix different types of fluid, they may not be compatible. (1) front brake reservoir cap screws •The recommended brake fluid is Honda DOT 4 (2) reservoir cap Brake Fluid or an equivalent. (3) set plate...

  • Page 131: Brake Pad Wear

    (1.0 mm) (1) brake pads (3) brake disc (2) rear brake caliper replace 0.04 in (1.0 mm) (1) brake light switch (2) adjusting nut wear indicator grooves (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...

  • Page 132: Wheels

    Wheel Rims & Spokes Axles & Wheel Bearings Keeping the wheels true (round) and maintaining 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Service Manual for correct spoke tension are critical to safe damage. inspection information: motorcycle operation.

  • Page 133: Tires & Tubes

    Use a replacement tube equivalent to the original. Use an accurate gauge to measure the air pressure in your tires before each off-road ride and whenever you return to pavement after riding off- road. If you only ride on pavement, check the Servicing Your Honda...

  • Page 134: Tire Replacement

    The old tube will probably be stretched. If installed in a new tire, it could fail. If you have a tire professionally replaced at a non- Honda facility, we recommend that you have the work checked by your Honda dealer. Servicing Your Honda...

  • Page 135: Side Stand

    4. Pull the clutch lever in. 5. Shift the transmission into gear. 6. Lower the side stand all the way. The engine should stop as you lower the side stand. If the engine doesn’t stop, see your dealer for service. Servicing Your Honda...

  • Page 136: Drive Chain

    Adjust chain slack if needed (page 131). 1 – 1 3/8 in (25 – 35 mm) (3) chain guide slider (4) wear limit Servicing Your Honda...

  • Page 137: Drive Chain Rollers

    Drive Chain Drive Chain Rollers Adjustment Lubrication Lubricate the drive chain with Pro Honda HP Check the upper drive chain roller (1) and lower 1. Loosen the rear axle nut (1). Chain Lube or an equivalent chain lubricant or drive chain roller (2) for wear or damage.

  • Page 138: Removal, Cleaning & Replacement

    1. Clean the side surfaces of the chain with a dry Teeth Teeth cloth. Use a high flash point solvent such as kerosene or Pro Honda chain cleaner – not gasoline. Do not brush the rubber O-rings. Brushing will damage them. Use of a solvent REPLACE REPLACE may also damage the O-rings.

  • Page 139: Exhaust Pipe/Muffler

    5. Install the washer (7), muffler mounting B bolt (8) and A bolt (9). (2) muffler mounting A bolt (3) muffler mounting B bolt (4) washer (5) muffler (7) washer (8) muffler mounting B bolt (9) muffler mounting A bolt (cont’d) Servicing Your Honda...

  • Page 140: Exhaust Pipe Removal

    5. Tighten the muffler clamp bolt, muffler mounting A bolt and B bolt (page 133). (7) washer (8) muffler mounting B bolt (9) muffler mounting A bolt 8. Install the right side cover (page 47). 9. Install the seat (page 46). Servicing Your Honda...

  • Page 141: Spark Arrester

    Check the gasket. Replace, if necessary. 3.9 lbf·ft (5.25 N·m, 0.5 kgf·m) (1) muffler (2) tail cap cover bolts (3) washers (4) tail cap cover (8) spark arrester screen (1) muffler (2) tail cap cover bolts (3) washers (4) tail cap cover Servicing Your Honda...

  • Page 142: Additional Maintenance Procedures

    If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to an official Honda Service Manual for replacement or adjustment procedures, or see your dealer.

  • Page 143: Nuts, Bolts, Fasteners

    (6) cylinder head bolts (2) clutch cover bolts (8) drive sprocket bolt (3) water pump cover bolts (9) engine oil drain bolt (4) crankshaft hole cap (6) cylinder head bolts (7) exhaust pipe joint nuts (10) coolant drain bolt Servicing Your Honda...

  • Page 144: Battery

    The battery is located under the seat. replace the battery. Always replace the battery with another lithium-ion (li-ion) battery of the same type. The lithium-ion (li-ion) battery contains a fuse inside. If the fuse blows, the battery needs replacement. Servicing Your Honda...

  • Page 145: Battery Charging

    Using a battery charger that is not recommended can cause permanent damage to your battery. (1) battery (3) negative (–) terminal bolt (2) positive (+) terminal bolt (4) battery band Servicing Your Honda...

  • Page 146: Headlight Aim

    You can adjust vertical aim of the headlight for proper alignment. Turn the screw (1) in or out as necessary using a Phillips screwdriver (2). Obey local laws and regulations. (1) screw (A) Up (2) Phillips screwdriver (B) Down Servicing Your Honda...

  • Page 147: Appearance Care

    High You may use Pro Honda Hondabrite, a multi- 4. After washing, rinse your motorcycle pressure washers (like those at coin-operated surface cleaner/degreaser, to remove both dirt and...

  • Page 148: After Cleaning Lubrication

    Do not use steel wool to clean the frame as it could damage or discolor the frame surface. Scotch Brite Hand Pad #7447-maroon is for removing stains on the non-coated aluminum frame only. Servicing Your Honda...

  • Page 149: Adjustments

    Adjustments This section tells you how to fine tune your Front Suspension Adjustments ......144 motorcycle for maximum performance. Front Suspension Air Pressure....144 Front Suspension Damping......145 Off-Road Use only Rear Suspension Adjustments......146 Initial suspension adjustments should be Rear Suspension Spring Pre-Load performed after a minimum of 2 hours of easy (Off-Road Use Only) .........146 break-in time.

  • Page 150: Front Suspension Adjustments

    Front Suspension Adjustments Front Suspension Adjustments The front suspension can be adjusted for the rider's 4. Install and tighten the pressure release screw to Front Suspension Air Pressure weight and riding conditions by using one or more the specified torque: of the following methods: 1.0 lbf·ft (1.3 N·m, 0.1 kgf·m) Air is an unstable gas which builds up pressure as it...

  • Page 151: Front Suspension Damping

    Front Suspension Adjustments NOTICE Front Suspension Damping Always start with full hard when adjusting Compression Damping Adjustment damping. This adjustment affects how quickly the fork Do not turn the adjuster screw more than the given compresses. The fork compression damping positions or the adjuster may be damaged.

  • Page 152: Rear Suspension Adjustments

    One turn equals: spring proper tools, safety equipment and an official specified torque: length/spring pre-load: Honda Service Manual. 32 lbf·ft (44 N·m, 4.5 kgf·m) Standard: 0.06 in (1.5 mm)/18 lbf (78 N) Off-Road Use only Pin spanners should be used for turning the shock If your motorcycle is new, put enough part-throttle spring lock nut and adjusting nut.

  • Page 153: Rear Suspension Damping

    Rear Suspension Adjustments High Speed Damping: Low Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by The low speed damping can be adjusted by turning turning the hexagonal portion of the compression the center screw of the compression damping Compression Damping damping adjuster.

  • Page 154: Rear Suspension Race Sag (Off-Road Use Only)

    Rear Suspension Adjustments Rebound Damping unloaded: motorcycle on an optional workstand Rear Suspension Race Sag The rebound damping adjuster (6) is located at the with rear suspension fully extended, no rider. (Off-Road Use Only) lower end of the rear shock absorber. loaded with rider: motorcycle on ground, with rider.
  • Page 155 Rear Suspension Adjustments Ask the other helper to measure the loaded with rider dimension. SEAT MOUNTING BOLT LOADED MEASUREMENT (with rider) EXAMPLE: 20.7 in (525 mm) CHAIN ADJUSTER LOCK NUT Example: Unloaded = 24.6 in (625 mm) – Loaded = 20.7 in (525 mm) Race Sag = 3.9 in (100 mm) 4.

  • Page 156: Suspension Adjustment Guidelines (Off-Road Use Only)

    Suspension Adjustment Guidelines (Off-Road Use Only) Follow the procedures described below to accurately adjust your motorcycle, using the methods described on pages 144 – 148. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track...
  • Page 157 Suspension Adjustment Guidelines (Off-Road Use Only) Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 158 Suspension Adjustment Guidelines (Off-Road Use Only) Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: –...

  • Page 159: Tuning Tips

    Tuning Tips NOTICE NOTICE Spark Plug Reading (Off-Road Use Only) Using spark plugs with an improper heat range or An improperly tightened spark plug can damage Refer to Spark Plug on page 86. incorrect reach can cause engine damage. the engine. If a plug is too loose, the piston may be damaged.

  • Page 160: Chassis Adjustments

    Chassis Adjustments Chassis Adjustments The following suggestions may improve a specific Fork Height/Angle (Off-Road Use Only) Wheelbase (Off-Road Use Only) concern. Subtle changes in overall handling may also be noted. The position of the fork in the clamp is not Adjusting your motorcycle’s wheelbase can offer adjustable.

  • Page 161: Tire Selection For Track Conditions (Off-Road Use Only)

    Tire Selection for Track Conditions (Off-Road Use Only) Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in off-road use. added traction, remember that it may transfer The tires on your motorcycle offer a “happy additional loads to the transmission because it medium”...

  • Page 162: Personal Fit Adjustments

    If an holders 180 degrees). assembly does not rotate, it may bend or break Refer to an official Honda Service Manual for a control lever. Make sure that the bolts are installation instructions. Be sure to check...

  • Page 163: Tips

    Here’s helpful advice on how to transport and store your motorcycle, as well as three troubleshooting flow charts. Transporting Your Motorcycle...... 158 Storing Your Honda ........159 Preparation for Storage......159 Removal from Storage ......159 You & the Environment ........ 160 Troubleshooting..........

  • Page 164: Transporting Your Motorcycle

    Transporting Your Motorcycle Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport To secure your motorcycle, brace the front wheel your motorcycle, we recommend that you follow against the front of the truck bed or trailer rail. these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 165: Storing Your Honda

    Storing Your Honda If you won’t be riding for an extended period, such 4. Remove the radiator cap and coolant drain bolt 11. Stuff a rag into the muffler outlet. Then tie a as during the winter, thoroughly inspect your...

  • Page 166: You & The Environment

    You & the Environment You & the Environment Owning and riding a motorcycle can be enjoyable, NOTICE but you must do your part to protect nature. When you show respect for the land, wildlife, and other Improper disposal of drained fluids is harmful to people, you also help preserve the sport of off-road the environment.

  • Page 167: Troubleshooting

    • Excessive carbon build- parenthesis. The items that require use of an the engine at high up in combustion official Honda Service Manual are followed by an CORRECT speed chamber asterisk (*). • Ignition timing too advance (Faulty ECM)* 8.
  • Page 168 Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy 1. Check the spark INCORRECT • Incorrect spark plug heat 1. Check the ignition INCORRECT • Faulty ECM* •...

  • Page 169: Taking Care Of The Unexpected163

    Taking Care of the Unexpected This section discusses the more common problems General Guidelines ........164 that can occur with your motorcycle while you’re If Your Engine Quits or Won’t Start....165 riding. It tells you how to evaluate each problem If You Have a Flat Tire ........167 and what actions you can take to try to resume Should You Repair or riding.

  • Page 170: Taking Care Of The Unexpected

    Taking Care of the Unexpected Taking Care of the Unexpected General Guidelines Keeping your motorcycle well-maintained is the best way to reduce the possibility of having a problem on the road. Remember to take along your owner’s manual, the tool kit that came with your motorcycle, and any other items (such as tire repair supplies and additional tools) that might help you solve a problem on your own.

  • Page 171: If Your Engine Quits Or Won't Start

    If Your Engine Quits or Won’t Start Proper operation and maintenance can prevent starting and engine performance problems. In many cases, the cause of the problem may be a simple operational oversight. If you have a problem starting the engine – or experience poor engine performance – the following information may help you.
  • Page 172 If Your Engine Quits or Won’t Start SYMPTOM: Engine starts, but runs poorly. POSSIBLE CAUSE WHAT TO DO idles roughly, too fast, stalls Check engine idle adjustment (page 80). If the problem persists, see your dealer. overheating Check the coolant temperature indicator. Refer to If the High Coolant Temperature Indicator Lights, page 170.

  • Page 173: If You Have A Flat Tire

    For a full discussion of repairs and 4. Remove the front axle nut (8) and loosen the Honda does not recommend that you make a replacement, see the text beginning on page 127. axle pinch bolts (9) on both forks. Pull the front temporary repair to a tube-type tire.
  • Page 174 If You Have a Flat Tire Installation 6. Operate the front brake and pump the fork (14) 1. Clean the surfaces where the axle and axle several times. Check for free wheel rotation clamps contact each other. Apply grease to after the brake is released.

  • Page 175: Emergency Rear Wheel Removal/Installation

    If You Have a Flat Tire 2. Make sure that the lug (10) on the caliper Emergency Rear Wheel Removal/ bracket is positioned in the slot (11) on the Installation swingarm (12). 3. Insert the rear axle shaft from the left side, Refer to Important Safety Precautions on page 33.

  • Page 176: If The High Coolant Temperature Indicator Lights

    If the High Coolant Temperature Indicator Lights If the High Coolant Temperature Indicator Lights Normally, the temperature of the coolant in the • If the reserve tank is low or empty, don’t ride cooling system will rise to a level about midway without adding coolant (page 72).

  • Page 177: If You Have A Burned-Out Light Bulb

    If You Have a Burned-out Light Bulb Brake light/Taillight License Plate Light Burned-out Light Bulb The brake light (1) and taillight (2) uses several The license plate light (1) uses an LED. LEDs. If there is an LED which is not turned on, see your All light bulbs on the motorcycle are LEDs.

  • Page 178: If A Fuse Blows

    If a Fuse Blows If a Fuse Blows All of the electrical circuits on your motorcycle have a fuse to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your motorcycle stops working, the first thing you should check for is a blown fuse (1).

  • Page 179: If You Crash

    If You Crash Personal safety is your first priority after a crash. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. Call for emergency assistance if needed.

  • Page 180: If You Lose Your Key

    If You Lose Your Key If You Lose Your Key Be sure to record your key number (1) provided with the key number plate (2). Store the spare key and recorded key number in a safe location. You’ll need this number to have a duplicate key made. A lost key won’t be a problem if you take preventative action.

  • Page 181: If Your Battery Is Low (Or Dead)

    If Your Battery Is Low (or Dead) If an overvoltage, overcurrent, or short circuit is applied, the battery fuse may blow. Do not jump-start as this can damage your motorcycle's electrical system and battery. Bump starting is not recommended. Check the battery voltage using a digital multi meter with the cable connected.
  • Page 182 BLANK PAGE Taking Care of the Unexpected...

  • Page 183: Technical Information

    Problems Affecting Motorcycle Exhaust Emissions ...........185 Catalytic Converter ........186 Oxygenated Fuels...........187 Off-Road Logbook.........188 Optional Parts List .........190 Spare Parts & Equipment.......191 Spare Parts ..........191 General Tools..........191 Honda Special Tools........191 Chemical Products ........191 Other Products ...........191 Wiring Diagram ..........192 Technical Information...

  • Page 184: Vehicle Identification

    Vehicle Identification Vehicle Identification The engine number (2) is stamped on the right Serial Numbers crankcase. 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 this manual.

  • Page 185: Specifications

    Specifications Fork oil capacity Item English Metric Item English Metric 12.0 US oz 355 cm (except damper) Dimension Engine Fork oil capacity 8.2 US oz 243 cm Overall length 89.8 in 2,280 mm Type Liquid cooled, 4-stroke (damper) Overall width 32.5 in 825 mm Cylinder...
  • Page 186 Specifications Item English Metric Drive train Clutch type Wet, multi-plate type Transmission 6-speed, constant mesh Primary reduction 2.357 Gear ratio I 2.357 Gear ratio II 1.705 Gear ratio III 1.300 Gear ratio IV 1.090 Gear ratio V 0.916 Gear ratio VI 0.793 Final reduction 3.923...

  • Page 187: Torque Specifications

    Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Item Remarks Check and tighten nuts, bolts, and fasteners before every outing. lbf·ft N·m kgf·m Cylinder head cover LEFT SIDE socket bolts Clutch cover bolts Water pump cover bolts Crankshaft hole cap NOTE 1 Oil filter cover bolts Cylinder head bolts NOTE 2...
  • Page 188 Torque Specifications LEFT SIDE FRAME (21) (16) (13) Torque Item Remarks (14) lbf·ft N·m kgf·m Steering stem nut 11.0 Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts NOTE 1 Front axle nut Axle pinch bolts Rear axle nut 13.1...
  • Page 189 Torque Specifications FRAME LEFT SIDE (41) (48) (47) (53) (31) (51) (38) Torque Item Remarks lbf·ft N·m kgf·m Brake hose oil bolts (35) Front brake caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 Brake pedal pivot bolt Spokes...

  • Page 190: Emission Control Systems

    Compliance with the terms of the Distributor's The PGM-FI (programmed fuel injection) system Warranties for Honda Motorcycle Emission uses sequential multiport fuel injection, and is Control Systems is necessary in order to maintain Fuel Permeation Emission Control comprised of air intake, engine control, fuel a valid emissions system warranty.

  • Page 191: Noise Emission Control System

    Emission Control Systems Noise Emission Control System Problems Affecting Motorcycle Exhaust Emissions TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Have your motorcycle inspected and repaired by U. S. federal law prohibits, or Canadian provincial your dealer if you experience any of the following laws may prohibit the following acts or the causing symptoms: thereof: (1) The removal or rendering inoperative...

  • Page 192: Catalytic Converter

    A defective catalytic converter contributes to air pollution and can impair your engine's performance. A replacement unit must be an original Honda part or equivalent. Follow these guidelines to protect your motorcycle's catalytic converter. • Always use unleaded gasoline. Leaded gasoline will damage the catalytic converter.

  • Page 193: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating symptoms, with alcohol or an ether compound. These try another service station or switch to another gasolines are collectively referred to as oxygenated brand of gasoline. fuels.

  • Page 194: Off-Road Logbook

    Off-Road Logbook Off-Road Logbook Any serious off-road effort relies heavily on the Tuning & Adjustment Records Racing Records knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of racing events. The best way to organize the many worked best at a particular location.
  • Page 195 Off-Road Logbook Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.) Time (Make several photocopies of this page for future use) Technical Information...

  • Page 196: Optional Parts List

    Optional Parts List Optional Parts List These tools may be ordered from your authorized dealer. TOOLS Remarks Pin spanner A To adjust spring preload. (two spanners required) Workstand For maintenance Air gauge For checking tire air pressure Technical Information...

  • Page 197: Spare Parts & Equipment

    Pro Honda GN4 4-stroke Oil following: screwdrivers: blade & Phillips No. 1, 2, 3 (Engine Oil) wrench, large adjustable Pro Honda HP Fork Oil, SS-19 Spare Parts wrenches: open end & box Honda DOT 4 Brake Fluid wrenches: hex (Allen)

  • Page 198: Wiring Diagram

    Wiring Diagram FRONT WHEEL STARTER BANK ANGLE FUEL REAR BRAKE Black Light Green IGNITION SWITCH SPEED SENSOR RERAY SENSOR THERMISTOR PUMP LIGHT SWITCH Brown Orange Blue Pink Green Gray White Light Blue Yellow (Bl) EXHAUST COLOR COMB : GROUND / MARKING AIR INJECT FUEL PURGE...

  • Page 199: Consumer Information

    Consumer Information This section contains information about contacting Authorized Manuals........194 Honda and how to get an official Honda Service Warranty Coverage ........195 Manual. Warranty Service ...........196 Contacting Honda ..........197 Your Honda Dealer ........198 Reporting Safety Defects (USA only) ...199 Consumer Information...

  • Page 200: 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 and ATV.

  • Page 201: Warranty Coverage

    Warranty Coverage Your new Honda is covered by the following warranties: • Motorcycle Limited Warranty • Emission Control System Warranty • Noise Control Warranty (USA only) The responsibilities, restrictions, and exclusions that apply to these warranties are explained in the Warranties Booklet given to you by your Honda dealer at the time of purchase.

  • Page 202: Warranty Service

    Maintenance Schedule is not included in your warranty coverage. If you believe you have a problem with your motorcycle, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. You will be asked to authorize that inspection, and your dealer will return the results of the inspection.

  • Page 203: Contacting Honda

    Please include the following information in your letter: • Name, address, and telephone number • Product model, year, and VIN • Date of purchase • Dealer name and address We will likely ask your Honda dealer to respond, or possibly acknowledge your comments directly. Consumer Information...

  • Page 204: Your Honda Dealer

    Once you purchase your new Honda, get familiar The sales department offers the Honda Protection with the organization of your Honda dealer so you Plan to extend almost all of your warranty can utilize the full range of services available.

  • Page 205: Reporting Safety Defects (Usa Only)

    However, NHTSA cannot become involved in individual problems between you, your dealer, or American Honda Motor Co., Inc. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800- 424-9153);...

  • Page 206: Index

    ............147 backlight brightness adjustment rear fork, ..26 ........198 ....144 bank angle sensor ignition cut-off system dealer, your Honda front suspension adjustment ..........23 ......... 192 ....105 basic operation diagram, wiring front suspension inspection ............138 ........
  • Page 207 ........19 pre-ride inspection ......15 ..38 headlight dimmer switch maintenance record (on-road use only) ........2, 18 protective apparel Honda, maintenance, ..........197 ........44 contacting after competition ........194 ...... 43 service manual before & after competition ...........
  • Page 208 Index ..... 164 safety, taking care of the unexpected ........5 ........29 a few words about theft-prevention tips ....... 2 important information throttle, ........ 2 ..........78 important precautions freeplay ............5 ..........79 labels inspection ........... 33 ..........79 maintenance lubrication ........

  • Page 209: Quick Reference

    91 or higher tank: 2.01 US gal (7.6 ℓ) Engine Oil/Capacity Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil. 1.22 US qt (1.15 ℓ) after draining and filter change 1.16 US qt (1.10 ℓ) after draining...

  • Page 210: Quick Reference

    Quick Reference These symbols are used in Operating Controls and Basic Operating Instructions sections: SYMBOL COMPONENT SEE PAGE fast idle knob START button RUN – engine stop switch STOP – engine stop switch HI – headlight dimmer switch LO – headlight dimmer switch turn signal switch horn button PASS –...
  • Page 211 California Proposition 65 Warning WARNING Operating, servicing and maintaining a passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well- ventilated area and wear gloves or wash your hands frequently when servicing your vehicle.

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